伟创力制造系统介绍

ABasicIntroductiontoFMS伟创力制造系统FMS介绍AwarenessSessionforDL直接员工认知课程FlexManufacturingSystemBanishWastesCreateValueFlexE2EValueStream2ABriefIntroductiontoFMSFMS简介•TPS,DFT,&Lean•丰田生产系统,需求流程技术,&精益生产•IntegratingLean&DFTFMS•FMS是精益生产&需求流程技术的集成3TPS*:PresentDayStructure丰田生产系统的结构Quality,Cost,Delivery品质,成本,交期ShortenProductionFlowbyEliminatingWaste通过消除浪费缩短生产流程JustInTime准时生产RightPartattheRightTimeintheRightAmount只在正确的时间生产正确的产品和数量ContinuousFlow连续流PullSystems拉动系统LevelProduction分级生产Built-InQuality(Jidoka)过程品质控制(自动化)ErrorProofing–PokaYoke防错法VisualControls目视控制OperationalStability操作稳定性StandardizedWork标准化作业RobustProducts&Processes强大的产品&工艺TotalProductiveMaintenance全员生产性维护保养SupplierInvolvement供应商参与Kaizen改善5S/VisualManagement5S/可视化管理HighlyMotivatedandCreativePeople高主动性和创造性的人员*ToyotaProductionSystem4DFT*inFlexToday伟创力目前实施的需求流程技术*DemandFlowTechnology需求流程技术5/Value价值CorrectlySpecifyValueofProduct/ServicewithCustomerinmind从正确识别产品/服务的价值,始终考虑客户的需求/ValueStream价值流IdentifytheValueStreamandremovealltheWastes识别价值流,消除浪费/Flow流程MaketheProductandValueFlowSmoothly理顺产品关系和价值流/Pull拉动ProduceonlytothePullofCustomerDemand以客户需求拉动生产/Perfection完成WastesEliminationasanOngoingProcesstowardsPerfection浪费消除,流程趋于完善TheUniversalLeanPrinciples普遍的精益原则6TheOriginofFMS:FlexManufacturingSystem伟创力制造系统的起源ToyotaProductionSystem丰田生产系统DFT需求流程技术LEAN精益生产FlexManufacturingSystem伟创力制造系统BanishWastesCreateValueFlexE2EValueStream7FlexManufacturingSystem(FMS)伟创力制造系统LeadTimeImprovement+BanishWastesDriveValueCreation缩短生产周期+消除浪费以驱动价值创造LeanisamanufacturingphilosophythatrecognizesWASTEastheprimarydriverofcycletime,andemploystechniquestocontinuallydriveoutthewasteinprocesses.精益生产是这样一种制造业哲学,它认为生产周期,员工的操作方法是造成浪费的主要原因,并致力于消除这些浪费PRODUCTSHIPMENT出货TotalLeadTime生产周期BusinessasUsual正常工作Waste浪费CUSTOMERORDER客户订单LeanManufacturing精益制造PRODUCTSHIPMENT出货CUSTOMERORDER客户订单LeadTime(Shorter)生产周期(更短)Waste浪费WhyLeadTimeiscrucialtobecomeLean?为什么生产周期在精益生产中如此的至关重要9CycleTimeandWaste生产周期和浪费TypesofWaste*1七种浪费Transportation运输Inventory库存Motion动作Waiting等待Overproduction过量生产Over-processing不必要的过程Defects缺陷*1Prompter:Whois“TIMWOOD”?敦促者:谁是”TIMWOOD”Waste浪费Waste浪费MUDA*=WasteMUDA=浪费*Japanese101.Overproduction过量生产Makingmore-earlier-fasterthanthenextprocessorcustomerneedsit相对于下一工序或客户过早过快生产-Justincaselogic以防万一的逻辑-Unbalancedworkload工作量不平衡-Improperscheduling不适当的计划2.Defects缺陷NotdoingworkRighttheFirstTime没有做到第一次就把工作做对-NotusingPoka-yoke*1没采取防错法-LackofStandardization,inconsistentworkmethods缺乏标准化,不一致的工作方法-Ineffectivecommunication无效的沟通-Littleinvestmentintraining缺乏培训3.Inventory库存Anysupplyinexcessofone-pieceflow一个流之外的任何供给品-Oftentheresultof“Overproduction”常常是”过量生产”的结果-Unbalancedworkload工作量不平衡-Improperscheduling不适当的计划-Unreliablesuppliers不可靠的供应商7TypesofWaste七种浪费*1-alsocalledmistakeorerror-proofing117TypesofWaste七种浪费4.Over-processing不必要的过程Processingbeyondthecustomer’s(internalorexternal)requirements过程超过客户(内部或外部)的要求-Poorknowledgeofspecsorcustomerrequirements缺乏对客户规格或要求的知识-Inconsistentworkmethods(non-standardization)不一致的工作方法(非标准化)-Ineffectivecommunication无效的沟通Examples:举例:-Manuallycleaningproductbecauseofdirt用手清除产品上的尘土-100%visualinspectionatend-of-line线末100%目视检验5.Transportation运输Inefficientmovementofpeople,materialsandinformationintheorganization人员,物料和信息的低效率的移动-Poorlayout差的工厂布局-Inefficient“flow”低效的流动-Carryinglargeinventories大量库存-Exposesproducttopotentialdamage/lossduringtransportation产品在运输过程中遭受潜在的损害/损失Examples:-Anywheresequentialoperationsarebroken任何连续作业中断的地方-Materialstoredtoofarfromworkstation物料存储离工作站太远-Toomanyconveyors,forklifts,pallettrucks,etc.过多的传送带,铲车,叉车127TypesofWaste七种浪费6.Waiting等待Waitingfor…man,machine,materials,information,etc.等待…人,设备,物料,信息等-Unbalancedworkload工作量不平衡-Unplanneddowntime无计划的停机时间-Poorworkplacediscipline工作场所无纪律Examples:举例:-Lookingfortoolstorepairmachines寻找工具维修设备-Firstpiecewaitingfortheentirebatchtofinish第一件等待整批完成-Peopleidlebecauseofnomaterialstoworkon因为缺料造成的人员空闲-Waitingforinstructionstoproceed等待继续的指示7.Motion动作Unnecessarymovementofpeople,partsormachineswithintheprocess生产过程中,不必要的人员,工件或机器的移动•Poorlayout不好的工厂布局•InefficientWorkplaceOrganization工作场所缺乏组织•LackofStandardization,inconsistentworkmethods缺乏标准化,不一致的工作方法•Increaseoperatorfatigueleadingtootherwastese.g.defects增加作业员疲劳造成浪费,如缺陷•Ergonomicissuescausinghealthe.g.repetitivemotioninjuries,etc.工效问题对健康的影响,如重复的动作性伤害13•Understandthedifferenttypesofwaste理解不同的浪费种类•Identifythem识别浪费•Carryoutyourprocessaccordingtoprocedure按照程序实施你的方法•ProperhandlingofPCBandmaterials恰当的处理物料•Followthetakttime,worktocycletimeoftheprocess跟随节拍时间工作以形成过程的周期时间•Reporttosupervisorifyouspotanyofthe“waste”,like…“Iamwaiting”当你发现任何浪费应该报告给你的主管HowcanIcontributetoeliminatewaste?怎样才能消除浪费14FlexManufacturingSystem(FMS)伟创力制造系统(FMS)•FMSCharacteristics•FMS的特点•FMSToolsandTechniques•FMS的工具和技术15WhatFMSis什么是FMSAnintegratedsystemofprinciples,operatingpractices,andelementsthatdrivetherelentlesspursuitofbusinessexcellencethroughwasteidentification,eliminationandprevention.Peoplemakesithappen.FMS是一个集成了众多生产原理,生产实践的综合系统,它通过浪费的识别,消除和预防以求对卓越事业的不懈追求.其中人是最关键的因素.Outcome:ValueCreationfortheCompanyandCustomer结果:为公司和客户创造价值•Outcome:AJourney