5S及目视化--车间基础管理培训

BasicWorkplaceOrganization车间基础管理5SMethodology5S方法Howaboutyourenterprise什么样的企业垃圾到处都是，没有人捡起来别人扔的垃圾由专人捡每个人自觉维护环境整洁，没人乱扔垃圾三流企业二流企业GoalandRationale目的和原理•Intuitivegoodness.良好的直觉感受•Helpsestablish,reinforceanddisciplineStandardWork有助于导入，强化和规范标准化工作•ReducesWaste,ImprovesSafety,andImprovesQuality.减少浪费，提高质量和保障安全•EasierMaintenanceandincreasesvalueofequipment.设备更易于维护，提高设备的使用价值•ExemplifiesRespectofCustomersandAssociates体现了客户与员工之间的相互尊重•SupportsaPositiveMentalAttitude保持积极的精神状态•ConveysPrideintheWorkplace让车间洋溢着自豪的情绪LearningObjectives学习目标ConveythepurposeforusingtheLeantoolof5StocreateaVisualworkplace.使用精益生产工具：5S实现目视化管理的车间ProvideadetaileddescriptionoftheSeparate,Straighten,Shine,Standardize,Sustainstagesofthe5Sprocess.解释5S（整理、整顿、清扫、清洁、素养）的真正含义ExplaintherelationshipbetweentheLeantoolsof5SandStandardWork.说明精益生产工具：5S和标准化工作之间的关系Describetheprocessforinitiatinga5Sevent.开展5S活动的实施步骤DescribetheimportanceandusesofVisualManagementtoolsintheworkplace.车间目视化管理工具的使用及其重要性Whatis5S?何为5S？5SIs:-Aprocesstoensureaclean,orderly,safeandproductiveworkplaceaccomplishedthroughthecreationofaself-explaining,self-regulating,andself-controllingenvironmentthateliminatesconfusionandambiguity.5S就是通过创造自明自觉、自我控制的环境来消除混乱不清的情况，从而实现一个干净、整洁、安全、高效的车间.Benefitsof5S5S的益处•Thebenefitsof5Scanbemeasuredby:5S的益处可以从以下几方面来衡量：–Safety:Reducethenumberoflosttimeaccidents,workman’scompensationclaimsandOSHArecordables.安全：减少损失工时事件指数、员工赔偿、职业安全和健康管理局的不良记录–Quality:Eliminatethepossibilityofusingpreviouslyrejectedpartsorthewrongtools.Eliminatecontaminationandassurecompliancetostandardprocedures.质量：消除使用以前报废的零件或使用不当工具的可能性，提高清洁度，确保执行标准流程–Productivity:Eliminatewastedtimelookingfortools.Reducecycletime,reduceequipmentdowntimethroughregularcleaningandinspection.生产效率：消除寻找工具浪费的时间，减少生产周期，通过对设备经常的清洁、检查而减少设备的故障时间Benefitsforpersonalityof5S5S对个人的益处•Comfortableworkenvironmentforyou;使您的工作环境更舒适；•Workmoreconveniently；工作更方便；•Worksafer工作更安全；•Communicatehappilywithcolleagues与同事合作更愉快……Whatarethe5S’s?何为5S？Separate(Seiri)整理Sort/straighten(Seiton)整顿Sweep/Shine(Seiso)清扫Standardize(Seiketsu)清洁Sustain(Shitsuke)素养Clearlydistinguishingbetweenwhatisnecessaryandwhatisunnecessary.Disposingoftheunnecessary.清楚地区分必需品和非必需品，将非必需品处理掉Organizingandlocatingthenecessaryitemssothattheycanbeusedandreturnedeasilynearthepointofuse.将必需品有条理地定位在较近的位置以便使用和归还Cleaningandinspectionoffloors,equipment,furniture,etc…inallareasoftheworkplace.清洁和检查车间所有区域的地面、设备、器具等等Maintaining,improving,documentingandverifyingthestandardsofthefirstthreeS’s.持续改进，将前3个S标准文件化并加以验证Achievingthedisciplineorhabitofproperlymaintainingthecorrect5Sprocedures.形成纪律或养成习惯来完整地维护5S的正确流程SEPARATE整理IdentifyTrulyNeededItems判定必需品–Whatisitfor?这个作什么用？–WhydoIhaveit?一定要用吗？–HowoftendoIuseit?多久用一次？–Doessomeoneelsehavethesamething?其他人是否也有？Clearlydistinguishingbetweenwhatisnecessaryandwhatisunnecessary.Disposingoftheunnecessary.清楚地区分需品和非必需品，将非必需品处理掉11Askingwhyenablesthesortingprocess.整理时要问为什么Forexample,whenintheworkarea,foreach“thing”ask:例如，在工作区，对每一样物品都要问：Whydoweneedit?为什么需要这个？Whyisitusedthewayitis?为什么要这样使用它？Ifweneedit,Whydoesitnothaveahome?如确实需要，为什么没有它自己固定的位置？Whyaretherenovisualcontrolstomanageit?为什么不能做到目视化管理？Whyaretherenopostedstandardsorstandardworktotellhowtouseitandassignresponsibilityforit?为什么没有标准或标准化工作来告之如何使用它而且有人对它负责？A“thing”canbematerialorinformation.所指物品包括物料或信息SEPARATEthroughthe5Whys用5个为什么来整理SEPARATE整理•ThingsWhichShouldbeReviewed需要确认的物品Cabinets抽屉Components部件Documentation文件Gages量具Machines机器PackagingMaterial包装材料Parts零件Prints印刷品Shelves架子Supplies耗品Tables工作台Tooling工具Towels毛巾Trash垃圾PRODUCTIONAREAS生产区Books书籍BusinessForms表格Cabinets抽屉Catalogs目录Correspondence信件Equipment设备Magazines杂志Paper纸张Parts零件Records记录Samples样品Shelves架子Supplies耗品OFFICEAREAS办公区CATEGORIZEITEMS:物品分类•RARELYUSED很少使用•OCCASIONALLYUSED偶尔使用•FREQUENTLYUSED经常使用1SSEPARATE整理REDTAGSTRATEGY红牌策略ATTACHTOALLUNNECESSARYITEMS悬挂于所有非必需品DISCARDUNNECESSARYITEMS扔掉不需要的物品DIVIDEITEMSINTOTWOCATEGORIES将物品分成必需品和非必需品NECESSARY必需品UNNECESSARY非必需品SEPARATE整理Factory厂区BeforeApplying1stS整理前AfterApplying1stS整理后SEPARATE整理Office办公区BeforeApplying1stS整理前AfterApplying1stS整理后SEPARATE-REDTAGGING整理-挂红牌•RedTagging挂红牌•RedTaggingisatrackingprocesstoprovidevisualidentificationofunneededitems.对非必需品挂红牌为了目视化的辨别和跟踪处理•RedTaggingisasafeguardtotheaccidentalremovalofcostlyandcriticalitems.挂红牌也是为了防止意外地把昂贵、重要的物品丢掉•Afterallobviousitemshavebeenthrownaway,remainingitemsare“red-tagged”toassureproperdisposition.在明显的非必需品处理掉以后，剩下的物品挂上红牌以便正确处置•SampleRedTags红牌示例SEPARATE-REDTAGGING整理-挂红牌CELL/AREAREDTAGTAGNUMBERCATEGORY1.RawMaterial2.WIP3.FinishMaterials4.Tools5.Supplies6.Equipment7.Furniture8.OfficeMaterials9.Books/Magazines10.Other:TAGDATETAGGEDBYITEMNAMEQUANTITYREASONTAGGEDDISPOSITIONREQUIRED1.Discard2.InCellsStorage3.LongTermStorage4.ReduceInventory5.Sell/Transfer6.Other:ACTIONTAKENDATECELL/AREAREDTAGLOCATORTAGNUMBERRecommendations建议Shouldbefullsize尽可能大些Brightredtobeveryvisible亮红色异常醒目Shouldhavepre-printedsequentialtagnumbers有预先印刷的序列号STRAIGHTEN整顿Organizingandlocatingthenecessaryitemssothattheycanbeusedandreturnedeasilynearthepointofuse.将必需品重新组织、定位在较近的位置以便使用和归还•PlaceAllNece