5s工艺流程精益思维

AJCIManufacturingSeriesTrainingProgramJCI制造培训系列LeanThinkinginProcessMapping工艺流程计划中的精艺思维Quest7/7/98©JohnsonControls,Inc.leanmap.ppt2QuestCourseObjectives课程目标•Understandtherelationshipbetweenleanthinkingandallbusinessprocesses(productionandadministrative)•理解精艺思维与所有业务流程之间的关系（生产与管理）•Learnhowtoconstructthe“as-is”processmap•学会如何构建“如果－那么”的工艺流程•Learnhowtoapplyleanprinciplesofwastereduction(the8KindsofWaste)inagapanalysisofthe“as-is”map•学会如何将减少浪费的精艺思维运用于“如果－那么”的流程分析中•Learnhowtoperformvalue/non-valueaddedanalysis•学会如何进行增值/无增值的分析•Learnhowtoconstructthe“should-be”processmap•学会如何建立“应该”的工艺流程•Learnhowtodocumentandverifyimprovementsinanybusinessprocess•学会如何在业务流程中对改善进行验证并将其文件化7/7/98©JohnsonControls,Inc.leanmap.ppt3QuestLogistics后勤•Starting/EndingTime开始/结束时间•SafetyRequirements安全要求•LunchArea/Timing午餐地点/时间•MeetingLocation(s)会议地点•Restroom(s)休息室•Telephones,Messages,Pages•电话，便条，记录•CallinNumber定制定位•Refreshments茶水•CopyMachines复印机•Timekeeper钟表7/7/98©JohnsonControls,Inc.leanmap.ppt4QuestGroundRules基本规程•Discussideasandissues,notpeople•讨论想法和问题，而不是人•Inbrainstorming,noideaiswrong•进行头脑风暴，所有的主意都是好主意•Respectforparticipants-donotinterruptspeaker•尊重参与者，不要打断别人的发言•EveryoneParticipates•人人参与7/7/98©JohnsonControls,Inc.leanmap.ppt5QuestWhyMapABusinessProcess?为什么要有业务流程？•Needa“snapshotintime”•需要“及时的简单印象”•Cannotmeasureimprovementwithoutabaseline•没有基准久无法衡量改善•Quantitativeandqualitativemeasureables•衡量要定性定量•Ifyou’renotcontinuouslyimproving,thecompetitioniscatchingup!•如果你不能做到持续改善，竞争就会随之而来！•Benchmarkingisnotenough.•基准是不够的•Thetruecompetitorisperfection.•真正的竞争者是完美的7/7/98©JohnsonControls,Inc.leanmap.ppt6QuestLeanThinkinginProcessMapping工艺流程中的精艺思维•Theleanor“valuestream”approachstartswiththecustomerneedandthe“pull”thatneedcreates.精艺思维和“价值流”的方法是从客户需求和“拉动”开始的•TheCustomer:Ineedacar…•客户：我要一辆车…•TheOEM:Ineedanengine,Ineedtires…•整车厂：我要一个引擎，轮胎…•TheSupplier:Ineedrubber…•供应商：我要橡胶…•TheRawMaterialSupplier:Ineedrubbertrees...•原材料供应商：我要橡胶树…7/7/98©JohnsonControls,Inc.leanmap.ppt7QuestLeanThinking(cont’d)续上•Aleanprocessstrivestofulfillaneedwiththehighestquality,bestdeliveryandlowestcost.精艺流程努力以最高的质量，最佳的货运和最低的价格来满足客户需求•Anythingwhichthatdoesnotcontributetothisgoaliswaste.Anything.任何不能为了这一目标而服务的都是浪费•Aleanprocessstrivesfora“perfect”valuestream,inwhichthereisnowaste.•精艺流程是为了完美的价值流而努力的，要求没有任何浪费7/7/98©JohnsonControls,Inc.leanmap.ppt8QuestResources&Timing资源＆时间•Resources:资源–Facilitator厂房，设备–CoreTeamMember核心团队–ProcessSupplier/Customer(s)工艺的客户与供应商•Timing:时间–Ifthe“as-is”mapexists,4-6hours–如果“如果－那么”图存在，则4－6小时–Ifthe“as-is”mapmustbecreated,8-10hours–如果“如果－那么”图必须被建立，则8－10小时7/7/98©JohnsonControls,Inc.leanmap.ppt9QuestLeanProcessMappingOverview精艺流程图大概1)Processmapthe“as-is”stateoftheprocess对工艺流程建立“如果－那么”图2)Dotheprocesswalkthrough:documentthe7TypesofWastefoundineachprocessstep工艺预演：对每个工艺找出7种浪费3)Performa“gapanalysis”and“value/non-valueaddedanalysis建立“差距分析”和“增值/不增值”分析4)Processmapthe“should-be”stateoftheprocess对工艺流程建立“应该”图5)Verifytheperformanceofthe“should-be”process验证“应该”工艺流程图的执行情况7/7/98©JohnsonControls,Inc.leanmap.ppt10QuestWhatisaProcessMap?什么是工艺流程图？•Aprocessmapisagraphicalrepresentationoftherelationshipbetweenresourcesandthetasksthatareperformedtocompleteagivenprocess.Themapcanbeasbasicorelaborateasdesired.Thetasksarenormallywritteninsideshapessuchasboxes.Therelationshipbetweentasks,resourcesandthestepsoftheprocessarenormallydenotedwitharrows.•工艺流程图是一张关于完成对给定的工艺进行资源和任务之间关系的分析的图表。这张图可以做到十分基础和详细。任务通常被写在一个个方框内。任务，资源，工艺步骤之间的关系相互之间用箭头连接。7/7/98©JohnsonControls,Inc.leanmap.ppt11QuestWhatisaLeanProcessMap?什么是工艺流程图？•Aleanprocessmapusesthestandardprocessmapasitsbasis,andaddsthedimensionoftime(cycletimeandelapsedtime)精艺工艺流程图使用标准的工艺图作为他的基础，然后加上时间的分配。（周期时间＆总计时间）•Cycletimeistheamountoftimeittakestoactuallycompletethetaskinthebox.周期时间是实际完成方框内任务所用的时间。•Elapsedtimeistheamountofcalendartimeinwhichtheprocessstaysintheboxwhilethetaskiscompleted.总计时间是当任务完成时所用的总时间。•Example:Ittakes4hourstowriteareport(cycletime).Thereportisworkedonintermittentlyfor3days(elapsedtime).•举例：花4小时完成报告（周期时间），报告的断断续续完成共用了3天（总计时间）7/7/98©JohnsonControls,Inc.leanmap.ppt12QuestProcessMappingConventions工艺流程图的惯例规则•Useaboxforvalue-addedactivites对增值活动使用一个方框•Usearoundedboxfornon-valueaddedactivities对不增值活动用一个圆框•Usetheleftsideofthemaptoshowresources在流程图的左侧表明资源•Usethebottomofthemaptoshowprocesstimeline在流程图的底部表明流程时间•Oneboxforonediscretetask一个离散的任务用一个方框•Onlyshow“repeatloops”once.只用一个重复循环•Usealarge“returnarrow”toshowmultiplerepeatloops.用一个大的反向箭头表明多重复循环•Use“averagetimes”foreachtask对每个任务使用平均时间•Ineachtaskbox,show:在每个任务方框内显示：–Taskdescription任务描述–Cycletime周期时间–Elapsedtime总计时间7/7/98©JohnsonControls,Inc.leanmap.ppt13QuestTaskBoxExample任务框举例TaskboxSquare=ValueAddedRound=Non-ValueAddedPerformanalysisandwritereport(2days/5days)TaskDescriptionElapsedTimeCycleTime任务框方框＝增值圆框＝无增值任务描述周期时间2天总计时间5天进行分析并作出报告7/7/98©JohnsonControls,Inc.leanmap.ppt14QuestLeanProcessMapExample精艺工艺图举例TimelineResourcesContractorManagementConductPreliminaryDesignReview(1day/10days)Test(7days/7days)UpdateDesign(2days/20days)Day240Day342Thisprocessrepeated3timesRespondtoCorrectiveActionItems(1day/4days)