精益生产基本概念介绍

精益生产基本概念介绍SPS的四个主要组成部分4KeyElementsOfTheSolectronProductionSystem精益之屋HouseofSPSSixSigma检查缺陷ErrorProof零缺陷ZeroDefects利用数据分析来解决系统的问题SystematicProblemSolvingViaDataAnalysis拉动生产PullProduction一个流SinglePieceFlow平衡化生产TaktTimeProductionJidokaJIT基础Foundation客户之声VoiceOfCustomer;质量体系QualitySystem;5S;平整化生产Heijunka不断地改善和提高GembaKaizen(ShopFloorContinuousImprovement)集中在效率上EfficiencyFocus自动化Stop@Abnormality集中在质量上QualityFocus质量灵活性竞争力精益给客户带来什么?LEANSolectronProductionSystemTM(SPS)LEANImplementation(2004)…1Of3ElementsForCustomerValueProposition消除缺陷的二个途径6Sigma消除缺陷SMTSolderPT/HHPtestFQACustomerTestPrinter立刻有效!用眼镜看,采取行动TestTest25%缺陷Test现场改善消除缺陷75%缺陷用测量系统和数据分析,再采取行动•6Sigma项目•GageR&R•DOE•防呆•扩展好的改善方法基础:现场改善可消除75%的缺陷为什么要六西格码精益生产？/Why6-SigmaLean?•满足客户需求•Tomeetcustomerdemands.•客户只会为有价值的行为买单•Customeriswillingtopayforonlyvalue-addedactivities.•没有价值的行为会增加生产的成本•Non-valueaddedactivitiesaddcosttomanufacturing.•要想在竞争激烈的商业环境下生存，就必须最充分地利用资源•Tosurviveinthiscompetitivebusinessenvironment,thereisaneedtomaximiseutilisationofresources.•保持公司的收益•Sustainedprofitabilityofthecompany.对于公司FortheCompany对于个人ForYou•为了在旭电的安全工作•JobsecurityforSolectron•集中你的时间成就有价值的分派任务•Focusyourtimeandeffortonvaluabletasks.•停止步行/检查/查找/重做和其他一些无价值的行为•Stopwalking,checking,searching,reworkingandothernon-valueactivities.•加入到工厂的成功当中•InvolvedinthesuccessofthePlant.•你的技能和领导能力的提高从而得到认可•Yourskillsandleadershipdevelopmentandtheopportunitytoberecognized.•客户愿意付钱,并使产品发生转变或给产品增加价值的行为才是有价值的生产活动•Activitiesthattransformtheproducts,oraddvaluetotheproductswhichthecustomeriswillingtopayfor.例如/Examples：-贴装元件-Mountingcomponentsontheboard;-集成电路程序烧制-ProgrammeIC-印刷电路板放入盒子-SecurePCBtothechassis;-手工插装元件-Handloadthecomponents;-波峰焊操作等-WavesolderthePCBetc什么是有附加值的活动？/WhatareValue-Added(VA)activities?什么是可增加附加值的行为？/WhatareValue–Enabled(VE)activities?•不增加附加值但是必须要做的事情•Activitieswhicharenon-valueaddedbutnecessary…today例如/Examples:-视觉检查与测试-Visualinspectionandtesting-为了组装操作在小范围拿取工具和原料-Smallmovementstoreachfortoolsormaterialsforassemblyetc;什么是浪费？/Whatiswaste?•做不增加产品附加值的工作•Workwhichdoesnotincreasethevalueoftheproducts例如/Examples-错料返修-Reworkduetotheuseofwrongparts;-补焊-Touch-up;-当机器运转时，操作工等待的时间-Operatorwaiting-timewhilemachineisrunning;-找料，计算-ARF,lookingforparts,counting;-走动-Walkingetc.什么是七大浪费？/Whatis“7+1Waste”?•Overproduction过量生产•Overprocessing多余的工作程序•Inventory库存•Motion多余动作•Transportation运输•Rework返修•Waiting等待•Intellectwaste人才浪费消除7大浪费过量生产多余搬运等待多余的工作程序库存多余动作不良品生产过剩/Overproduction•客户何时需要，需要什么是我们的生产目的•Ourgoalistoproduceonlywhatthecustomerswant,whentheywantit.•过量生产是一种最大的浪费，它能够导致更多的浪费，诸如多余动作，等待，运输，返修;•Overproductionistheworsttypeofwasteasitleadstofurtherwaste,suchasmotion,waiting,transportation,rework.例如/Examples:-为了周末的野餐,而带了一周的食物-Bringoneweeksworthoffoodforaweekendpicnic;-存货的返修-ECreworkforinventory;-提前36小时备好料-Kit36hoursbeforepartsareneeded;-后道工序运作得比前道工序快-Runbottomsidefasterthantopsideetc•等待材料和机器操作时不做任何事•Doingnothingwhilewaitingformaterialsormachinetocompleteaprocess.•机器和人力利用率低下•Underutilisemachineormanpower•实质浪费时间会降低生产运作•Essentialwastetimecanbefilledwithproductiveactivities•重新平衡生产线会减少等待时间•Rebalanceactivitiestoremovewaitingtime.例子/Examples-提早到达,等待开会-Arrivinganhourearlyforameeting;-开会迟到,所以其他与会人员等待-Cominglateforameetingwhiletherestarewaitingforyou;-板子等待压配合-Boardsawaitingpress-fit;-手工组装的操作员等待板子-Handloadoperatorswaitingforboardsetc.等待/Waiting运输/Transportation•工艺过程中不必要的物料和人力移动•Unnecessarymovementofpartsorpeoplebetweenprocesses.•差劲的物流安排导致不必要的材料运输•Poorlogisticslayoutthatcauseunnecessarytransportationofmaterials.•能造成运输损坏或是产品质量问题等•Cancreatehandlingdamageandcauseproductionrejectssuchasknock-off,droppedboardsetc•例如/Examples:-传送带太长或工艺间隙太远-Conveyoristoolongorgapbetweenprocessistoofarapart;-在两站之间不必要的存货,板子送去清洗和5DX等-Unnecessaryinventorybetweenstations,boardssenttowashand5DXetc库存/Inventory•原料放置不动不能增加附加值•Materialsthataresittingidledonotaddvalue.•库存与现金紧密相联•Inventorytiesupcash(million/billionUSD)•库存可能是仓库里的原料或是生产线上的在制品•Inventorycanberawmaterialsinwarehouse/storeorWIPontheline.•大量库存会增加成本，并提高损坏，丢失，被盗等的可能性•Highinventoryincreasesthepotentialforhigheroperationcosts,scrap,loss,theftetc•差的生产线5S•Poor5Sontheline•例如/Example:-Stockupamonth’ssupplyofMaggieMeewhenthesupermarketisnearby;-Absenteeismthatcausesinventorytopileupatcertainoperations;-Comboboardstrafficjam;-Overflowofinventoryatparkinglotsetc多余的工作程序/OverProcessing•客户不需求的工艺作业是一种浪费•Processingbeyondwhatthecustomerrequiresisawaste.•可能是由于缺乏标准,或不了解客户的需求,或知识不知道规范•Maybeduetoalackofstandardsorlackofknowledgeofcustomersrequirementsorsimplydonotknowthespecifications.•多余的工作程序不能增加附加值,因为客户并不打算为之付钱•Overprocessingdoesnotaddvalueascustomerisnotgoingtopayforit.•例如/Example：-咖啡里加太多的糖-Puttoomuchsugarforcoffee-焊料过多-Extendedstirringofsolderpaste-将已经清洗干净的镜子再清洗一次-Cleaningthemirroroverandoveragaineventhoughthemirrorisalreadyclean.多余动作/Motion•在一个工序中不必要的物品或人员移动•Unnecessarymovementofpartsorpeoplewithinaprocess•差的工作站规划,差的5S.•Poorworkstationlayout,poor5S.•安排人员或物品围绕工作站,改善5S,并消除动作浪费•Arrangepeopleorpartsaroundstation,improve5Sandeliminatemotionwaste.•例如/Example:-手工组装的元件远离操作员-Handloadcomponentsareplacedfarfromtheoperator;-常用的工具远离工作站等-F