福特生产系统的使命(1)

MASSLEANCULTURE福特生產系統的使命我們將教導,吸引,以及激發福特汽車公司的所有組織和每一個人來了解以及應用精實的行為原理和方法-以促使連續不斷的改進安全,品質,速度,和總成本-更而帶給顧客更多的價值MASSLEANCULTURE一個不斷學習的組織Ateachingorganization….從大量生產到精實生產的轉變...TransformationfromMasstoLean…MASSLEANCULTURE附加價值與非附加價值附加價值是顧客願意出錢購買一些事物而這些事物帶給他外觀舒適功能非附加價值=浪費MASSLEANCULTURE何謂附加價值?範例:•鑽孔•裝設凸緣•驅動螺絲有附加價值2%浪費60%無附加價值,但是必要的38%時間12639範例:•走去取零件•等待時間•儲存零件•運輸範例:•拿取鑽孔機•放下扳手•挾住或鬆綁工具MASSLEANCULTURE它是一個能改變產品之型式、裝配、及功能以合乎消費者之規格的程序。Processesthatchangetheproductform,fit,orfunctiontomeetcustomerspecifications.消費者願意付費的工作Workthecustomeriswillingtopayfor.何謂附加價值?MASSLEANCULTURE只增加成本及工時未增加附加價值之部份消費者不願意付費的工作問題之癥兆而非問題之根源瞭解與認知才是找出浪費的根源Therecognitionandunderstandingofwasteiskeyindefiningtherootcause必須認識浪費才能減少浪費Toeliminatewaste,youhavetobeabletorecognizewaste何謂浪費?MASSLEANCULTUREMOVEITOVERTHEREUNTILWENEEDIT___________________________________________________________________________________________________七大浪費SUPPLEMENTD1MASSLEANCULTUREMOVEITOVERTHEREUNTILWENEEDIT等待過度加工庫存移動搬運矯正生產過剩SUPPLEMENTD2七大浪費MASSLEANCULTUREMakingmorethanthenextprocessneeds生產過剩MASSLEANCULTURE什麼是生產過剩?生產的數量比下一工程所需用的還多以比下一站還快的速度生產以比下一工程所需的速度還快的生產MotionInventoryExtraProcessingTimeWaiting生產過剩MASSLEANCULTURE生產過剩為什麼這一類的浪費會發生?勞動成本及間接成本的指標可驅使人員和設備的使用率LaborandOverheadMeasurabledrivingutilizationofpeopleandequipment庫存而引起的損失Lossesfromoutofstockconditions堵塞及斷線而引起的損失Lossesfromblockedandstarvedconditions特殊材料的需求MaterialproducedtospeculativedemandMASSLEANCULTURERejects,rework,reruns改善CorrectionMASSLEANCULTURE改善Correction為什麼這一類的浪費會發生?品質回饋太慢Poor,slowqualityfeedback增加生產線外之撿察工作Incrementalinspectiondoneoutsideprocessstation認可檢修工作Repairoperationsareviewedasacceptable缺乏有效之錯誤防止措施FeweffectiveErrorProofingdevicesinuse未推行標準作業Standardizedworknotinplace產品與製程不相容Product/processincompatibility產品過度複雜Productover-complexityMASSLEANCULTURE沒必要的步驟或程序Unnecessarystepsorprocesses過度加工OverProcessingMASSLEANCULTURE過度加工Overprocessing為什麼這一類的浪費會發生?作業標準不明確Standardsunknown/uncleartooperators顧客之規格不明確或常變動Customerspecificationsarevagueorfluctuate產品試驗過多Producttestingandre-testingoccurs部門間目標不一致且溝通不良Functionaldepartmentshavemisalignedgoalsandpoorcommunication多多益善的想法ConceptthatmoreisbetterMASSLEANCULTURE動作Motion多餘的移動作業員的走動Excessmovement;operatorwalkingMASSLEANCULTURE動作Motion為什麼這一類的浪費會發生?外觀及組織不良之工作站Poorworkstationconfigurationandorganization工作量不平衡Workimbalance未實施目視化工廠VisualFactorynotimplemented未實施標準化StandardizedWorknotimplementedMASSLEANCULTURE長距離或重複搬運材料Longdistanceordoublehandlingofmaterial“運輸工具”Conveyance將它移到這裡等到我們需要時再動MASSLEANCULTURE運輸工具Conveyance為什麼這一類的浪費會發生?工作間距離過長Longdistancesfromoperationtooperation物料輸送未按排訂路線MaterialHandlersnotonscheduledroutes倉庫在工廠內部或外部Warehouseonoroffsite收料點與工作站間距離太遠Distancebetweenreceivingandpointofuse庫存過量HandlingexcessinventoryMASSLEANCULTURE缺乏部品作業或看顧機台Lackofpartsorwatchingmachine等候WaitingMASSLEANCULTURE等候Waiting為什麼這一類的浪費會發生?等候支援訊息及物料Waitingforsupport,information,and/ormaterials總和設備效率過低，機器停擺過高LowOverallEquipmentEffectivenessandhighmachinedowntime作業線不平衡Unbalancedoperations長且不一致的等候時間Longandinconsistentleadtimes生產時程經常變動Continualproductionschedulefluctuations看守自動機台Watchingautomatedmachines未事先安排的會議UndisciplinedmeetingsMASSLEANCULTURE過剩的原材料半成品或成品庫存Excessrawmaterials,WIP,orfinishedgoods庫存InventoryMASSLEANCULTURE過度庫存Inventory(Excess)為什麼這一類的浪費會發生?堅持大量生產的想法MassProductionmindset,batchandqueue產能無法預估Unpredictableproductivity內外部材料供應不順Infrequentdelivery/shipmentofmaterialsinternallyandexternally排程與製程間不相連結Schedulesnotlinkedbetweenprocesses未啟用目視化工廠管理VisualFactorynotinusetocontrol大料架或大批量Largecontainers/batchsizesMASSLEANCULTURE改善的機會躲藏於超額庫存之間Excessinventoryhidesopportunitiesforimprovement如汪洋大海之庫存SeaofInventory過多之庫存EXCESSINVENTORY認知MASSLEANCULTURE過度庫存成本之知多少TheTRUECOSTofExcessInventory•額外的運送成本ExtraCarryingCost•額外的庫存成本ExtraStorage•額外的料架ExtraContainers•額外的管理ExtraHandling•額外時間浪費ExtraTime•額外損害ExtraDamage•不安全UnsafeConditions•過度庫存隱藏品質問題Excessinventoryhidesqualityproblems...無止盡的改善Nocontinuousimprovement!MASSLEANCULTURE其它浪費OtherWastes人員People心態Minds想法Ideas能力Abilities科技Technologies有關安全之浪費AllwastesrelatetosafetyMASSLEANCULTURE精實製造LeanManufacturing以消除浪費來說縮短顧客之等候時間Amanufacturingphilosophywhichshortensthetimelinebetweenthecustomerorderandtheshipmentbyeliminatingwaste貨品送達PRODUCTSHIPMENT顧客訂單CUSTOMERORDER時間TimeBusinessasUsualLeanManufacturing貨品送達PRODUCTSHIPMENT顧客訂單CUSTOMERORDER時間〈縮短〉Time(Shorter)WasteWasteMASSLEANCULTURE福特生產系統FordProductionSystem福特生產系統是以減少浪費來穫致持續的改善TheFordProductionSystem(FPS)isdefinedasasystemofcommonprocessesandtoolsthatsupportcontinuousimprovementthroughtheeliminationofwaste.MASSLEANCULTUREFTPMTrainingISPCMEEnvironmentalIMSHARPSMFWorkGroups福特生產系統之要素FPSElementsMASSLEANCULTUREFTPMTrainingISPCMEEnvironmentalIMSHARPSMFWorkGroups福特生產系統之要素FPSElementsMASSLEANCULTURE精實之家HouseofLeanHighestQuality,LowestCost,ShortestLeadTime作業穩定STABLEPROCESSES平準化生產LeveledProduction標準化作業StandardizedWork改善KaizenJITJidokaMASSLEANCULTURE往未來圖五個階段的目的PurposeofFivePhasestoFutureStateContinuous連續的流動Flow後拉式系統PullSystem平準化生產LevelProduction同步生產SynchronousProduction穩定性StabilityMASSLEANCUL