波音-精益生产案例(外文)

BoeingEverettIntroductionLeanEfforts777FloorGridComponentDeliveryImprovements747LineSideSupplyandSimplifiedOrderingSystemChemicalPointofUseStations767&747WingSealMovingLines747HorizontalStabilizerProjectIntroductionBoeingisimplementingLeanprojectsinvariouswaysthroughoutitsEverettPlant.TheCompanycreatedanoverallLeanGrouptoassistinthedevelopmentandimplementationofLeaninitiativesthroughouttheplant.ProgramsinvitetheGrouptoparticipateinspecificLeanprojectsifdesired.ThedifferentairplaneprogramsandorganizationshavealsocreatedtheirownLeanofficestofocusspecificallyonLeaneffortswithintheparticularprogram.Forexample,the777programhasdevelopeditsownoffice,CriticalProcessReengineering(CPR),tolookforopportunitieswithinthe777line.波音在埃弗雷特工厂实施“精益工程”，这家公司创建了一个“精益小组”去帮助工厂全程积极的发展和实施“精益生产”，并参与到具体的精益工程中去。不同飞机项目和组织也会创立自己的“精益办公室”对具体项目重点实施精益生产。例如，波音777项目已经建立了自己的精益办公室-关键流程再造（CPR），去挖掘波音777生产线的改善机会。ThroughouttheEverettplant,Leaninitiativeshaveyieldedmeasurableresults.Largerefforts,likesomeofthosedescribedbelow,haveresultedinsubstantialresourceproductivitygainsandsavings.Smallereffortshavealsoproducedsignificantbenefits.Forexample,thedevelopmentandimplementationofanalodinepentobeusedpriortoprimertouchup,hasreducedhazardouswastegenerationbyapproximately36,55-gallondrumsperyear.Aspartofasmalltoolrecyclingandreconditioningprogram,the777WingMajorsshopisrecyclingplasticspatulasusedtoapplysealant,reducinghazardouswastegenerationbyapproximately90percent(onlythescrapedsealantresidueandvelcropadaredisposedof,notthespatulaitself).贯穿整个埃弗雷特工厂，积极主动的精益推广已经产生出重要的成果。大的成就：像接下来会描述到的，像在重要资源生产效率和节约上取得了好的成效。小的成就：也产生了巨大的效益，例如：金属表面处理笔的发展和实施优先于底漆润色的使用，这项技术的应用减少了大约36-55加仑的有毒有害废液每年的排放。作为小工具循环使用和修复项目的一部分，波音777机翼大部分车间正在循环使用废弃的漆工铲刀应用于密封剂，减少有毒有害废液大约90%（）LeanEffortsToillustrateingreaterdetailtheaffectofLeanManufacturingeffortsattheEverettplant,fiveLeanprojectswereselectedforcloserexamination.Theinitiativesselectedanddetailedbelowarethe777FloorGridComponentDeliveryProcess,the747LineSideSupplyandSimplifiedOrderingSystem,ChemicalPointofUseStations,767&747WingSealMovingLines,andthe747HorizontalStabilizerproject.Theseeffortsareatvariousstagesofimplementationandthefinaleffort,the747HorizontalStabilizerProjecthasbeenputonholdduetotechnicalandregulatoryconstraints.为了详细说明埃弗雷特工厂精益生产的制造成就，遴选了5个精益工程作介绍。1.波音777客机地板网格组件的运输过程；2.波音747生产线侧面供应和简化订单系统；3.化学的使用；4.波音767&747机翼密封线移动；5.波音747客机水平稳定器项目。这些成就是在精益生产实施的不同阶段，其中最后一项成就，波音747客机水平稳定器项目已经由于技术和监管约束而搁置。1.777FloorGridComponentDeliveryImprovementsBoeing,aspartofitsoverallLeanefforts,createdaLeanOfficetosupporttheTwinAisleProgram(747s,767s,and777s).The777Linealsoformeditsowngroup,CPR,toanalyzecurrentpracticesandidentifypotentialLeanopportunitieswithinthe777program.Inidentifyingpotentialopportunities,777operationswereexaminedintotal,providingabroaderperspectiveoftheoverallprogram.Intakingthismoreglobalapproach,CPRidentifiedascostreductionopportunitiestheshippingprocessesusedforseattracksandfloorbeams.BoeingproducesthepartsinWichita,KansasandTulsa,OklahomaandthenshipsthemtotheEverettplantinWashingtonState.作为整个精益生产成就的一部分，波音创建了精益办公室去支持双过道项目（波音747，,767和777机型），波音777生产线也组建了属于自己的团队CRP去分析现状，并识别波音777项目中的精益生产潜在机会。在识别潜在机会方面，波音777的运营得到了全面的检验，为整个项目提供了宽广的愿景。在全面推广精益生产技术手段的过程中，CRP在装运的过程中使用座椅导轨和门梁来减少成本，波音是在威奇托、堪萨斯、达拉斯和俄克拉荷马生产这部分成品的，并将其运送到位于华盛顿州的埃弗雷特工厂。CPRheldaLinktheFlowworkshoptodevelopaLeanVisionfortheshippingof777floorgridcomponents.Workshopparticipantsfocusedonshorteningtheoverallvaluechainanddevelopedavisionoftheidealshippingprocess.Theparticipantsalsodevelopedaninterimvision,whichservesasamidpointtargetintheprocessofcontinuallyimprovingtheshippingsystem.CRP坚持车间“一个流”的思想来发展波音777机型地板网格组件生产的精益生产愿景，车间参与者重心放在缩短整个价值链和发展装运过程的理想愿景，参与者也发展那些不断提升装运系统折中方案的过度愿景。Previously,Boeingdelivered777seattracksfromWichitaandTulsatotheBoeingEverettplantbytruck.ThepartswereunloadedatReceivingandInspectionandthendeliveredtothefactoryforassembly.Boeingshipped777floorbeamsbytruckfromTulsatoKansasCitythenloadedthemontoatrainforshipmenttoSeattleviarail.FromSeattle,atrucktransportedthefloorbeamstoReceivingandInspectionattheEverettplant.Eventuallythepartswerebroughttothefactoryforproductionpurposes.先前，波音用卡车将777机型的座椅从威奇托、达拉斯运送到埃弗雷特工厂的。这部分座椅在接受和检验是被卸载，然后运送到工厂进行装配。波音用卡车将777机型的门梁从达拉斯装运到堪萨斯城，然后装载到火车上，通过铁路运送到西雅图。从西雅图，一个卡车将门梁送到埃弗雷特工厂并检验，最后这部分门梁被送到各个工厂用于生产。TheWorkshopresultedinanewdeliverymethodfor777floorgridcomponents.TrucksnowtransportseattracksfromWichitatoTulsa,pickupthefloorbeamsthen,carryingcompleteshipsets,traveldirectlytoEverettanddeliverthepartsdirectlytothefactoryforuse.Receivingandinspectionprocessesareconductedattheplant.Theredesignedshippingprocessallowsasingletrucktodeliverashipsetoffloorgridcomponentsdirectlytotheirpointofuse.这个车间为777机型地板网格组件开发了一个新的运输方法，现在改为卡车将座椅从威奇托运输到达拉斯，Asaresultofthenewshippingprocess,Boeinghasrealizedthefollowingresourceproductivitygains:Multipletransfers,railtravel,andtrucktraveltotherailheadshavebeencompletelyeliminated.TrucksnolongerrunemptyfromKansasCitytoTulsabecauseshippingbyrailhasbeenremovedfromtheprocess.Eightdaysoftravelandthreedaysofrece