精益生产Lean Manufacturing WK2

leanmanufacturingtrainingweek2[]Copyright©FuturisAutomotiveInteriorsAllRightsReserved[2]TPS–TotalProductionManagementVisualManagementStableandStandardizedProcessesLeveledProduction(Heijunka)Just-in-TimeRightpart,rightamount,righttime•Takttime•Continuousflow•Pullsystem•QuickChangeover•IntegratedlogisticsJidoka(In-stationquality)MakeproblemsvisibleAutomaticstops•Andon•Person-machineseparation•Errorproofing•In-station-qualitycontrol•Solverootcauseofproblem(5Why’s)BestQuality–LowestCost–ShortestLeadTime–BestSafety–HighMoraleThroughshorteningtheproductionflowbyeliminatingwasteleanmanufacturingfoundationsPeople&Teamwork*Selection*Rigiddecisionmaking*Commongoals*Cross-trainedWasteReduction*GenchiGenbutsu*Eyesforwaste*5Why’s*ProblemsolvingContinuousImprovementCopyright©FuturisAutomotiveInteriorsAllRightsReserved[3]standardizedwork“standardizationisthestartingpointforcontinuousimprovementandquality”Copyright©FuturisAutomotiveInteriorsAllRightsReserved[4]standardizedworkifstandardsarenotdefined,itisnotpossibletotrulymakeimprovementsQ.Ifaprocessisnotstandardized(i.e.itisrandomandchaotic)andimprovementsaremade,whatwasimproved?nobaselineforevaluationhowdoyouknowifyouarewinningifyoudon’tkeepscore?Copyright©FuturisAutomotiveInteriorsAllRightsReserved[5]standardizedworkstandardizedprocessesandproceduresarethegreatestkeytocreatingconsistentperformanceongoingactivityofidentifyingproblems,establishingeffectivemethods,anddefiningthewaythosemethodsareperformedtoensurethebestpossibleresultspeopledoingtheworkunderstanditsufficientdetailtomakethebestcontributiontostandardizationCopyright©FuturisAutomotiveInteriorsAllRightsReserved[6]standardizedwork型号:（MODEL）CheryS21管理者（Manager）NameSignatureDateDatePreparedBy:RevNo.质量（Quality）制造（Manufacturing）工程师（ProcessEngineering）16-Jan-07MelinaMatsakosOriginal零件编号零件名称过程号符号作业步骤主要步骤=蓝色字体,关键点=橙色字体,原因=绿色字体联系人或监督者工具STARTSubAssembly1-Page11Determineseatvariantviabuildlabel根据生产计划查明座椅配置CheckwhichFSBtobeassembledCorrectFSBassembledtoseatContactSupervisorBuildLabelCG000252Foam2Selectfoamandplaceonpindownfixture取出左前靠泡沫并套在专机上部的滑块的定位块上PositionfoamcorrectlyonpindownfixtureEasiertocompleteFSBassemblyContactSupervisorPinDownFixtureCG000254Trim3Selecttrimandinsertoverfoam取出面套总成并套在专机工作台的夹具上EnsurecorrectalignmentoftrimtofoamGoodvisualappearancetothecustomerContactSupervisorCG000287HogRing4Securetrimtofoamviahogring按顺序在面套和泡沫打9颗C形环FollowpindownsequenceGoodvisualappearancetothecustomerContactSupervisorHogRingGunPage1of3GOTOSubAssembly1-Page2标准操作规程STANDARDOPERATINGPROCEDURES21FrontSeatAssembly批准（Approval）修改记录（AmendmentRecord）CG000068LH&CG000067RHS21FRONTSEATLH&RH工位FSA01SA01图片零件编号：（PARTNO.)描述：(DESCRIPTION)-CriticalCharacteristicsSC-SignificantCharacteristics-TeamMemberSafetyCCCopyright©FuturisAutomotiveInteriorsAllRightsReserved[7]standardizationandlearninggohandinhandandarethebasisforcontinuousimprovement.ifwedonotstandardizetheimprovedprocess,thelearninguptothatpointfallsintoablackhole,lost,forgottenstandardizedworkCopyright©FuturisAutomotiveInteriorsAllRightsReserved[8]takttime•timerequiredtocompleteonejobatthepaceofcustomerdemand•derivedfromtheGermanword“taktzeit”whichtranslatestoclockcycle•leanmanufacturingenvironmentpacetimeisequaltotakttime•theheartbeatofonepieceflow•nottobeconfusedwithcycletime–timenecessarytocompleteataskCopyright©FuturisAutomotiveInteriorsAllRightsReserved[9]takttimetakttimedefinedas:t=tatdwheret=takttimeta=netavailabletimetoworktd=totaldemand(customerdemand)Copyright©FuturisAutomotiveInteriorsAllRightsReserved[10]takttimebenefits:•productionstability–limitsoverproduction•workstationdesign–worktasksarebalanced–anyoperationrequiresmorethanthetakttimethestationcannotproducethenecessaryrate•improveperformance–awareofoutputratesandpotentialproblemsandimplementnecessarycorrectionsCopyright©FuturisAutomotiveInteriorsAllRightsReserved[11]visualcontrols•anycommunicationsdeviceused(signs,labels,colourcoding,andonetc)intheworkenvironmentthattellanyoneunfamiliarwiththeprocesswhatisgoingon,understandtheprocessandknowwhatisbeingdonecorrectlyandifitisdeviatingfromthestandardandonCopyright©FuturisAutomotiveInteriorsAllRightsReserved[12]visualcontrolsAndon–ancientJapan“paperlantern”functionedassignalingdevice-Green:normaloperations-Yellow:changeoverorplannedmaintenance-Red:abnormal,machinedownCopyright©FuturisAutomotiveInteriorsAllRightsReserved[13]visualcontrol•describeworkplacesafety,productionthroughput,materialflow,qualitymetrics•informationissharedandcommunicatedataglanceusevisualcontrolsonoproblemsarehiddenCopyright©FuturisAutomotiveInteriorsAllRightsReserved[14]5SbasedonJapanesewordsthatbeginwith‘S’,the5Sphilosophyfocusesoneffectiveworkplaceorganizationandstandardizedworkprocedures.5Ssimplifiesyourworkenvironment,reduceswasteandnon-valueactivitywhileimprovingqualityefficiencyandsafety.ThePrinciple-Cleanitup,makeitvisualCopyright©FuturisAutomotiveInteriorsAllRightsReserved[15]5Sbenefits•Improvedsafety•increaseemployeemoral–feelbetterwheretheywork•createpositiveimpressionsoncustomers•increaseefficiency