精益管理体系-精益生产中缺失的文化

泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.20161LeanManagement精益管理JustinTao陶建刚20162泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.2016HowCanYouRecognizeCulture?你如何认知文化？It`seasilypossibleto“see”workcultureinaproductionenvironmentbyaskingbasicquestions:采用询问一些基本问题，会使认知生产环境中的工作文化变得简单些：Whatareinventorypracticesaroundhere?这里的库存怎么样？Howoftendoesmanagementlookatthestatusofproduction?管理层多久来看一下生产状态？Whoisinvolvedinprocess-improvementactivitiesinthisarea?在这儿那些人参与了持续改进活动？3泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.2016DifferentCulturesinTraditionalandLeanProductions在传统生产和精益生产之间明显不同的文化属性Cultural A)ribute文化属性Tradi/onal Produc/on Culture 传统生产文化Lean Produc/on Culture 精益生产文化Inventory Prac-ces库存习惯 • Managed by computer system电脑系统管理 • Ordered by forecast通过预计下单 • Stored in warehouse areas or automated storage and retrieval facili-es储存在库房或自动化存取设备 • Held in bulk containers批量存放 • Moved by li? truck / cranes用叉车或天车转运 • Many hours’ worth or more per delivery每次转运要花几个小时或更多 • Delivered by the skid or tube by forkli? to vicinity of use 用轨道或叉车转运到邻近地使用 • Managed visually用可视化管理 • Ordered to replenish actual use根据补充实际使用下订单 • Stored in FIFO racks or grids addressed by part number使用部件地址系统存储在快进快出货架或栅格 • Help in point-of-use containers存放在使用点箱中 • Container quan-fy and number of container specified per address每个地址有确定的箱子数量 • Precise quan--es (o?en less than an hour`s worth) delivered to point of use精确地数量（经常少于一小时量）运送到使用点 • Deliveries by hand cart or tug使用手推车或拖车 4泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.2016DifferentCulturesinTraditionalandLeanProductions在传统生产和精益生产之间明显不同的文化属性Cultural A)ribute文化属性Tradi/onal Produc/on Culture 传统生产文化Lean Produc/on Culture 精益生产文化Produc-on Status 生产状态• Checked at end of shi?, beginning of next shi?, or end of week 在每个班次结束、下一次班次开始或一周结束时检查• Checked by supervisor, higher level managers 由主管或经理来检查• Checked by team leaders several -mes an hour 班组长一小时几次地检查• Checked by supervisors four or more -mes a shi? 主管每班四次或更多次数地检查• Checked by value stream managers once or twice during the shi? 价值流经理每班一两次地检查• Updated for all involved in a sequence of brief daily reviews of the previous day’s performance 向大家及时更新，每天回顾前一天的绩效5泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.2016DifferentCulturesinTraditionalandLeanProductions在传统生产和精益生产之间明显不同的文化属性Cultural A)ribute文化属性Tradi/onal Produc/on Culture 传统生产文化Lean Produc/on Culture 精益生产文化Process Improvement 流程改进• Made by technical project teams 由技术项目小组来做• Changes must be specifically “chartered” 一些改变需要特批• No Changes between “official” projects 对于“权威”的项目不能改变• Can be and rou-nely are ini-ated by anybody, including operators 任何人能而且日常地发动改进，包括操作者• Regular, structured mechanisms encourage every one from the floor on up to suggest improvements and most likely get involved in implementa-on 正规的结构化的媒介鼓励大家提出改进提案，并且很多人都愿意参与实施• Improvement goes on all the -me (con-nuously) 改进在不断持续地进行6泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.2016DifferencesinHabitsandPracticesBetweenTraditionalandLeanCultures在传统生产和精益生产之间明显不同的文化属性TraditionalProduction:传统生产PersonallyFocusedWorkPractices个人聚焦工作Independent独立的Self-pacedworkandbreaks工作和休息节拍自定“Leavemealone”“让我自己来”“Igetmyownpartsandsupplies”“我只管自己的部件和补给”“Wedowhateverittakestogetthejobdone;IknowwhomIcanrelyonatcrunchtime”“我们想尽办法来完成工作；我知道在紧急情况下找谁”LeanProduction:精益生产ProcessFocusedWorkPractices流程聚焦工作实践Interdependent,closelylinked互相依赖的，紧密相连的Process-pacedwork,timeasadiscipline工作过程节拍，时间就是纪律“Iworkaspartofateam”“我作为小组的一员在工作”In-andout-cycleworkareseparatedandstandardized输入和输出地循环工作是分离的，而且标准化的There’sadefinedprocessforprettymucheverything;followtheprocess几乎所有的事都有流程；并遵循流程7泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.2016DifferencesinHabitsandPracticesBetweenTraditionalandLeanCultures在传统生产和精益生产之间明显不同的文化属性TraditionalProduction:传统生产PersonallyFocusedWorkPractices个人聚焦工作“Idefinemyownmethods”“我定义自己的工作方式”Resultsarethefocus,dowhateverittakes不管用何种手段，结果才是最关注的“Improvementissomeoneelse’sjob;it’snotmyresponsibility”“改进时别人的工作，不是我的责任”“Maintenancetakescareoftheequipmentwhenitbreaks;it’snotmyresponsibility”“当机床停了，维修部才需管它，不关我的事”Managedbythepayorbonussystem”由薪水或奖金系统来管理LeanProduction:精益生产ProcessFocusedWorkPractices流程聚焦工作实践Methodsarestandardized工作方式是标准化的Processfocusisthepathtoconsistentresults过程关注是获得一致结果的途径Improvementisthejobofeveryone改进时所有人的工作Takingcareoftheequipmenttominimizeunplanneddowntimeisroutine保管设备使故障最小化融入日常工作中Managedbyperformancetoexpectations由期望值的业绩来管理8泰谋企业管理咨询（上海）有限公司©TXMLeanConsulting(Shanghai)Co.,Ltd.2016• ChangingHabits改变习惯• ExtinguishingversusBreakingHabits消灭习惯VS割裂习惯• Someexamplesofoldhabitsreassertingthemselvesinareasnewlyconverted刚转变后旧习惯重新复辟一些例子- Buildupsomeinventory库存增大- Allowlongerorextrabreaks允许更长的或额外的休息- Sendpeopleoffbalancedlinetochasepartsorrework派平衡生产线上的员工去做其他的赶活或返工- Workaroundproblemstodayandlettomorrowtakecareofitself今天避重就轻地解决一下问题，以后让它自生自灭吧- Leaveimprovementsto“theexperts”ratherthanspendingtimeinemployeesuggestions把改进活动留