通用电气精益生产培训(GE-Lean-Basic-Training)

1/GETitleorjobnumber/6/12/2020LeanBasicTrainingTopicsWhatisleanandhistory什么是精益及精益的历史Definevalueandwaste价值和浪费的定义FundamentalToolsintheLeanToolkit精益生产常用工具IntroductionofAWO流程改进介绍2/GETitleorjobnumber/6/12/2020Whatisleanandhistory什么是精益及精益的历史3/GETitleorjobnumber/6/12/2020WhatisLean?什么是精益?“我们所做的一切就是关注从客户提出订单的那一刻到我们收到付款的整个时间进度，并且通过减少非增值部分的浪费来缩短这个时间进度。”Allwearedoingislookingatthetimeline,fromthemomentthecustomergivesusanordertothepointwhenwecollectthecash.Andwearereducingthetimelinebyreducingthenon-valueaddingwastes.通过消除浪费达到对完美的不懈追求ContinuouslystriveforperfectbyeliminatingwastesLEANisaJOURNEY,notaDESTINATIONLean是一个旅程不是目的地…We’vejustBEGUN…我们刚刚开始个大野耐一丰田生产体系创始者TaiichiOhnoTPSPioneer4/GETitleorjobnumber/6/12/2020HistoryofTheToyotaProductionSystem…“Lean”丰田生产体系的历史---精益生产ItstartedinJapanattheToyotaMotorCompany起源于日本丰田汽车公司In1902SakichiToyoda,founderoftheToyotagroup,inventedanautomatedloomthatstoppedanytimeathreadbroke.丰田集团的创始人丰田佐吉在1902年发明了一台自动织布机，这台织布机在任何断线的时候都能自动停止。SeveraldecadeslaterTaiichiOhno,aproductionengineerattheToyotaMotorCompanyappliedthesameconceptashesoughttoeliminatewaste,ornon-valueaddedactivities,withintheToyotaorganization.Inadditiontostoppingproductionateverydefect(Jidoka),heemployedanotherkeyconcept,JIT(justintime).Together,JidokaandJITarethepillarsoftheToyotaProductionSystem,supportedbyafoundationofHeijunka(levelloading)…thebasisofLean.几十年后，丰田汽车公司的生产工程师个大野耐一应用同样的理念在丰田集团推行消除浪费，减少非增值行为的活动。他不但继承了任何异常发生立即停止生产的理念（自动化），还提出了另外一个关键的理念，那就是准时生产。至此，自动化和准时生产作为平准生产的支撑成为丰田生产体系的支柱。5/GETitleorjobnumber/6/12/2020JITJidokaHeijunkaTPSJIT准时生产Jidoka自动化Heijunka平准化TPS丰田生产体系PullProduction拉动式生产SinglePieceFlow单件流TaktTimeProduction按节拍生产Stop@Abnormality异常发生，停止生产Automation自动控制Leveling均衡化Sequencing顺序化AddingValue&EliminatingWaste增加价值&减少浪费TheHouseofToyota丰田屋6/GETitleorjobnumber/6/12/2020Definevalueandwaste价值和浪费的定义7/GETitleorjobnumber/6/12/2020ValueAddedActivity有价值的行为Anyactivitythatchangestheform,fit,orfunctionofmaterialsorinformationtomeetcustomerrequirements.为满足客户要求，任何改变物料形态，大小和功能或者信息交流的活动-OR-或者Somethingcustomersarewillingtopayfor…客户愿意支付费用的活动Non-ValueAddedActivity无价值的行为Allotheractionsandunwantedfeaturesarebydefinition…WASTEaddingnovaluetothecustomer….simplyraisecostsinourbusiness!所有被定义为浪费，不会给客户带来价值增值但增加我们业务费用的行为DefiningValue定义价值TimeAfterBeforeValueAddedWork有价值的工作AfterBeforeNonValueAddedWork无价值的工作TimeEliminateNon-ValueAddedActivity消除无价值行为8/GETitleorjobnumber/6/12/20207Waste7种常见的浪费分类废品，返工(Defect)过度生产(Overproduction)运输搬运(Transporting)过度库存(Inventory)不必要的过程(ExcessProcessing)等待(Waiting)行动的浪费(Motion)Wasteaddsnovaluebutraisescost...浪费不增加价值，只增加成本9/GETitleorjobnumber/6/12/2020FundamentalToolsintheLeanToolkit精益生产常用工具10/GETitleorjobnumber/6/12/2020Eliminatethe7typesofWaste•DEFECTIVEPARTS•OVERPRODUCTION•INVENTORY•MOTION•PROCESSINGTRANSACTIONS•TRANSPORTATION•WAITING???searching???searching???searchingturningaroundturningaroundturningaroundchoosingchoosingchoosingbendingoverbendingoverbendingoverWasteElimination消除浪费WasteElimination=Efficiency消除浪费=效率TheFutureStateMapCustomerMACHININGC/T=1568mC/O=50min.2SHIFTSOPER.48DailyDailyFIFOFIFOProd’nCont.SupplierOrdersOrdersIRREGULARASSEMBLYC/T=936mC/O=0min.1SHIFTOPER.24TESTC/T=60mC/O=30min.1SHIFTSOPER.5FINISHC/T=210mC/O=0min.1SHIFTSOPER.6DISPATCHC/T=30mC/O=0min.1SHIFTSOPER.2FIFOFIFOFIFOFIFOOXOX1DAY2DAYS2DAYS900MINS900MINS240MINS150MINS120MINS1568MINS936MINS60MINS210MINS30MINS4WEEKSOUT12WEEKFORECAST1/2DAY2ENGINES2ENGINESPITCH=60MINUTESLT31/2DAYSMANUFACTURINGLEADTIME=31/2DAYSCUSTOMERLEADTIME=2WEEKSValueStreamMapping价值流程图SeetheEntireProcess…NotIslands看到全部的流程=没有孤岛7FlowsofProduction生产的7种流动•PEOPLE-StdWork-TaktTime•RAWMAT’L•SUBASS’YMAT’L•FINALASS’YMAT’L•RAWMAT’L•SUBASS’YMAT’L•FINALASS’YMAT’L•EQUIPMENT-carts-conveyors-andons-racks-TPM•INFORMATIONProductinfoinrelationtomat’l-productionschedule-kanban-pullsystemAretherelationships1:1?•ENGINEERING-quality-tooling-OMS-programsProcessSynchronization流程同步After30Seconds!!30Seconds!!OperationProblemActionsTakenResultsOperationProblemActionsTakenResultsOperationProblemActionsTakenResultsUnloadBase•NewhandlingTechnique••CraneEliminated•Standardizedmotion•30SecondUnload•20min+/-UnloadTime•ErgoIssues•NoStandardMotion•Mat’lhandlingDamageBefore20Min=20min=5??Before20Min20Min=20min=5??=20min=5??=30Seconds=5??=30Seconds=5?=30Seconds=5??ActionWorkout流程改进5DaystoaWorkingSolution!5天的解决方案SeiriProperarrangementSortSeitonOrderlinessStandardizeSeiketsuCleanupSimplifySeisoCleanlinessSweepShitsukeDisciplineSelfDiscipline5S整理,整顿,整洁,维持,素养The“BuildingBlocks”ofLean精益的构成要素MaterialPresentation物料摆放EliminatetheNeedtoSearch杜绝寻找OperatorEaseKitting0102030405060708090F1F1F2F24QLevelLoading均衡生产SmoothOutProduction使生产流畅FundamentalToolsintheLeanToolkit精益生产常用工具11/GETitleorjobnumber/6/12/2020FundamentalToolsintheLeanToolkit精益生产常用工具ThePullSystemKanBan看板VisualSignaltoDoSomething可视化信号ContinuousFlow连续流WorkdoneastheunitmovesdowntheLine产品下线，工作结束3P…ProductionPrepProcessNewProcessDevelopmentMachineShutDowntoPreventWaste关闭机器，阻止浪费StopatAbnormalities异常发生，停止生产TAKTTime节拍时间10.5min0.02.04.06.08.010.012.0LATHE#1LA