工厂快速诊断工具

No.Dimensionsofassessment评估维度Score得分Measures衡量指标1CustomerSatisfaction客户满意7CPPM客户PPMWrittenConcern客户书面抱怨2Safety,environment,cleanliness,&order安全，环境，清洁与秩序5LostTimeIncidenRate损失工作日事故伤害率SafetyIncidentRate总事故发生率3VisualManagementDeployment可视化管理的实施34Schedulingsystem生产计划系统3EPEI5Product&materialflows;spaceuse产品与物料流；空间的利用3Proportionofproductionarea生产面积占比Ratiooflogisticsoperatorstodirectworkers物流操作工与直接工比率6InventoryLevels库存水平7InverntoryTurns存货周转率增值比ProcesscycletimetoflowtimeratiosPercentageofinventoryolderthan180days大于180天库龄的库存百分比7Peopleteamwork,skilllevel,&motivation团队工作，技能水平与激励Paticipantrateofemployeeproposal合理化建议的参与率Percapitanumberofemployeeproposal合理化建议的人均条数Multiplejobratio多岗工比率8Equipment&toolingstate&maintenance设备和模具的状态与维护3OEE设备综合效率TEEP设备全局效率平均切换时间Meantimeofchange-over9AbilitytoManageComplexity&Variability管理复杂性和不确定性的能力7indirecttodirectlaborratio间接与直接劳动比Supportstafftototalworkforceratio支持人员与总劳动力比Overheadcostratios变动制造费用比率柔性设备的比率Flexiblemachineratio10SupplyChainIntegration供应链整合3Supplierontimedelivery供应商供货及时率供应商PPMSPPM11质量系统的部署QualitySystemDeployment9废品损失率Scraprate最佳实践复制率ReplicationrateofBestPracticeNote:Starting-1;Developing-3;Meet-5;Excellent-7;Benchmark-9Factors因素Marketshare市场份额Customerratings/qualitycertifications&ratings客户评级/质量认证与评级Customerclaimsandwarranty客户索赔与售后市场索赔Rateofnewproductintroduction&acceptance新品导入及接受情况Employeeknowledgeofexternalandinternalcustomerrequirements,visitorwelcome员工对内外部客户需求的了解情况，以及对访客的友好度Safety&environmentrecord安全环境记录Color&othercodingforsafety安全色标Placeforeverything&everythinginitsplace,cleanlinessofoperations--exterior&interior,floors,equipment,spills,leaks,noise,lighting,paint,dust,airquality,employeedress,restroomconditions,desks&workbenchorder&cleanliness所有东西都有地方放置，所有东西都物归其位；运作的清洁度——外部和内部，地板，设备，溢出，泄漏，噪音，照明，油漆，灰尘，空气质量，员工着装，卫生间条件，桌子和工作台的顺序和清洁度Inventoryorder,materialfloworder&cleanliness库存，物流的有序和清洁度Operationsmission&performanceobjectivesvisible运作的使命及业绩目标目视化Visibilityoflabeling&codingofproductlines,inventory,equipment,&tooling；colorcoding&differentiation;产线，库存，设备和模具等标识可见，通过色标体现状态差异Visibilityofcustomeridentification&ratings所服务的客户及其评级可见Visibilityofchartstrackingoperation's&teams'safety,quality,&productivity有图表可以跟踪运作团队在安全，质量，效率等方面的表现Showingstatusofcustomerorder&orderfulfillmentvisibility,Kanbandeployment,inventorycountcanbemadevisually,machines&toolpreventivemaintenancevisibility,productdisplays,auditresultsvisible能够展示客户订单及执行情况，看板实施状况，库存数量，设备和模具的预防性维护，产品及开展产品AUDIT的结果Degreeofschedulingtocustomerorder,orderprocessefficiency,productlineschedulingatsinglepoint,schedulingbuckets(eachorder,hourly,daily,weekly,ormonthly)按客户订单排程的程度，订单处理的效率，在产品链条中按一个点排程的状况，排程时段（每个订单、每小时、每天、每周或每月）Supplierscheduling&delivery,replenishmentversusorderfulfillment,computerschedulingversuskanban,pullversuspushsystems,flowtimeefficiencies,backroomcostsofscheduling,MRPcosts,dataentrycosts供应商计划与交付、补货与订单履行、计算机计划与看板、拉式与推式系统、流程时间效率、计划的后台成本、MRP成本、数据输入成本Productlineversusshoplayout是按照产品线，还是按车间布局Rollingcartspulledbytractorsorbyhand由人工拉车还是以机械牵引Conveyersversusforklifts使用传输机，还是叉车Traveldistancesbetweenprocesses搬运的距离Materialmovementresponsibility--processownedorseparatematerialstaff物料移动的责任——加工者，还是独立的物料人员Containersize(forkliftrequirement),containersdesignedforpartsfamilies容器尺寸（叉车要求？），为零件系列设计的容器Singleversusmultipledockstominimizematerialtravel设置了单个，还是多个道口，以尽量减少材料运输Spaceutilization,goalsforspaceusereduction空间利用率、减少空间利用率的目标WIPlevelsateachprocess,WIPintransitinplant各工序的自制品水平，工厂内转运中的在制品水平Separatestoresversuslinesidestorage,numberofinventorystorageareas线边存储，还是独立的存储，存货存储区的数量Finishedproductlevels成品库存水平Countabilityofinventory存货盘点情况WIPmovementtriggeredbycomputer,materialdepartmentornextprocess在制品的移动由计算机驱动，还是物流部门或后道工序Theoreticalversusactualflowtimes理论的Flowtime与实际Flowtime的比较Teamproblemsolvingcapability&history团队解决问题的能力和历史Employeewillingnesstotalkaboutcustomers,products,&company员工谈论客户、产品和公司的意愿Uniformityofdress服装的统一性Communications&recognitionenvironment交流与认可的氛围Teammeetingareas&performancecharts团队会议的场所与绩效图表Traininginvestments,educationalsupport培训投入与教育支持Benefitpackage&costs,unionizationactivity福利包和成本，工会活动Workforce-managementrelationship,communitysupport,company-supportedactivities(picnics,openhouses,sportsteams,localinvolvement）员工管理关系、社区支持、公司支持的活动（野餐、开放日、运动队、当地参与）Employeeknowledgeof&supportofcustomers&business,workinstructionsstandards员工对客户、业务、工作指导标准的了解和参与Preventivemaintenancesystem预防性维护系统Setupchangetimes切换时间Integratedgo-no-goqualitychecks集成的阈值检测Machineperformancedataavailability设备运行绩效数据易于获得Knowledge&utilizationofbottleneckprocesses了解瓶颈过程的利用率Processcontrolcapability过程控制能力Totalassetutilization整体资产的利用情况Operatorroutinemaintenance,maintenancestaff&teams操作员的日常维护、维护人员和团队MROreplenishmentefficiency设备维修的供给效率（MRO-MaintenanceRepairOperating）Tool&fixtureorderliness,cleanliness,&storagelocation工具和夹具的整齐，清洁，存储位置Equipmentimprovementpolicy,equipmenttechnologystrategy设备改进政策，设备技术策略Useofcommonparts,processes通用零件和流程的使用Commonalityoftooling&fixturing,commonalityofequipment&tools,commonalityofsupportsoftware&applicationsprogramsacrosstheoperation&amongsisterplants工装夹具的通用性、设备和工具的通用