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1、丰田精益生产手册中英文对照版,Lean Hand Book精益生产手册,Kaizen Workshop o目标Productivity Improvement.端到端(从头到尾)产能提高DoubleETE Zero Defect(Qualitya DefectX1/10the Good好的加倍TPM,OEE&etc.)端到端(从缺陷降低90%头到尾)零缺陷(质量,全面生Halve产维护,全局设备利用率等)库存减半the Bad坏的减半条低nventory Reductions降生产效率翻倍X12DoubleLead Time Reductions缩短生产周期减半ScrapX1/10产前置期报废
2、降低90%Crew Size Optimization优化SpaceX12改善速度加倍员数量面积减半Goal:Add Value Eiiminate wvasie.Relentlessly for Our Customers目标:减少浪费&创造价值全心全意为客户服务No Money不投入更多金钱No Space不占用更多面积No Manpower不使用更多人力,Standard work standard combination sheet标准化作业&标准作业合并表1)Standard work defined标准作业定义a)Takt time defined节拍时间的定义b)Work seq
3、uence defined工序的定义3 Key Elements3项关键要秦c)Standard wiP defined标准在线库存定义d)Cycle time defined周期时间定义e)No of operators defined操作员数量的定义Safetyg)Multi skill2)Standard work combination sheet defined标准作业合并表定义a)Manual time手动时间b)Auto time机器(自动)时间c)Walking time走动时间d)Waiting time等待时间3)Is the Quality check legend de
4、fined on each process on std work sheet?标准作业合并表上,有定义每个流程中的品质管控的关键点吗?,3 Types of Standard Works3种标准作业Type类型机器例子节拍时间顺序信专触发工具标准在制品SwCsStandardWork标准作业Work Load Hand LoadChart/SwCS手动作业装配WorkStandard3异常报警系作业标准,3 Types of Standard Works3种标准作业Type 1:Standard Work to support machine(90%)&man(10%)combination
5、 task类型1:标准作业适用于90%的机器作业和10%的手动作业的组合作业方式。Type 2:Standard Work to support man(90%)&machine(10%)combination task类型2:标准作业适用于90%手动作业和10%机器作业的组合作业方式Type 3:Standard Work(also called as Work Standard)to support task carried out once signal is类型3:标准作业(也叫做作业标准)适用于当信号产生时才去执行相应任务的作业方式No Std Work means no Kaize
6、n.Std Work is the Mother of all Kaizen没有标准作业就没有改善标准作业是改善之母,How to start the Takt Time CalculationBased on Customer Demand怎样根据客户需求计算拍时间Step 1:Calculate Takt time Based on Customer Demand第一步:根据客户需求计算节拍时间EXample例如Customer Demand per Month 792K.Working hour per day is 22 hours,20 days a month客户每月需求量是792
7、K。每天工作小时是22小时,一个月20天Takt TimeAvailable Time有效时间Customer Demand客户需求22 Hours x 20 days x 3600s792,000pcs1584,000792,000=2secTakt Time calculation shall display all the variable and unitsto make clarity to all.计算节拍时间时要显示所有变量及单位,便于大家理解。,How to start the Takt Time CalculationBased On Product and Process
8、Design怎样根据产品和制程设计计算节拍时间Step 2:Calculate Process Takt time Based on Product and Process Design第二步:根据产品和制程设计计算节拍时间Based on Step 1,Takt Time is 2 second to produce 1 pcs根据步骤1,节拍时间是每2秒生产1件产品,How to start the Takt Time CalculationBased On Product and Process Design怎样根据产品和制程设计计算节拍时间Scenario 1:Product desi
9、gn is 6 pcs per one PCB panel.The Process Takt Time will be every12 second a panel.Besides,your process design is using a pallet to place 4 panels theryour Process Takt Time is 48 second a pallet.If 2 line running,process Takt time will be 96sec情节1:产品设计为每块PCB板由6块小板组成,节拍时间是每块PCB板12秒;制程设计治具同时放置4块PCB板,
10、则制程的节拍时间是48秒/治具。如果同时有2条生产线生产,制程的节拍时间则为96秒As such the Process Takt Time Calculation as following:制程节拍时间计算如下Takt Time X Product Up x Process Up X Number of Line2 sec x 6 products per panel x 4 Panel per pallet x 2 LinessecScenario 2:If Top and Bottom product running on same line at the sametime,Takt t
11、ime shall be half 48sec情节2:如果正反面产品同时在一条生产线生产,节拍时间则为一半,48秒。,What is Standard WIP什么是标准WPVarious types of WiP in our manufacturing process生产过程中存在各种类型的WIP标准WP2.Process WIP制程W|P3.Process To Process wiP制程与制程间W|P4.Station To station w|P工位与工位间WP,What is Standard WIP什么是标准WPWIP means INVENTORY INVENTORY is Ba
12、sically badWP就是库存。库存从根本上说是“不好”的。Standard WiP is the ldeal or should be conditions for wip标准WP是理想WP或者是WP的应有状态However,before you fully achieved Standard WIP Quantity,you might need to go throughvarious stages to understand your process Muda and bottle neck然而,在完全达到标准WP数量前,你需要经过不同的阶段了解制程中的浪费和瓶颈Key Note
13、from Sensei:老师的重要提示:To understand the above WiP definitions,go to The Genba and perform your ownwork towards Establishing the right WiP quantities.This is the Only way you canunderstand the definition.要理解WP定义,你需要去到现场在工作中实践正确的WP数量。这是让你理解这个定义的唯一方法。,谢谢,骑封篙尊慈榷灶琴村店矣垦桂乖新压胚奠倘擅寞侥蚀丽鉴晰溶廷箩侣郎虫林森-消化系统疾病的症状体征与检查林森-消化系统疾病的症状体征与检查,11、越是没有本领的就越加自命不凡。邓拓12、越是无能的人，越喜欢挑剔别人的错儿。爱尔兰13、知人者智，自知者明。胜人者有力，自胜者强。老子14、意志坚强的人能把世界放在手中像泥块一样任意揉捏。歌德15、最具挑战性的挑战莫过于提升自我。迈克尔F斯特利,
