精益生产管理手册(中英文版).ppt
《精益生产管理手册(中英文版).ppt》由会员分享,可在线阅读,更多相关《精益生产管理手册(中英文版).ppt(59页珍藏版)》请在课桌文档上搜索。
1、1,Lean Hand Book精益生产手册,2,Defect:X 1/10缺陷降低90%Inventory:X 库存减半Productivity:X 2生产效率翻倍 Lead Time:X 生产周期减半 Scrap:X 1/10报废降低90%Space:X 面积减半,Goal:Add Value&Eliminate Waste Relentlessly for Our Customers目标:减少浪费&创造价值 全心全意为客户服务,ETE(End to End)Productivity Improvement 端到端(从头到尾)产能提高ETE Zero Defect(Quality,TPM,
2、OEE&etc.)端到端(从头到尾)零缺陷(质量,全面生产维护,全局设备利用率等)Inventory Reductions 降低库存Lead Time Reductions 缩短生产前置期Crew Size Optimization 优化人员数量Space Reduction 减少使用面积,Doublethe Good好的加倍Halvethe Bad坏的减半Double theSpeed改善速度加倍,Kaizen Workshop Goal改善目标,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,3,Standard Work&Standard
3、 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 sequence defined 工序的定义 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 f)Safety 安全性 g)Multi skill多技能 2)Standard work combination sheet defined 标准作业合并表定义a)Ma
4、nual 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 defined 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 Key Elements3项关键要素,4,3 Types of Standard Works3种标准作业,5,3 Types of Standard Works3种标准作业,Type 1:Standard Work to support machine(90
5、%)&man(10%)combination 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 triggered.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
6、行相应任务的作业方式。,No Std Work means no Kaizen 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,6,How to start the Takt Time CalculationBased On Customer Demand 怎样根据客户需求计算节拍时间,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
7、per day is 22 hours,20 days a month.客户每月需求量是792K。每天工作小时是22小时,一个月20天。,Takt Time calculation shall display all the variable and units to 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。,7,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,Step 2:Calculate Process T
8、akt 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。,8,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 design is 6 pcs per one PCB panel.The Proce
9、ss Takt Time will be every 12 second a panel.Besides,your process design is using a pallet to place 4 panels,then your Process Takt Time is 48 second a pallet.If 2 line running,process Takt time will be 96 sec.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,则制程的节拍时间是 48 秒/治具。如果同时有 2 条生产
10、线生产,制程的节拍时间则为 96 秒。,Scenario 2:If Top and Bottom product running on same line at the same time,Takt time 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。,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 Line=2 sec X 6 products p
11、er panel X 4 Panel per pallet X 2 Lines=96 sec,9,What is Standard WIP什么是标准WIP,Various types of WIP in our manufacturing process 生产过程中存在各种类型的WIPStandard WIP 标准WIPProcess WIP制程WIPProcess To Process WIP制程与制程间WIPStation To Station WIP工位与工位间WIP,10,What is Standard WIP什么是标准WIP,WIP means INVENTORY.INVENTOR
12、Y is Basically bad.WIP就是库存。库存从根本上说是“不好”的。Standard WIP is the Ideal or Should be conditions for WIP标准WIP是理想WIP或者是WIP的应有状态。However,before you fully achieved Standard WIP Quantity,you might need to go through various stages to understand your process Muda and bottle neck然而,在完全达到标准WIP数量前,你需要经过不同的阶段了解制程中
13、的浪费和瓶颈。Key Note from Sensei:老师的重要提示:To understand the above WIP definitions,go to The Genba and perform your own work towards Establishing the right WIP quantities.This is the Only way you can understand the definition.要理解WIP定义,你需要去到现场在工作中实践正确的WIP数量。这是让你理解这个定义的唯一方法。,11,What is Standard WIP什么是标准WIP,T
14、he purpose of Standard WIP is:标准WIP的目的:Separation between machine job and man job 区分机器作业和手动作业Ensures quality requirements确保质量要求Ensures smooth flow based on Takt time确保基于节拍时间的连续流Example 1:例子1WIP in the reflow oven for curing with process time 6 min and Takt time 30 sec.在回流焊炉中固化的WIP,制程时间 6 min,节拍时间 30
15、 sec.Standard WIP in the curing oven=Process Time/Takt Time 回流焊炉的标准WIP=6 min/30 sec=12 Pcs,12,What is Standard WIP什么是标准WIP,Example 2:例子2WIP in the tester at backend assembly with process time 60 sec and Takt Time 30 sec.后段组装线测试机的WIP,制程时间 60 sec,节拍时间 30 sec.Standard WIP in the Test station=60 sec/30
16、sec测试工位的标准WIP=2 pcsIn other words,Standard WIP in order to fulfill the above 1),2),3)functions,It is the compulsory WIP in the machine/process before establish standard work for the process.换句话说,标准WIP能够确保上述1),2),3)达成,在建立标准作业前,标准WIP是机器和制程强制的WIP。,13,What is Standard WIP什么是标准WIP,Process WIP 制程WIPWIP wi
17、thin same process with low variation of cycle time同一个制程中的WIP,周期时间CT变化很小It is all that WIP in the same process,not categorized as Standard WIP or PTP WIP.所有在同一个制程中的WIP,不是标准WIP或制程间WIP.Example:-例如Before Kaizen,Manual Insert(MI)Line Process WIP=9 pcs.After Kaizen MI Process WIP is 3.Standard WIP for eac
18、h station is 1pc.改善前,插件拉的制程WIP=9 pcs。改善后插件拉制程WIP=3pcs。每个工位的标准WIP为1pcs.,variance,After,Before,Process WIP=3,Standard WIP=1,Process WIP=9,No standard WIP,14,What is Standard WIP什么是标准WIP,Process To Process WIP(PTP WIP)制程间WIPWIP between 2 different processes with big gap cycle time两个周期时间相差很大的不同制程间的WIP.P
19、TP WIP Is needed due to changeover in upstream line.上游制程需要转拉,则需设定制程间WIP.,Not All line need PTP WIP.不是所有产线都需要制程间WIP.If Cycle time of Upstream Process is Less then Down stream process 如果上游制程的周期时间小于下游制程的周期时间Example 1:-SMT Cycle time(30 sec)Less then Manual Insertion(60 sec)例1:SMT周期时间(30 sec)小于MI插件周期时间(
20、60 sec)CT(Upstream process)Need PTP WIP 需要制程间WIP If Cycle time Upstream process is Equal or greater then Down stream process,No PTP WIP required.如果上游制程的周期时间大于或等于下游制程的周期时间,不需要制程间WIP.,15,What is Standard WIP什么是标准WIPProcess To Process WIP制程间WIP,Example 2:-Process A cycle time 15 sec.It is faster then P
21、rocess B cycle time 25sec.Process A is running 2 product models as capacity requirement.In order to Keep Process line running,process to process WIP is required between Process A and B.The calculation as below:-例2:制程A周期时间是15sec,比制程周期时间25sec快。制程A根据生产能力需求,需要生产2种产品。为了保证产线正常运作,需要在制程A和制程B之间设定制程间WIP。计算如下:
22、,Takt Time=30secChangeover Time=5 min,30sec,Process A,Process B,16,Takt Time 节拍时间,Cycle time Takt time(1 Station Process)C/TTakt Time(1个工位),Cycle time than takt for single process(2 same stations needed)C/TTakt(需要2个相同工位),TAKT Time=20s,Note注:CT TT:Additional Machine/Man needed 需要额外的机器/人员,It can be us
23、ed to calculate 节拍时间可以计算 Total Operators needed员工需求数量 Total machines needed机器需求数量 Standard WIP needed&Etc标准WIP需求数量,等,17,Is the Takt time visible(with counter and triggering point)?节拍时间可以直观地看出来吗?有没有借助工具(计数器和触发机制)。2)Is the Takt board defined(on the board)?节拍时间确定了吗?(把节拍时间写在白板上)3)Are the Standard WIP de
24、fined?标准WIP有定义吗?4)Do you know how to separate manual(persons)from auto(the machines)work?你知道如何区分手动作业和自动作业吗?5)Is the Work load leveling defined for man,machine and C/O?人工,机器以及换线使用工作负荷均衡表分析了吗?6)Is the H/C calculated based on Takt time?人力的多少是根据节拍时间计算出来的吗?7)Is the Std work(front page)SWCS(back page)post
25、ed in front of each operator?每个工站前都有标准作业(前页)和标准作业合并表SWCS(背页)吗?,Operations操作,18,Operations(continue)操作(续页),8)Is the std work being followed by the operator?操作员有没有按照标准作业流程作业?9)Is the std work defined for water strider?有没有定义物料员的标准作业?10)Is the operator idle at the station?在作业过程中,操作员是否有等待?11)Does the ope
- 配套讲稿:
如PPT文件的首页显示word图标,表示该PPT已包含配套word讲稿。双击word图标可打开word文档。
- 特殊限制:
部分文档作品中含有的国旗、国徽等图片,仅作为作品整体效果示例展示,禁止商用。设计者仅对作品中独创性部分享有著作权。
- 关 键 词:
- 生产管理 手册 中英文
链接地址:https://www.desk33.com/p-378944.html