精益生产线体设计以及LeanProductionSystems系统

精益生产的12种工具—精益系统传统装配线设计TRADITIONALASSEMBLYLINEDESIGN物料储存MaterialStorage悬挂式电动输送带Powered&freeconveyor物料储存MaterialStorage物料储存MaterialStorage物料储存MaterialStorage物料储存MaterialStorage精益生产系统装配线模式特点LEANPRODUCTIONSYSTEMASSEMBLYLINEMODELCHARACTERISTICS工人灵活Flexibleoperators走动方便Freedomofmovement标准化作业Standardoperations目视工场Visualworkplace最少线上存货Minimallinestock柔性生产Flexibleproduction调速器Pacemakers保证质量Qualityensured六西格玛制程能力(西格玛改善)SixSigmaProcessCapability(SigmaKaizen)重点缩短制造周期Focusonlead-Timereductionto:增加客户忠诚度和市场份额IncreasecustomerLoyaltyandMarketShare取得销售和收益双增长AchieveGrowthinSales&Earnings保持竞争优势SustaintheCompetitiveAdvantages提升利益相关者价值ImproveStakeholderValue精益西格玛®变革LeanSigma®transformation精益生产系统LeanProductionSystem改善突破法KaizenBreakthroughMethodology精益生产系统LeanProductionsystem及时JustinTime生产有效使用EfficientUseof员工People设备Equipment物料Materials厂房Space均衡生产ProductionSmoothing提升工艺流程能力ImproveProcessCapability尽量减少变化Minimizevariation控制异常Manageabnormality驱动成本下降DrivescostreductionJidoka自働化精益生产系统LeanProductionsystem及时生产就是Just-In-TimeIs...这样的生产系统Amanufacturingsystemwhichproduces:按客户所需进行生产Whatthecustomerwants按客户要求数量生产Inthequantitythecustomerwants按客户要求时间生产Whenthecustomerwantsit利用最少的Whileusingtheminimum:原料Rawmaterials设备Equipment工人Labor厂房Space核心概念和工具KeyConceptsandTools符合节拍时间PacetoTakttime单件流One-pieceflow拉动系统Pullsystem精益生产系统LeanProductionsystem节拍时间的重要性IMPORTANCEOFTAKTTIME客户需求Customerrequirements净操作时间Netoperatingtime将运作和客户需求同步Synchronizesoperationstocustomerdemand防止过量生产Preventsoverproduction建立流动生产的工具Toolforcreatingflow确定最佳生产人数Determinesoptimalstaffing推动产能分析和设备利用率Drivescapacityanalysis&equipmentutilization必须定期更新以适应需求的变化Mustbeupdatedperiodicallyasdemandchanges单件流ONE-PIECEFLOW超市运作SupermarketOperation过道AisleEDCBAIHGFABCDEFGHI单件流－ONEPIECEFLOW按需生产ProducetoActualCustomerDemand拉动系统PULLSYSTEM实施拉动系统IMPLEMENTPULLSYSTEM线旁供货LSS线旁供货LSS收集看板Pick-upKanban供应商Supplier物料超市Supermarket投递生产看板DropProductionKanban原料RM成品FG生产计划板Scheduleboard生产看板ProductionKanban现场送料员WaterSpider看板拉动的例子-KanbansystemSupplier供货商Customer顾客ReplenishesConsumedProducts补充已消耗的产品Visual直观TOTEFrequentDeliveries供货频繁FIFO先进先出OnePieceataTime每次一件Whatyouwant你想要什么Whenyouwantit何时需要Intheamountsyouwantitin要多少13及时生产的要素JITELEMENTS小巧便宜机器Small,inexpensivemachinesinprocessorder单件流生产,反时针方向One-pieceflowproduction,counterclockwise人机正确结合Ergonomically-correctoperations站立操作,边走边做Standingoperations,movingwhileworking拉动系统训练Pullsystemdiscipline定义和实施“标准化作业”“Standardoperations”definedandimplemented及时生产的好处JITBENEFITS消除生产过程浪费Eliminateswasteinproductionprocesses缩短运作周期时间Reducesleadtimes品质…成本…交货!Quality…Cost…Delivery!不能容忍生产异常Createsasystemwhichisintolerantofproductionabnormalities精益生产系统LeanProductionsystem及时JustinTime生产有效使用EfficientUseof员工People设备Equipment物料Materials厂房Space均衡生产ProductionSmoothing提升工艺流程能力ImproveProcessCapability尽量减少变化Minimizevariation控制异常ManageabnormalityJidoka自働化自働化是JIDOKAIS…A.减少不良品AmethodforreducingdefectsB.设备自动化，提高生产率Equipmentautonomationtoimproveproductivity自働化JIDOKAA.减少不良品的工具或方法ToolsorMethodstoReduceDefects发现不良品的产生Detectdefectswhentheyoccur防止不良品进入下一道工序Preventdefectsfrompassingtonextoperation识别不良品产生根源Identifyrootcausesofdefects消除根源Eliminaterootcauses减少或消除不良品Reduceoreliminatedefects自働化的要素JIDOKAELEMENTS目视控制VisualControl5S信号灯Andon异常反应AbnormalityResponse/Reaction作用/责任Rolesandresponsibilities停工指引Linestopguidelines西格玛改善SigmaKaizen(DMAIC)基本品质工具BasicQCTools先进统计工具AdvancedStatisticalTools措施Countermeasures防错措施Mistake-proofing(Poke-Yoke)手动操作ManualWork自动操作Automaticmachinework新标培训NewStandardOperationsandtraining技巧矩阵,表现量度Skillmatrixandperformance自働化Autonomation人机分离Separatepersonfrommachine自働化的要素JIDOKAELEMENTS目控VisualControl5S信号灯Andon零件展示Partspresentation工具展示Toolpresentation包装线Packline信号灯Andon标准化作业Standardwork异常反应过程ABNORMALITYRESPONSEPROCESS发现问题ReacttoproblemQCDS衡量影响Measureimpact提醒同事Alertteam标准化后,训练员工TrainaffectedassociatesinnewstandardoperationsMANEFFECTMACHINEMATERIALMETHOD找出原因Findrootcause提出改善,进行试验DevelopandtestimprovementCheck2BGauge4试验成功,更改运作Updatestandardoperationswithtestedimprovement自働化JIDOKAB.设备自働化Equipmentautonomation人机分离Separateoperatorworkfrommachinework改善前Before:操作员监控机器工作Operatorwatchesmachinerun改善后After:操作员装卸零件Operatorloadsandmoves自动关闭Autoshut-off“自动退件”自动卸货“Hanedashi”autounload操作员进入下一道工序Operatormovestonextoperation问题：你看过洗碗机是如何工作的吗？Question:Doyouwatchyourdishwasherrun?自働化的好处JIDOKABENEFITS改善产品质量Increasesproductionquality提升生产力Increasesproductivity保证准时交货Ensureson-timedelivery品质…成本…交货!Quality...Cost...Delivery!精益生产系统LeanProductionsystem及时JustinTime生产有效使用EfficientUseof员工People设备Equipment物料Materials厂房Space均衡生产ProductionSmoothing提升工艺流程能力ImproveProcessCapability尽量减少变化Minimizevariation控制异常ManageabnormalityJidoka自働化均衡生产是PRODUCTIONSMOOTHINGIS...调整生产速度,满足客户需求Adaptingproductionratestovariationsincustomerdemand产品数量变化Variationinvolume产品种类变化Variationinproductmix每日平均需求=生产目标AverageDailyDemand=TargetProduction数量Quantity时间Time客户需求CustomerDemand均衡生产PRODUCTIONSMOOTHING产量的变化VariationinVolume均衡生产PRODUCTIONSMOOTHING天Day每月计划:(3