[精选]企业精益生产培训课程.pptx

Components Components Components Components Precision is ourPrecision is our lifelifelifelife LEAN MANUFACTURING TRAINING企业精益生产培训企业精益生产培训2Precision is ourPrecision is our lifelifelifelife What Shall We Talk?内容安排内容安排 精益生产系统简介精益生产系统简介 质量、成本和交货周期质量、成本和交货周期 现场管理及班组建设现场管理及班组建设 价值流分析价值流分析 运行效率运行效率 柔性生产单元柔性生产单元 看板拉动和精益供给链看板拉动和精益供给链 精益指标和推行策略精益指标和推行策略Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo3Precision is ourPrecision is our lifelifelifelife Lean Manufacturing System Briefing精益生产系统简介精益生产系统简介1制造系统的要点制造系统的要点市场竞争及全球化市场竞争及全球化精益生产五项原则精益生产五项原则最好的工厂？最好的工厂？Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo4Precision is ourPrecision is our lifelifelifelife 精益思想的要点精益思想的要点“精益释义：精益释义：精益-形容词：无肉或少肉，少脂肪或无脂肪，文体或措词简练反义词：肥胖的，多肉的，过重的，不结实的，过分肥胖的，饱满的，粗短的，肥大的，软的精益生产：精益生产：通过消除企业所有环节上的不增值活动，来到达通过消除企业所有环节上的不增值活动，来到达降低成本、缩短生产周期和改善质量的目的降低成本、缩短生产周期和改善质量的目的Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo5Precision is ourPrecision is our lifelifelifelife Starting with Toyota in the late 50s and catching on in the mid 80s in the reminder of the industrial world,Lean Manufacturing has be e a key strategy for manufacturers起起源于源于2020世纪世纪5050年代丰田汽车公司，而在年代丰田汽车公司，而在8080年代年代中期被欧美企业纷纷采用。随着微利时代的来临，中期被欧美企业纷纷采用。随着微利时代的来临，精益生产模式成为企业竞争的有力武器精益生产模式成为企业竞争的有力武器Lean Thinking and Lean Manufacturing System 精益思维和精益生产系统Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo6Precision is ourPrecision is our lifelifelifelife Manufacturing Evolution 制造系统演化史Henry Ford Assembly line mass production Produce in high volume with low variety Single skill福特首创的装配线是大规模低品种生产方式的代表，工人被当成工作的机器Toyota Production System TPS Just-In-Time Production produce only what is needed Pull System High variety to meet customers wants 丰田系统是建立在准时化观念上的拉动 式生产模式，以应付小订单多品种的挑战Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo7Precision is ourPrecision is our lifelifelifelife Key Points for Manufacturing System 制造系统要点手工生产手工生产大量生产大量生产精益生产精益生产产品特点产品特点完全按客户要求标准化，品种单一品种多样，系列化设备设备通用，灵活，简便专用，高效，昂贵柔性高，效率高，追求零故障分工分工粗略，丰富多彩细致，简单，重复较粗，多技能，丰富操作人员操作人员自己设计，技能高不需要专门技能多技能库存水平库存水平高高低，追求零库存制造成本制造成本高低更低产品品质产品品质低高更高，追求零缺陷市场要求市场要求极少量需求供不应求买方市场Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo8Precision is ourPrecision is our lifelifelifelife What is Lean Manufacturing 什么是精益生产-五个原则Lean Manufacturing精益生产精益生产Value 价值价值站在客户的立场上Value Stream 价值流价值流从接单到发货过程的一切活动Flow 流动流动象开发的河流一样通畅流动Demand Pull 需求拉动需求拉动BTR-按需求生产Perfect 完美完美没有任何事物是完美的不断改进降低成本，降低成本，改善质量，改善质量，缩短生产周期缩短生产周期Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo9Precision is ourPrecision is our lifelifelifelife 精益思想：从增值比率看改善空间精益思想：从增值比率看改善空间增值比率增值比率增值时间（Value added time）制造周期（Manufacturing cycle time）X 100%=增值时间增值时间：站在客户立场看制造过程中的增值动作和时间如：改变形状改变形状、改变性能改变性能、组装组装、包装包装等物料从进厂到出厂，只有不到物料从进厂到出厂，只有不到物料从进厂到出厂，只有不到物料从进厂到出厂，只有不到 10%10%的时间是增值的！的时间是增值的！的时间是增值的！的时间是增值的！Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo10Precision is ourPrecision is our lifelifelifelife Quality,Cost and Delivery质量、成本和交货期2对待质量的心态和改进工具成本的构成及控制手法流动的物流和信息流是缩短 交货期的保障Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo13Precision is ourPrecision is our lifelifelifelife The Attitude to Quality对待质量问题的心态对待质量问题的心态 People CAN and WILL make inadvertent mistakes!If one person makes a mistake ANYONE can!ONE mistake out the door is too many!Mistakes CAN be eliminated and MUST be eliminated for us to be e PETITIVE!人们可能而且也会在无意中做出错误人们可能而且也会在无意中做出错误如果一个人会犯错误，那么任何人都会犯错误如果一个人会犯错误，那么任何人都会犯错误一个错误出门，带来麻烦多多一个错误出门，带来麻烦多多为使我们更有竞争力，错误必须消除而且也能消除为使我们更有竞争力，错误必须消除而且也能消除Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo14Precision is ourPrecision is our lifelifelifelife 99.9%的正确率意味着什么？的正确率意味着什么？每天北京机场有一次飞机着陆是不平安的每天北京机场有一次飞机着陆是不平安的每年发生两万起药物处方错误每年发生两万起药物处方错误每天发生每天发生50起新生婴儿掉在地上的事件起新生婴儿掉在地上的事件每小时发生两万起支票帐户的错误每小时发生两万起支票帐户的错误一个人出现三万二千次心跳异常一个人出现三万二千次心跳异常The Attitude to Quality对待质量问题的心态对待质量问题的心态 Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo15Precision is ourPrecision is our lifelifelifelife Standards Is The Foundation标准是改进的基础标准是改进的基础为什么要标准化？为什么要标准化？-代表最好的、最容易的和最代表最好的、最容易的和最 平平安的方法安的方法 -提供了一种衡量绩效的手段提供了一种衡量绩效的手段 -表现出因果之间的联系表现出因果之间的联系Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo19Precision is ourPrecision is our lifelifelifelife To The Defects,I Will Say No!No!No!对待缺陷，三不政策对待缺陷，三不政策DONT ACCEPT 不接受！DONT MAKE 不制造!DONT DELIVER 不传递!Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo20Precision is ourPrecision is our lifelifelifelife Error Proofing 过失预防过失预防 Preventing or detecting errors at the sourceFMEAs provide basis for error proofing在源头预防或探测过失失效模式分析是过失预防的基础zzCopy Right By Macro-Brain Co.,Ltd.Jimmy Guo21Precision is ourPrecision is our lifelifelifelife 健忘健忘误解产生的错误误解产生的错误识别错误识别错误新手错误新手错误疏忽的错误疏忽的错误迟钝的错误迟钝的错误缺少标准的错误缺少标准的错误蓄意的错误蓄意的错误错误有八种不同的类型Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo22Precision is ourPrecision is our lifelifelifelife 防错十大原理防错十大原理l断根原理断根原理l保险原理保险原理l自动原理自动原理l相符原理相符原理l顺序原理顺序原理6.隔离原理7.复制原理8.层别原理9.警告原理10.缓和原理Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo23Precision is ourPrecision is our lifelifelifelife The Way To Low Down Cost降低成本的手段降低成本的手段重新思考成本的构成改善生产力消除浪费Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo24Precision is ourPrecision is our lifelifelifelife 在价格，成本和利润的关系中，有两种不同在价格，成本和利润的关系中，有两种不同的思考方法：的思考方法：传统的方法 销售价格销售价格=成本成本+利润利润 New Thinking To The Cost对成本的重新思考 新的方法 利润利润=销售价格销售价格 成本成本一定要现金！Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo28Precision is ourPrecision is our lifelifelifelife Correction 返工Overproduction 过量生产Conveyance 搬运Motion 多余动作Waiting 等待Inventory 库存Processing 过程不当消除浪费：降低成本消除浪费：降低成本Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo29Precision is ourPrecision is our lifelifelifelife Waste of Overproduction 过量生产 生产多于下游客户所需生产多于下游客户所需生产多于下游客户所需生产多于下游客户所需 Making More Than NeededMaking More Than Needed 生产快于下游客户所求生产快于下游客户所求生产快于下游客户所求生产快于下游客户所求 Making Faster Than NeededMaking Faster Than Needed劳模？Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo30Precision is ourPrecision is our lifelifelifelife Rework of a Productor Service to Meet Customer Requirements为了满足顾客的要求为了满足顾客的要求而对产品或效劳进行而对产品或效劳进行返工返工Waste of Inspection/Correction/Rework 检验检验/校正校正/返工返工Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo31Precision is ourPrecision is our lifelifelifelife Any movement of material that does not support a lean system不符合精益生产的不符合精益生产的一切物料搬运一切物料搬运活动活动Waste of Material Movement/Conveyance物料搬运Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo32Precision is ourPrecision is our lifelifelifelife Effort which adds no valueto a product or service对最终产品或效劳对最终产品或效劳不增加价值的不增加价值的过程过程 Waste of Processing 过程不当过程不当Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo33Precision is ourPrecision is our lifelifelifelife Any supply in excess of process requirements necessary toproduce goods任何超过加工必须的任何超过加工必须的物料供给物料供给Waste of Inventory 库存浪费库存浪费Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo34Precision is ourPrecision is our lifelifelifelife Inventory Covers All Problem库存掩盖所有问题库存掩盖所有问题交货问题交货问题质量问题质量问题效率问题效率问题维修问题维修问题库存水平库存水平Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo35Precision is ourPrecision is our lifelifelifelife Low Down Inventory To Expose Problem通过降库存暴露问题通过降库存暴露问题交货问题交货问题质量问题质量问题效率问题效率问题维修问题维修问题库存水平库存水平Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo36Precision is ourPrecision is our lifelifelifelife Low Down Inventory To Expose Problem通过降库存暴露问题通过降库存暴露问题交货问题交货问题质量问题质量问题效率问题效率问题维修问题维修问题库存水平库存水平Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo37Precision is ourPrecision is our lifelifelifelife Idle Time That Is Produced When Two Dependent Variables Are Not Fully Synchronized当两个关联要素间当两个关联要素间未能完全同步时未能完全同步时所产生的空闲时间所产生的空闲时间Waste of Waiting 等待等待Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo38Precision is ourPrecision is our lifelifelifelife Any movement which does not contribute value to the product or service 任何不增加产品或效劳价值的人员任何不增加产品或效劳价值的人员和设备的动作和设备的动作Waste of Motion 多余动作多余动作Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo41Precision is ourPrecision is our lifelifelifelife Shorten The Lead Time Batch Or Flow缩短交付周期：成批或流动操作操作#1C/T=1min操作操作#3C/T=1min操作操作#2C/T=1minRawF/G?操作操作#1操作操作#2操作操作#3C/T=1minC/T=1minC/T=1minRawWIPWIPF/G?练习：以下练习：以下B/F中的中的?各为多少？各为多少？BFCopy Right By Macro-Brain Co.,Ltd.Jimmy Guo42Precision is ourPrecision is our lifelifelifelife StoreHandleInspectProcessDescriptionValueAddedNonValueAddedDistanceTimeStore in WarehouseInspect PartsMove to linePerform Operation#1Store inBuffer BinPerformOperation#2360 Ft.350 Ft.7 Ft.1 Ft.2 Ft.4 Ft12 min.4 min.1.5 min.2 sec.8 sec.2 sec.Shorten The Lead Time Flow Chart 流程图入手，缩短交付周期流程图入手，缩短交付周期 Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo43Precision is ourPrecision is our lifelifelifelife 客户需求客户需求 8600 个个Inventory Control Small Lot Strategy 小批量策略ALOT=1000，9 箱多出箱多出 400 个个CBLOT=500，17 箱少了箱少了100 个个LOT=200，43 箱刚好箱刚好Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo85Precision is ourPrecision is our lifelifelifelife -Monitors the status of production at any given moment in time.监控生产在任何时间的状态-Provides the historical data necessary to continuously improve operational availability 记录历史数据以不断改善运行能力-Production hour by hour 每小时生产状态如型号、产量等-Down time 故障维修时间 -Change over 换型次数和时间-Planned down time 方案停机时间 -Quality loss 质量损失 -Speed loss 速度损失 -Other lost time，people，material，etc 其他损失时间Production Reporting&Charting生产报告及图示Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo88Precision is ourPrecision is our lifelifelifelife TOP 5 根源分析根源分析Improve Overall Equipment Effectiveness改进总的设备有效性PARETO主次分析主次分析Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo89Precision is ourPrecision is our lifelifelifelife Total Preventive Maintenance is the total activities of all employees work to increase uptime,improve quality of output,improve safety,and reduce costs through the continuous improvement of equipment operation 全员设备维护是所有的员工努力通过持续改善设备的运行来增加有效时间、提高产品质量、加强平安性及减少设备成本的全系统的活动Total Preventive Maintenance全员设备预防维护Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo90Precision is ourPrecision is our lifelifelifelife TPM 的五大支柱的五大支柱训练和技能的开展Training andSkill Development早期设备管理 维护预防设计Early Equipment Management自主性的维护AutonomousMaintenance维护程序改善Maintenance ProcessImprovement系统的设备改善Systematic EquipmentImprovement小组小组Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo91Precision is ourPrecision is our lifelifelifelife Zero Defect Principle零缺陷法则零缺陷法则隐藏的异常现象隐藏的异常现象Hidden abnormalities缺陷只是露在水面上的冰山一角缺陷只是露在水面上的冰山一角 A failure is the tip of the iceberg!暴露隐藏的异常现象，暴露隐藏的异常现象，在它们发生之前预防品在它们发生之前预防品质和功能的缺陷质和功能的缺陷Expose hidden abnormalities andprevent quality and functional failures before they happen FAILURES缺陷缺陷磨损、松动、泄漏、污垢、灰尘腐蚀、变形、原物料的粘连、外表缺陷破裂、过热、颤抖、噪音、及其它异常现象。Wear,play,slackness,leakage,dust,dirt,corrosion,deformation,adherence of raw materials,surface damage,cracking,overheating,vibration,noise,and other abnormalitiesCopy Right By Macro-Brain Co.,Ltd.Jimmy Guo92Precision is ourPrecision is our lifelifelifelife Some Key Maintenance Data一些关键的维修数据一些关键的维修数据MTBF-平均故障间隔时间MTTR-平均修复时间PM%-预防维护时间占总维护及维 修时间的百分比，目标 70%Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo93Precision is ourPrecision is our lifelifelifelife TPM:Owner/Operator Concept责任人/操作员 观念The operator will be empowered to:monitor the equipment,notify maintenance prior to any machine downtime occurrence,assure that housekeeping is maintained,perform minor repairsand aid maintenance personnel with the suggestion操作员有责任：监测设备，在机器出现故障前通知维修人员进行维护，进行日常的清洁整理及小的维护调整工作，并把平常观察情况反映给维修人员LOCKOUTRULESCopy Right By Macro-Brain Co.,Ltd.Jimmy Guo94Precision is ourPrecision is our lifelifelifelife TPM Is A Paradigm ShiftTPM 是一种模式转变“我操作，你维修“我维修，你设计“我设计，你操作“I operate，you fix“I fix，you design“I design，you operate“We are all responsible forour equipment，our plant，and our future“我们对我们的设备，我们的工厂，和我们的未来都负有责任Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo95Precision is ourPrecision is our lifelifelifelife Zero accidentsZero unplanned down timeZero speed lossesZero defectsMinimum life cycle cost 零事故，零事故，零非方案停机时间零非方案停机时间 零速度损失，零废品零速度损失，零废品 产品生命周期成本最小化产品生命周期成本最小化TPM Goals 目标我们为什么达不到？Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo96Precision is ourPrecision is our lifelifelifelife Continue Improvement-5 Why？持续改进持续改进 5 Why？例子：设备停机第一个为什么：为什么停机了？机器过载，保险烧了第二个为什么：为什么会过载？轴承润滑不够第三个为什么：为什么润滑不够？机油泵没抽上足够的油第四个为什么：为什么油泵抽油不够？泵体轴磨损第五个为什么：为什么泵体轴磨损？金属屑被吸入泵中第六个为什么：为什么金属屑被吸入泵中？吸油泵没有过滤器。Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo97Precision is ourPrecision is our lifelifelifelife Flow Cell and“U Shape Layout柔性生产单元及柔性生产单元及U型布局型布局TAKTTAKT及生产速度及生产速度“U“U型布局和连续流型布局和连续流负荷平衡负荷平衡消除瓶颈和变差消除瓶颈和变差Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo98Precision is ourPrecision is our lifelifelifelife Flow Cell Design-Objective流动单元设计-目标“The objective of flow cell design is to create a manufacturing system.使我们有这样一个制造系统：.which provides for the smooth,uninterrupted flow of people and material让资源流和物流平滑而不间断地.from each value added operation to the next value added operation.从增值工位到增值工位.at a rate equal to customer demand以客户需求速度流动with the lowest life cycle cost 并且，使产品的生命周期成本最低Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo101Precision is ourPrecision is our lifelifelifelife TAKT Time and Line Rate需求节拍与生产线速度 TAKT Time determines the rate at which work must be ac plished at each operation Operational Cycle Time based on the line rate.节拍时间确定了每一工位必须完成工作的速率确定了每一工位必须完成工作的速率操作周期时间操作周期时间TAKT is the rhythm or beat of the flow line.节拍时间是流动线的节拍时间是流动线的节奏或或拍子Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo102Precision is ourPrecision is our lifelifelifelife Takt 节拍时间节拍时间=可用工作时间客户需求数量争取使争取使每一工位每一工位每每3分分20秒生产一件秒生产一件合格合格品品Takt节拍时间节拍时间=60 X 工作小时/天-休息&午餐&其它停顿时间=258 件例子例子:节拍时间节拍时间=60 x 17.0-15+15+30+20 x2=860 分钟258 件=860 分钟 x 60 秒/分200 秒秒/件件ABC 装配线装配线节拍时间节拍时间每天客户需求数量258 件TAKT Time and Line Rate需求节拍与生产线速度 Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo103Precision is ourPrecision is our lifelifelifelife Planning with a Workable Takt设计一个好的节拍时间Takt Time seconds30 120 改善余地小 很难应付变动 紧张 太长的工作步骤，难以标准化 操作岗位轮换不容易 注意力分散适宜区域节拍时间复杂度Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo104Precision is ourPrecision is our lifelifelifelife 123 4561098712109348567U-Shape Cell Layout and Continuous Flow“U型布局和连续流 Flexible Line Capacity One-Piece Flow munication Save Space具有柔性生产能力有利于单件流便于员工沟通节约场地Why?Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo105Precision is ourPrecision is our lifelifelifelife U-Shape Cell-High Rate Status“U型单元-高速生产状态 TAKT 0 10 20 30 40 50 60TAKT 0 10 20 30 40 50 60TAKT 0 10 20 30 40 50 60TAKT 0 10 20 30 40 50 60TAKT 0 10 20 30 40 50 60TAKT 0 10 20 30 40 50 60TAKT 0 10 20 30 40 50 60TAKT 0 10 20 30 40 50 60TAKT 0 10 20 30 40 50 60TAKT 0 10 20 30 40 50 60123 4561098712109348567Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo106Precision is ourPrecision is our lifelifelifelife U-Shape Cell-Middle Rate Status“U型单元-中速生产状态 TAKT 0 10 20 30 40 50 60TAKT 0 10 20 30 40 50 60TAKT 0 10 20 30 40 50 60123 4561098712109348567Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo107Precision is ourPrecision is our lifelifelifelife U-Shape Cell-Middle Rate Status“U型单元-低速生产状态 123 4561098712345610987123456TAKT 0 10 20 30 40 50 60Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo108Precision is ourPrecision is our lifelifelifelife Establish Operation Standard建立操作标准建立操作标准操作标准分析操作标准分析 (OSA)生产速率操作者机器节拍时间走动空闲/等待TQCNVA时间估计操作时间操作/工序(x)操作机器移动 总时间总时间 作业准备时间操作者作业准备分析 批量大小机器12345678910 x13152642225814671830 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320105 件/每 班240 sec.节拍节拍 TAKT#拿零件，装上底座调整间隙选垫圈装垫圈装大垫圈和机盖紧定四螺钉检查外观并装进仪器卸下零件放进料箱 启动仪器检测等待下一零件Copy Right By Macro-Brain Co.,Ltd.Jimmy Guo109Precision is ourPrecision is o