生产管理之5SProject(ppt 43页)

1、1Contents1. 5S Team Organization Chart2. 5S Team Project Plan in BEE3. 5S Implement Plan in each area4. 5S Definition5. 5S Implement Instruction6. 5S Implement Check List7. 5S Evaluation Standards8. Case introduce : Cost saving in PL-2 & PL-59. Case analysis21. 5S Team Organization Chart3 BEE 5S

2、 Team Organization ChartChairman:Wang GilbertLeader:Tan JinConsultant:Li Min, Wang ZhouGeneral Secretary:Li Dongdong, Lin BingOffice AreaDongBinDianaDaiZhangXinliProduction AreaLiuTaizhongChenYang/QiuFengZhaoLiJiangYongLiWeiWarehouse/IQCBaoEricAlinPangTanQiFacility AreaZhouGangFanJinbaoShiLianqingDo

3、ngJianhuaXuHaijunZhangCongjunRobertLiuLiYongshan42) 5S Control System Project Plan in BEE5ItemContentsResponsible personImplementation statusDeadlineRemark1Current situation analysis for 5S system5S implement teamopenJune,26PL-1 have the current situation analysis for 5S system.2Publish 5S implement

4、 planGilbert Wang DoneApril,183Confirm responsible person from each Dept.Gilbert Wang, Robert Tan and Winter Li DoneApril,20Please see the attached document (5S implementation team member)4Prepare relative implement instructionRobert Tan and Winter LiDoneMay,25Please see the attached document (5S im

5、plement instruction) 5Publicize and push the 5S projectGilbert Wang, Robert Tan and Winter Li openJuly,5Please see the attached implement plan5.1Set up a Kan Ban for 5S project as information desk to all employees on WintercloseMay,205.2Take related photos at pl-1 and pl-4 ,compare the before and af

6、ter on siteWintercloseMay,23 5S Control System Project Plan in BEE 66Train and educate the member of 5S committee and all employees step by stepWinter Li/ 5S implement teamThe training was arranged by HR already.July,10Collect the training record of all employees and make the extra training for abse

7、ntees last time.7To arrange an examination to evaluate the training result.5S implement teamopenJuly,155S shift auditor will control the examination process for his own area.( Pls see the shift auditor namelist.)8Internal audit for 5S project5S implement teamopenJuly,309Make the corrective action 5S

8、 implement teamopenAug, 410Follow the corrective actionGilbert / 5S implement teamopenAug,1011Monthly checkGilbert / 5S implement teamopenevery month12Commend every Dept.5S implement teamopenNov,3013Annual achievements reviewGM/ Gilbert/ 5S implement teamopenDec,773) 5S Implement Plan in each area8P

9、L-1 5S implement plan9 P PL L- -1 1 5 5S S 实实施施计计划划 5S implement plan in PL-1序序号号No.实实施施内内容容Implement contents当当前前情情况况Current status改改进进措措施施Gap analysis andCorrective action责责任任人人Responsibility最最后后期期限限Deadline执执行行情情况况Implementstatus结结果果评评估估Assessment result1)目检区域手机样板卡没有放在固定位置，易损坏或混用。制作手机板卡的固定支架并予以定位

10、。陈杨、邱峰7月15日open2)切板卡机急停开关没有固定，且没有处于明显位置。将所有开关固定在设备的明显位置，John7月15日Open3)T29 索赔箱里面仍有废纸等杂物。对员工进行5S的培训陈杨、邱峰、Shift leader7月4日Open4)废弃物分类不准确，存在误扔原材料的可能性对员工进行废弃物处理程序的培训Shift leader7月10日Open5)切下的板卡框架没有及时清理明确清理人员及频次、时间陈杨、邱峰、Shift leader7月10日Open6) 缺少工位目视标识管理(如AOI、SPC、目检等)明确并统计各项区域，制作相应标识陈杨、邱峰、李冬冬7月20日Open7)生

11、产及目检设备布线不整齐，易造成安全事故对线路进行排部和整理钟明、李永山、蔡仑7月20日Open8)热风枪下面没有采取必要的隔热措施，易将静电垫损坏(pl-4 有同样问题)制作板卡的模板或金属垫板陈杨、邱峰、蔡仑7月20日Open9)目检及包装区域各类目视标识不清晰，易产生混淆。明确并统计各项区域，制作相应标识陈杨、邱峰、Shift leader7月25日Open10)办公区域东西摆放过多，无用的物品没有及时清理。由办公室人员自行整理7月15日Open11)机器表面放有物品。对员工进行培训，5S检查员进行检查陈杨、邱峰、Shift leader7月15日Open12)临时库房内存放的物品混乱对库

12、房做整理工作，清理无用的东西陈杨、邱峰、钟明等7月20日Open13)库房及生产现场没有明显的放泄漏措施(如棉布、纸巾相应区域及时配备陈杨、邱峰、Shift leader7月20日Open14)部分化学品没有领取及使用记录,以明确最大库存量及安全库存量。在线场建立相应的管理记录陈杨、邱峰、董斌7月20日Open15)没有专门的化学品存放柜及足量的的灭火器材购买专门的化学品柜，补充配备灭火器陈杨、邱峰、董斌、蔡仑7月25日Open1 1现现状状分分析析16)没有专门的化学品负责人员指定相应的化学品管理人员陈杨、邱峰、Shift leader7月25日Open102 2对现场主要人员进行5S 培训

13、仅(牛青莉、胡靖、古云、毛畅畅、刘英浩、贾克斌、张巍)参加June,22的培训由受训人员对所属人员进行培训，并作好培训记录李冬冬6月22日Close3 3由受训人员对所属人员进行培训，并作好培训记录没有实施相应的培训依据公司5S相关文件进行培训牛青莉、胡靖、古云、毛畅畅、刘英浩、贾克斌、张巍7月3日open4 4组织全体员工进行5S的考试已制定相应的5S 考试题没有实施。统一发放试题 考试李冬冬、张朝旭、杜建红7月15日Open5 5对现场的物品进行整理工作现场存在与生产无关或长时间无用的物品制作红色标签对现场物品进行区分陈杨、邱峰、Shift leader8月15日Open6 6对现场有用的

14、物品进行整顿工作已进行了基本的整顿工作根据实际使用情况，开发潜力陈杨、邱峰、Shift leader8月20日Open7 7由5S委员会人员对生产现场进行审核各班次5S负责人员依据5S检查表，对本区域进行自查。5S委员会人员依据5S检查表对现场检查5S委员会8月24日Open8 8对检查结果开具不符合项以现场审核为依据，开出相应的不符合项填写相应不符合项5S委员会8月28日Open9 9制定纠正预防措施以开具的不符合项为基础确定纠正预防措施陈杨、邱峰、Shift leader9月7日Open1 10 0跟踪开具的不符合项以开具的不符合项为基础跟踪开具的不符合项5S委员会9月10日Open1 1

15、1 1确认纠正预防措施的有效性以开具的不符合项为基础确认开具的不符合项5S委员会9月11日Open1 12 2再次对生产现场进行审核以第一次审核为基础确认开具的不符合项及实施效果5S委员会9月13日Open1 13 3评价生产现场5S实施的情况以5S检查为基础确认实施的纠正预防措施5S委员会9月18日Open1 14 4讨论是否可以向全厂推广以模范线5S实施为基础以评价结果为依据5S委员会9月20日Open11PL-2 5S implement plan12 P PL L- -2 2 5 5S S 实实施施计计划划 5S implement plan in PL-2序序号号No.实实施施内内容

16、容Implement contents当当前前情情况况Current status改改进进措措施施Gap analysis andCorrective action责责任任人人Responsibility最最后后期期限限Deadline执执行行情情况况Implementstatus1 11. The top of Siemens placementsystems is not been cleanedregularly.1.To do dailymaintenance morecarefully.Auditor group/Shift leaderASAPOpen2 22. Magazine

17、is piled a little bithigh. ( sometimes, over three)2. To order that onlycan two magazinesbe piled.Auditor group/Shift leaderASAPOpen3 33. Mobicheck, some forms, componentsand other things being useful for ourproduction on machine.3. To put them inthe right place.Auditorgroup/PREJul 13thOpen4 44. Som

18、etimes, some records are notbeen filled in clearly andorderly.4. To train operatorsand tell them how tofill in records, tomodify records.Auditor groupJul 12thOpen5 55. There are some labels underplateholders.5. To take labelsfrom plateholdersand put them at theright place.Auditor groupJul 12thOpen6

19、66. Some operators cant wear theESD shoes and uniforms correctly.6. To change newESD shoes for themand ask them towash their uniforms.Auditor group/Shift leaderJul 20thOpen137 77. Some area marks have beendestroyed.7. To replace newarea marks beforenext Monday.Auditor group/Shift leaderJul 17thOpen8

20、 88. We dont know the qualities definitionof chemicals stored in cabinets.8. To ask relateddepartment.Auditor group/Shift leaderUndefined9 99. We forget to shut down machinesand other equipment when we dontuse them any more.9. to train operatorsshut down machinesand otherequipment, whenthey dont use

21、 themagain.Auditor group/Shift leaderJul 17thOpen1 10 010. Our tables are not so neat.10. Make a clearnotice to all the relatedpeople that that thetables in theproduction area mustbe clean and neat.Auditor group/Shift leader/other officersASAPOpen1 11 111. Our troubleshooters putcomponents disorderl

22、y.11. To asktroubleshooters tomake componentsorderly and checkthem regularly.Auditor group/Shiftleader/MaterialhandlersJul 17thOpen1 12 212. Our tools are not fit in withscraping paste.12. To ask relateddepartment tochange our toolsAuditor group/Shift leaderUndefined14PL-3 5S implement plan15PL- PL-

23、 3 3 5S 5S 实施计划实施计划5S implement plan in PL-序号序号No.实施内容实施内容Implement contents当前情况当前情况Current status改进措施改进措施Gap analysis and Corrective action责任人责任人Responsibility最后期限最后期限Deadline执行情况执行情况Implement statusDistance between the cables insidethe case箱体中电缆的距离箱体中电缆的距离Not strictly controlled inproduction, may

24、cause cable shortcircuit电缆距离没有严格控制，电缆距离没有严格控制，可能导致短路可能导致短路1. Make inspection of the cable distance beforeresin filling a “must-do”(Yan Liping ASAP)打胶前必须检测电缆距离(闫立平闫立平)2. Prepare a 5mm-measure ruler (Robert Liu)准备准备5毫米的标尺毫米的标尺(刘志华)3. Re-stress the importance of keeping thedistance to operators(Yan Lip

25、ingASAP)再次对操作工强调保持电缆距离的再次对操作工强调保持电缆距离的重要性重要性 (闫立平)Yan Liping闫立平闫立平7/20/2001OngoingMaterial Qty Control原料数量控制原料数量控制Qty of some parts(such as Cable,nut, is quite different betweenphysical counting and Baan systemdata部分料件盘点数量与系统数量差距部分料件盘点数量与系统数量差距很大，如电缆，螺母，螺柱很大，如电缆，螺母，螺柱 等等)1. Review BOM(Blessings, Chr

26、istine)重新校订重新校订BOM (王卫红/史连庆)2. Calculate actual usage of Cable,Resin/Hardner, tube, sleeve etc. (WangChunli)计算电缆，胶计算电缆，胶/硬化剂，热缩管，电缆套等硬化剂，热缩管，电缆套等的实际用量的实际用量(王春丽)3. Daily counting for some key parts ifpossible. (Wang Chunli) ,如可能，每天盘点重要料件如可能，每天盘点重要料件(王春丽)WangChunli王春丽王春丽7/31/2001Ongoing1 1现现状分析状分析Resi

27、n Filling Pump抽胶泵抽胶泵Resin is pumped manually andmanual pump often breaks手工抽胶且手摇泵经常坏手工抽胶且手摇泵经常坏1. Buy electrical pump at an acceptableprice.(Allen Cai)购买价格合适的电动泵购买价格合适的电动泵(蔡仑)2. Build a Machnical/ Electrical device to helppump the resin (Robert Liu)制作一个机械或电动装置来帮助抽胶制作一个机械或电动装置来帮助抽胶(刘志华)BlessingsShi史连庆

28、史连庆7/20/2001Ongoing16PL-4 5S implement plan17PL- PL- 4 5S 4 5S 实施计划实施计划5S implement plan in PL-4序号序号No.实施内容实施内容Implementcontents当前情况当前情况Current status改进措施改进措施Gap analysisand Correctiveaction责任人责任人Responsibility最后期最后期限限Deadline执行情况执行情况ImplementstatusThere are a cabinet lock isdamaged, so it cant belo

29、cked .Contact withfacility andrepair itLi wei20 JulyopenMake some visul signs inproduction area, such as thescrap area ,chemicalMaterial areaContact the ADcompany and dothemLi weiLidongdong20 JulyopenAdd some mark in ourSiemens line visualinspection area, define thearea and put the right goodsin rig

30、ht place.Li weiYanglijie20 Julyopen1 1现现状分析状分析For the office , We willclean up our desks ,Isuggest that TQM can makesome audit and make someprice forGood 5S keeper.18PL-5 5S implement plan19 P PL L- -5 5 5 5S S 实实施施计计划划 5S implement plan in PL-5序序号号No.实实施施内内容容Implementcontents当当前前情情况况Current status改

31、改进进措措施施Gap analysis andCorrective action责责任任人人Responsibility最最后后期期限限Deadline执执行行情情况况Implementstatus化学品柜物品的存放不规范，化学品和生产辅料没有区分开。The storage of chemicals and the inside placement ofthe chemical cabinet are not standarlized(There arealso some other production aid-materials in thecabinet such as tweezers

32、 and cutting tools).Rearrange the cabinetand separate thestorage of thechemicals and othermaterials by differentshelves.ZhaoLiJuly 15thOpen目检工外观工位的包装用托盘摆放过高。The trays for packing at the Visual InspectionWorkstation are piped too high(sometimes more than1.7 meters)Limit the height ofthe trays at the

33、V&Istation within 1.6m.ZhaoliJuly 6thClosed某些目检工位桌子的防静电垫下有纸张如操作员用的QA检查申请单。Some paper is found under the ESD mat of some of theV&I station tables such as QA inspection applicationform.Make an clearannouncement thatthere should benothing under theESD mat.ZhaoliJuly 6thClosed生产线的区域标识有的已经破损。Some

34、 of the area marks has already been destroyed.Replace the newmarks a.s.a.pShift LeadersJuly 6thClosed有时生产线提前收工时没有及时将真空笔的气切断。The vacuum pens have not been unplugged sometimesafter the line stopped.Ensure the shiftleaders responsiblefor making all thevacuum pensunplugged after theline stopped.Shift Le

35、adersJuly 6thClosed生产线的物料车没有固定的摆放位置。There is no fixed position for the materialtrolleys.Mark a fixed positionfor those materialtrolleys.Shift LeadersJuly 10thOpen生产区办公桌台面摆放不整齐，杂物较多。The tables inside the production area are not neatenough.Make a clear noticeto all the relatedpeople that that thetable

36、s in theproduction area mustbe clean and neat.Zhaoli,XuPeng,Liu Zhihua,Wanglihui,Liu jinjuan,Ye YorkJuly 15thOpen1 1现现状状分分析析生产线来料的白托盘有堆放过多的现象。The white trays come with materials are sometimespiped too high.Make an agreementwith Sodexho thatthose plastic rubbishshould be cleanedevery half an hour.Zha

37、oliJuly20thOpen20PL-6 5S implement plan21P PL L- -6 6 5 5S S 实实 施施 计计 划划5S implem ent plan in PL-6序序 号号No.实实 施施 内内 容容Implementcontents当当 前前 情情 况况Current status改改 进进 措措 施施Gap analysis andCorrective action责责 任任 人人Responsibility最最 后后 期期 限限Deadline执执 行行 情情 况况Implementstatus生 产 装 配 时 ， 物 料 摆 放 不 整 齐Mater

38、ial disorder when assembling对 所 有 操 作 员 工 进 行 培训 。 Train and educate alloperators.江 勇Jiang YongJuly 12thclose备 料 工 位 不 能 及 时 清 理 地 面 上 的 废 弃 物 . didnt disposal the waste that dropped onthe floor on time.设 专 用 垃 圾 箱 ， 并 保 证废 品 入 内。Set up a special dustbinfor the w aste.江 勇Jiang YongJuly 12thclose1 1现

39、现 状状 分分 析析生 产 线 的 物 料 车 没 有 固 定 的 摆 放 位 置 ,缺 少 标 识 。 The handcart is not fixed on theproduction area, lack the visual signs.贴 地 标 ， 做 标 识Paste the visual signs张 颖Zhang YingJuly 12thclose22PRE 5S implement plan23 B Be ei ij ji in ng g E El lc co ot te eq q E El le ec ct tr ro on ni ic cs s C Co o. .,

40、 , L Lt td d. .北京艾科泰电子有限公司P PR RE E 5 5S S 实实施施计计划划5S implement plan in PRE序序号号No.实实施施内内容容Implement contents当当前前情情况况Current status改改进进措措施施Gap analysis andCorrective action责责任任人人Responsibility最最后后期期限限Deadline执执行行情情况况Implementstatus化学物品的存放不规范，化学品和备件没有很明确地区分开。The storage of chemicals are notstandarlize

41、d。(There are also someother chemicals in the spare partcabinets).Rearrange the cabinet andseparate one place to storeall of the chemicals.Xu Haijing &Fan JinbaoJuly 27thOpen设备维护用工具箱的存放位置没有固定且无标识。There is no fixed place to put all ofthe tool boxes and no any mark.Marked out and fixed thearea to p

42、lace all of the toolboxes.Fan JinbaoJuly 13thClosed库房内的货架表面不是很干净。The cabinets in the warehouse are notneat enough.Clean all of the cabinetstermly.Master liJuly 20thOpen库房内地面上有闲置的丝网。There are some idle stencils in thewarehouse.Let the productiondepartment deal with thesestencils uniformly.Ye Jun &

43、; LiuTaizhongJuly 20thOpen1 1现现状状分分析析Current status库房角落内有闲置不用的东西。There are some idle materials in thecorners of the warehouse.Arrange them in the orderand abandon those uselessmaterials.Xu Haijing,Fan Jinbao &Master LiJuly 27thOpen244) 5S Definition 25What is 5S?1S1S：Seiri Sort out unnecessaryit

44、ems in the workplace anddiscard them.?26What is 5S?2S2S： Seiton Arran ge nec essary items ingood order so th at the y can beeasi ly pic ked fo r use: A place for ev erythi ng Ev erythi ng in its pl ace27What is 5S?3S3S：SeisoSeiso Clean your place completely Clean your place completelyso that there i

45、s no dust on floor,so that there is no dust on floor,machines and equipmentmachines and equipment28What is 5S?4S: 4S: SeiketsuSeiketsu Maintain high standard ofhousekeeping and workplaceorganization at all time295S5S：ShitsukeShitsuke Train people to followgood housekeepingdisciplines autonomouslyWha

46、t is 5S?30The significance of 5S：5S5 S3.Optimize thehumor ofemployees5. Improve thequality of product7.Optimize thesituation of themarket2.Establish safetyproduction area4.Elevate theefficiency ofproduction line6. Extend thelifecycle ofequipment8.Willing Invitecustomer to visitour plant1.Make comfor

47、tableworkplace315) 5S implement Instruction(BP-63-0003)321 .P u r p o s e 5 S a c tiv ity a im s a t c re a tin g a c le a r ,c le a n a n d s a fe w o rk in g e n v iro n m e n t. Ita llo w s c le a r w o rk a rra n g e m e n t ,re d u c e s w a s te , in c re a s e e ffic ie n c y , e n s u re sq

48、u a lity ,a n d a t th e s a m e tim e p ro m o te s th e c o m p a n y p u b lic ity , e n h a n c e se m p lo y e e a llia n c e s , a n d m a rk e t c o m p e titiv e n e s s .2 . S c o p eT h is g u id a n c e a p p lie s o n a ll a re a s b e lo n g in g to e a c h d e p a rtm e n t (in c lu d

49、in go ffic e a re a a n d p ro d u c tio n a re a ), a n d o n p e rs o n n e l o f d iffe re n t a d m in is tra tiv ele v e ls .3 . D e fin it io n 3 .1 5 S : S o rt (S E IR I), C la s s ify (S E IT O N ), C le a n (S E IS O ) , C le a r (S E IK E T S U ) ,C u ltu re (S H IT S U K E )P le a s e s

50、e e A p p e n d ix (1 ) fo r d e ta ils 3 .2 5 S im p le m e n ta tio n : in c lu d in g p ro c e s s o f in s p e c tio n , e x a m in a tio n , a n dtra in in g e tc . 3 .3 5 S c o m m itte e : s e le c t re la te d p e rs o n n e l fro m e a c h d e p a rtm e n t to fo rmp ro m o tin g o rg a n i

51、z a tio n o f 5 S a c tiv ity .P le a s e s e e A p p e n d ix (2 ) fo r d e ta ils4 .D u t y 4 .1 T Q M ta k e s c h a rg e a ll 5 S re la te d a c tio n s o f c o m p a n y 4 .2 P ro d u c tio n s u p e rv is o r a n d p ro d u c t s p e c ia lis t ta k e s c h a rg e 5 Sim p le m e n ta tio n o f

52、 c o rre s p o n d in g d e p a rtm e n t 4 .3 H R o rg a n iz e s 5 S tra in in g a n d T Q M a n d re la te d p e rs o n n e l ta k e s c h a rg eim p le m e n ta tio n .335 .D e s c r ip tio n 5 .1 5 S S p e c ific a tio n 5 .1 .1 M a in ta in o rg a n iz e d a n d s m o o th p ro d u c tio n o p

53、 e ra tio n5 .1 .2 M a in ta in c le a r a n d b rig h t w o rk in g e n v iro n m e n t 5 .1 .3 R e g u la te p ro d u c tio n re la te d a s s is tin g w o rk to in c re a s e w o rk e ffic ie n c y 5 .1 .4 C o rre c t w o rk m e a s u re a n d p e rs o n a l m a n n e r (P le a s e s e e in d e x

54、 3 fo r 5 S re la te d s ta n d a rd )5 .2 D a ily 5 S in s p e c tio n a n d m a in te n a n c e 5 .2 .1 O ffic e a re a : E v e ry s ta ff c o n d u c ts s e lf C in s p e c tio n b a s e d o n 5 S s ta n d a rd a n d ta k e a c c o rd in g ly 5 .2 .2 P ro d u c tio n a re a : R e la te d p e rs o

55、 n n e l o f e a c h d e p a rtm e n t im p le m e n t 5 S in re s p o n s ib le a re a a n d in s p e c tio n re g u la rly . 5 .2 .3 P R E 、 IQ C ,w a re h o u s e : R e s p o n s ib ility p e rs o n n e l o f e a c h s e c tio n im p le m e n t 5 S in re s p o n s ib le a re a a n d in s p e c ti

56、o n re g u la rly .5 .3 In s p e c tio n a n d c o m p a ris o n 5 .3 .1 T Q M m a k e s in s p e c tio n c h a rt fo r e a c h a re a b a s e d o n re la te d 5 S s ta n d a rd a n d ite m s . (p le a s e s e e A p p e n d ix 4 fo r d e ta ils ) 5 .3 .2 D ire c t re s p o n s ib le p e rs o n o f e

57、 a c h s e c tio n in s p e c ts 5 S im p le m e n ta tio n fo r re s p o n s ib le a re a a t le a s t o n c e a d a y . 5 .3 .3 P rim a rily re s p o n s ib le p e rs o n o f e a c h d e p a rtm e n t s e c tio n in s p e c ts a n d m a k e c o m p a ris o n o f 5 S im p le m e n ta tio n fo r re

58、s p o n s ib le a re a a t le a s t o n c e a w e e k . 5 .3 .4 5 S c o m m itte e c o n d u c ts 5 S in s p e c tio n a n d s c o rin g to e v e ry s e c tio n a t le a s t o n c e a m o n th .346) 5S Implement Check List35OfficeItemImplement StandardScoreResult1.Desks and chairs should be put in s

59、traight lines.32.Empty chairs should be put under the table boards(including those in meeting rooms.)33.Never put clothes on the back of chairs.34.File trays, documents and telephone sets on desks shouldbe put in order.35.Electrical outlet, charger and telephone wires should bekept in proper length

60、and right order.36.Put only things of daily use on desks and timely clean thoseexpired ones.37.Personal accouterments on table boards should not be toomany (supposed no more than three items)3Desk8.Only those work related papers (such as working schedulesand telephone lists) are allowed to put up onto the walls.39.Shut d