精益生产系统课件.ppt

精益生产系统LeanProductionSystem,6西格玛流程能力(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LeanSigmatransformation,精益生产系统LeanProductionSystem,改善突破法KaizenBreakthroughMethodology,驱动成本下降Drivescostreduction,精益生产系统LeanProductionsystem,及时生产Just-In-TimeIs.,这个系统生产Amanufacturingsystemwhichproduces:客户所需的产品Whatthecustomerwants以客户要求数量Inthequantitythecustomerwants按客户指定时间Whenthecustomerwantsit,使用最少的Whileusingtheminimum:原料Rawmaterials设备Equipment人力Labor场地Space,KeyConceptsandTools关键的概念和工具PacetoTakttime(跟上节拍时间)One-pieceflow(单件流)Pullsystem(结合拉动系统),LeanProductionSystem精益生产系统,ImportanceofTaktTime节拍时间的重要性,Customerrequirements客户需求数,Netoperatingtime净操作时间,Synchronizesoperationstocustomerdemand生产与客户的需求同步Preventsoverproduction避免过量生产Toolforcreatingflow建立流程的工具Determinesoptimalstaffing确定最佳人员配置Drivescapacityanalysis&equipmentutilization驱动资源能力分析和设备利用Mustbeupdatedperiodicallyasdemandchanges必须按需求变化定期更新,拉动式单件流物料补充One-pieceflowwithPullReplenishment,超市运作SupermarketOperation,过道Aisle,E,D,C,B,A,I,H,G,F,A,B,C,D,E,F,G,H,I,按实际客户需求生产ProducetoActualCustomerDemand,拉动系统PullSystem,实施拉动系统ImplementPullsystem,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Eliminateswasteinproductionprocesses缩短制造周期时间Reducesleadtimes,品质成本交货!QualityCostDelivery!,不能容忍生产异常Createsasystemwhichisintolerantofproductionabnormalities,自働化是Jidokais,A.减少不良品AmethodforreducingdefectsB.设备自働化，提高生产率Equipmentautonomationtoimproveproductivity,自働化Jidoka,A.减少不良品的工具ToolsorMethodstoReduceDefects发现不良品的产生Detectdefectswhentheyoccur防止不良品进入下一道工序Preventdefectsfrompassingtonextoperation发现不良品产生根源Identifyrootcausesofdefects消除根源Eliminaterootcauses减少或消除不良品Reduceoreliminatedefects,2019/12/13,15,可编辑,自働化的要素JidokaElements,目视控制VisualControl5S信号灯Andon异常反应AbnormalityResponse/Reaction作用/责任Rolesandresponsibilities停工指引Linestopguidelines原因分析(定义/测量/分析/改善/控制)RootCauseAnalysis(DMAIC)基本品质工具BasicQCTools先进统计工具AdvancedStatisticalTools,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自働化人机分离AutonomationSeparatepersonfrommachine,目视控制Visualcontrol,5S灯号Andon,零件展示Partspresentation,工具展示Toolpresentation,包装线Packline,按灯Andon,标准化工作Standardwork,自働化的要素JidokaElements,自働化Jidoka,A.减少不良品的工具ToolsorMethodstoReduceDefects发现不良品的产生Detectdefectswhentheyoccur防止不良品进入下一道工序Preventdefectsfrompassingtonextoperation发现不良品产生根源Identifyrootcausesofdefects消除根源Eliminaterootcauses减少或消除不良品Reduceoreliminatedefects,异常反应过程AbnormalityResponseProcess,发现问题Reacttoproblem,自働化Jidoka,B.设备自働化Equipmentautonomation人机分离Separateoperatorworkfrommachinework之前Before:操作员监控机器工作Operatorwatchesmachinerun之后After:操作员装卸零件Operatorloadsandmoves自动关闭Autoshut-off“Hanedashi”自动卸货“Hanedashi”autounload操作员进入下一道工序Operatormovestonextoperation,问题：你是否观察过洗碗机工作？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!,均衡生产是ProductionSmoothingIs.,调整生产速度,满足客户变化Adaptingproductionratestovariationsincustomerdemand,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,均衡生产ProductionSmoothing,产量的变化VariationinVolume,均衡生产ProductionSmoothing,每月计划:3,200个MonthlySchedule(3200units),5,15,20,10,ModelC,800units,Day,每日计划(160个)DailySchedule(160units)生产模式:ProductionpatternAABCAABC,80,1,40,40,80,2,40,40,80,3,40,40,80,20,40,40,种类变化VariationinMix,均衡生产的好处ProductionSmoothingBenefits,保持一致优良品质Maintainsaconsi