GM 全球标准化PPT课件.ppt

Standardization标准化 员工参与 标准化 制造质量 缩短制造周期 持续改进 QualityFeedback Feed forward StandardizedWork VisualManagement Work placeOrganization ProblemSolving ContinuousImprovementProcess TotalProductiveMaintenance ScheduledShipping Receiving SupplyChainManagement InternalPull Delivery SimpleProcessFlow TemporaryMaterialStorage FixedPeriodOrderingSystem OrderParts TeamConcept PeopleInvolvement OpenCommunicationProcess Standardization标准化 Vision Mission ManagementbyTAKTTime ShopFloorManagement QualifiedPeople ProductQualityStandards QualitySystemManagement LeanDesignofFacilities Equipment ToolingandLayout EarlyMfg andDesignIntegration DFM DFA SmallLotPackaging ControlledExternalTransportation Standardization标准化 Whatisit 是什么 GroupDiscussion小组讨论 Standardizationisadynamicprocessbywhichwesetstandardsofterminology principles methods andprocesseswithinourorganization 标准化是指在我们的组织内部对各种术语 原则 方法及工艺建立标准的动态过程 DefinitionofStandardization标准化的定义 Standardization标准化 Thepurposeofstandardizationistoreducevariationandstabilize soastoachieveabasefromwhichtogrowandimprove 标准化的目的是减少变化与维持稳定 在此基础上进步与提高 PurposeofStandardization标准化的目的 Standardization标准化 Standardization标准化 WhyIsStandardizationImportant 为什么标准化很重要 SAFETY安全 QUALITY质量 COMMONDIRECTION共同方向 PRODUCTIVITY产量 WhatHappensWhenWeDoNotHaveGood ClearStandards 若没有良好 明晰的标准会怎样 Example 2000U S PresidentialElections VariationinVotingMachines MethodsCausedMajorElectionControversy 事例 2000年美国总统大选 投票机器与方式的不一致导致重大选举纷争 Standardization标准化 THEWEDGE TOSTABILIZEBESTPRACTICE 楔子 楔牢最优方法 ContinuousImprovement不断改进 Change改变 Standardization标准化 AStandardIsTheBestCurrentPracticeBasedOnManyPeople sExperience LessonsLearned so 标准是基于多数人的经验教训得来最优现行方法 所以 DON TSHORTCUTTHESTANDARD 切勿缩短标准 BADTHINGSCOULDHAPPEN ESPECIALLYSAFETY QUALITYPROBLEMS不良的事故会发生 尤其是安全及质量问题 IFYOUDON TLIKETHESTANDARD TRYTOCHANGEIT BUTNEVERSHORTCUTIT 若你不满意这个标准 试着改变它 切勿走捷径 Standard Shortcut WhatHappensWhenWeDoNotFollowStandards 如果不遵照标准会怎样 EVERYYEARPEOPLEDIEFROMNOTFOLLOWINGLOCK OUTPROCEDURE U SSUBMARINEHITSJAPANESEFISHINGBOAT SURFACINGPROCEDURENOTFOLLOWED EXXONVALDEZOILSPILL CAPTAINDIDNOTFOLLOWSTANDARDS GERMANPLANECRASHESINSWITZERLAND AIRTRAFFICCONTROLPROCEDURESIGNORED 每年都有人死于不遵循关阀规定 美国潜艇击沉不遵守海面规定的日本渔船 德国忽视空中飞行条例在瑞士坠毁 船长不遵循标准导致EXXON瓦尔迪兹石油泄露 STANDARDIZATIONEXERCISE标准化练习 Thinkofanyexampleinsideoroutsideworkwherestandardsnotbeingfollowedledtoabadsituation想想工作中或其它不遵守标准导致不良事件发生的例子 Discussasateamandreport Take5minutes小组讨论 汇报 5分钟 AlwaysRememberThePriorities 牢记的重点 Safety安全People员工Quality质量Responsiveness响应Cost成本 Importance重要 ForExample SometimesWeHaveToSacrificeEfficiencyToAchieveSafety 例如 有时我们必须为了安全而牺牲效率 MAKERULE制订条例TEACHRULE讲授条例KEEPRULE遵守条例 DOTHERIGHTTHING 做合理的事情 LEADBYEXAMPLE 榜样领导 StandardizationOnABroaderScaleLeadstoCommunization更大范围的标准化以达到共有化 One Language 同一语言CommonPrinciples通用原则CommonMethods通用方法CommonProcesses通用程序 Standardizationvs Commonization标准化与共有化 IfonefamilymadearecipefortheirKimchi thenitwouldbeStandardized 如果一个家庭为其泡菜定个菜谱 就是标准化 ButallfamiliesarestilldifferentsowearenotCommonized sometimescommonisnotappropriate 但是每个家庭做法不一样则没有达到共有化 有时共同的并非是正确的 ManufacturingProcessValidation In ProcessControl Verification VisualManagement ManagementbyTAKTTime ProblemSolving ContinuousImprovementProcess TotalProductiveMaintenance LevelVehicleOrderSchedules SupplyChainManagement TemporaryMaterialStorage HealthandSafetyPriority PeopleInvolvement Values Vision Mission ShopFloorManagement Standardization标准化 EarlyMfg andDesignIntegration DFM DFA LeanDesignofFacilities Equipment ToolingandLayout ScheduledShipping Receiving WorkplaceOrganization工作场地布置 Whatisit 指什么 GroupDiscussion小组讨论 WPOMotto 工作场地布置口号 Aplaceforeverythingandeverythinginitsplace 所有工作的场地 所有工作井井有序 WorkplaceOrganization 5S工作场地布置 5S PutordertotheworkplacebymakingStandardsthatallow out of standard conditionstobevisible 制定标准使工作场地井井有序 并使非标准的东西暴露出来 WhereisWorkplaceOrganizationImportant 哪些工作场地布置重要 Ontheshopfloor 车间地面 intheoffice 办公地点 Howisworkplaceorganizationdone 怎样布置工作场地 WorkplaceOrganization工作场地布置 5S 5SelfDiscipline Cont Improvement不断改进 4Sustain Maintain维护 2Sort Standardize整顿 1Sift Clear整理 3Sweep Clean清扫 清洁 Sift Clear整理 Dividetheneededandnotneededitemsatthejobsite andquicklyremovetheunneededitems 区分开工作场所中必要和不必要的东西 迅速将不必要的东西清除 AreasofFocus重点区域 Tools工具 2 Inventory Storage库存 储存 3 Equipment设备 KeepneededItems保留必要东西 RemoveunneededItems waste 清除不必要东西 废料 TheMostDifficultthingforustodo 这是最难做到的 1Sift Clear RedLabelCampaign Sift Clear整理 1Sift Clear IfInDoubt ThrowItOut 毫不犹豫扔掉 Sort Standardize整顿 APlaceforeverything andeverythinginitsplace所有工作的场地 所有工作井井有序 Thelocationofequipment toolingandmaterialshouldbeclearlydefined displayedandmaintained 各种设备 工具 材料明确区分 放置 维护 L850Hose30pcs SmallBolts小螺栓700pcs Med Bolts中等螺栓500pc LargeBolts大螺栓300pcs L850RubberHose橡胶管 2Sort Standardize 1Sift Clear Sort Standardize整顿 MakeAStandard 制定标准 2Sort Standardize 1Sift Clear Sweep Clean清扫 清洁 3Sweep 2Sort 1Sift Sweeping ischecking 清扫既是检查 Check Sustain Maintain维护 IdentifyTasks确定任务AssignResponsibility划分责任SetTargets设定目标 Safety 5SChecksMustBePerformedEverywhereandAtEveryLevelOfTheOrganization 安全 5S检查应该人人处处开展 Standardsareworthlessifthereisnosystemtocheck 如果没有系统检查 标准即毫无用处 Self Discipline ContinuousImprovement自律 不断改进 5SelfDiscipline Cont Improvement自律 不断改进 4Sustain Maintain维护 2Sort Standardize整顿 标准 1Sift Clear整理 3Sweep Clean清扫 清洁 Itiseveryone sresponsibility 这是每个人的职责 5SEXERCISE5S练习 Howwouldyouusethe5Sprocesstoimprovethesituationbelow 你怎样用5S程序来改善下图的情形 UtilizeALL5Ss利用所有5S程序Discussasateamandreport Take10minutes小组讨论 汇报 10分钟 5SEXERCISE INSERTWORKSHEET插入工作表 AnythingoutsidethestandardisWASTE 所有标准外的东西都是浪费 WPOisakeymeansofvisualizingandeliminatingwasteWPO是暴露及消除浪费的主要途径 Whyworkplaceorganization 为什么要场地布置 Whyworkplaceorganization 为什么要场地布置 ExampleofCabinet5S橱柜5S范例 Cabinet Before5S 5S之前的橱柜 Cabinet After5S 5S后的橱柜 Exampleof5S ManufacturingProcessValidation QualitySystemManagement In ProcessControl Verification VisualManagement AndonConcept ProblemSolving ContinuousImprovementProcess BusinessPlanDeployment TotalProductiveMaintenance ControlledExternalTransportation ScheduledShipping Receiving LevelVehicleOrderSchedules SupplyChainManagement SimpleProcessFlow TemporaryMaterialStorage HealthandSafetyPriority PeopleInvolvement Values Vision Mission ShopFloorManagement Standardization标准化 LeanDesignofFacilities Equipment ToolingandLayout EarlyMfg andDesignIntegration DFM DFA StandardizedWork标准化工作 Thedocumented currentbestmethodtoSafelyandEfficientlyperformworkthatmeetsthenecessarylevelofQuality 为了达到一定的质量标准 以文件化及最可行的方法来安全有效地开展工作 WithoutStandardization没有标准化 WithStandardization有了标准化 StandardizedWork标准化工作 StandardizedWork标准化工作 Standardizedworkisusedwhenthereisadefinable repeatableprocess 当工序明确可重复时 采用标准化工作 StandardizedWorkCanBePerformedEverywhere 随处都可以开展标准化工作 Everyonecanperformstandardizedwork 每个人都可以进行标准化工作 EmployeesShouldBeInvolvedInDevelopingStandardizedWork TheyKnowTheJobTheBest 员工应该加入标准化工作开展 因为他们最了解工艺 Standardization标准化 Improvement改进 StandardizedWork 标准化工作 StandardizedWorkIsABaselineforContinuousImprovement 标准化工作是不断改进的基线 Standardization标准化 Standardization标准化 Standardization标准化 Improvement改进 Improvement改进 EachIndividualHasGoodIdeas IfWeDoNotDocumentTheBestMethodsThenWeAreNotFullyUtilizingTheTeam sBrainpowerandWeWillNeverImproveOrWeMayActuallyGetWorse 每个人都有好主意 如果我们不把最好方法文件化 则不可能充分利用团队的智能 不但不能取得进步 甚至会越来越糟糕 WouldYouWantToGetIntoAPlaneWhereTheCrewDidNotExactlyFollowAStandardizedCheckProcess EvenThoughTheyHavePerformedItHundredsOfTimes 你会不会乘坐乘务员不履行标准检查程序的检查的飞机 即使他们重复操作过无数遍 CheckFuel 检查汽油 CheckTires 检查轮胎 CheckInstruments 检查仪表盘 ContinuousImprovement Standardization ThereIsaRealBalanceBetweenStandardizationandContinuousImprovement 标准化与不断改进之间有个天平 WeMustControlTheBalancetoBeSureThatWeAreNeithertoStrictWithStandardization NorTooFlexible 我们必须控制这个天平以确保既不要死守也不要脱离标准化 BUT LegoExercise StandardizedWorkBasics CycleTime 001L ActualTaktTime 5 4 3 2 1 Time StandardizedWorkBasics MakeWasteVisible 暴露浪费 WorkFlowDiagram工作流程表 TimeChart时间表 WasteofMotion 动作浪费 Non ValueAdded 非增殖时间 ValueAdded增殖时间 WaitTime 等待时间 Providesanoverviewoftheelementsandtheirtimesinthecorrectsequenceforonejob Identifiesimportantkeypointsusingsymbols Ensuresstandardacrossshiftsviasign off DocumentschangestotheStandardizedWork Documentsworklocation Visualizesworkermovementviasketch Symbol MOVINGLINESTANDARDOPERATIONSHEET Group team JOBNAME Operation S ElementName y s Work m t element b e Registered Handwork Model o p Number l Totalhandwork walkingbymodelsec Cycletimesec Volume Weightedaverage Return Walk R3 R2 R4 IR L3 L1 L4 R1 L2 IF E CF CR T C Quality Checks SafetyforOperator Critical Process for CR T L4 IR L3 IF L2 L1 CF E SUB MAT LocationLH Frequency CR T R4 IR R3 IF R2 R1 CF E SUB MAT LocationRH Frequency CycleTimeChart weightedaveragecycletime OptionorModel Time Volume s WalkTime walking ActualTaktTime SignatureTeamLdrSuperv ShiftMgr ShiftAShiftBShiftC Revisions Mo Yr Sign WhatChange ConfirmationofAdherence Date Signature VisualizesA T T Vs CycleTimesofthejobviatheCycleTimeChart ElementsOfGoodStandardizedWork Symbol MOVINGLINESTANDARDOPERATIONSHEET Group team JOBNAME Operation S ElementName y s Work m t element b e Registered Handwork Model o p Number l Totalhandwork walkingbymodelsec Cycletimesec Volume Weightedaverage Total Return Walk R3 R2 R4 IR L3 L1 L4 R1 L2 IF E CF CR T C Quality Checks SafetyforOperator Critical Process for CR T L4 IR L3 IF L2 L1 CF E SUB MAT LocationLH Frequency CR T R4 IR R3 IF R2 R1 CF E SUB MAT LocationRH Frequency CycleTimeChart weightedaveragecycletime OptionorModel Time Volume s WalkTime walking ActualTaktTime SignatureTeamLdrSuperv ShiftMgr ShiftAShiftBShiftC Revisions Mo Yr Sign WhatChange ConfirmationofAdherence Date Signature ElementsOfGoodStandardizedWork标准化工作要素 Useasbasisfortraining ProblemSolving作为培训问题解决的基点 Mustsupporttheuser bepostedvisually有利于操作者或张贴到明显处 Userinvolvedindevelopment操作者参加改进 AlwaysrespectStd Workofothers尊重他人的标准化工作 PerformregularchecksofStd Work定时检查标准化工作 FinalNotesonStandardizedWork标准化工作后注 FinalNotesonStandardizedWork标准化工作后注 TheTrueTestofGoodStandardizedWorkisWhenSomeoneDoesNotCometoWorkandtheJobStillGetsDoneSafely EfficientlyandwithQuality真正经得检验的标准化工作是当有人缺席时仍能安全 有效 高质地完成工作 WhatDoIDo QualitySystemManagement In ProcessControl Verification QualityFeedback Feed forward StandardizedWork VisualManagement Work placeOrganization AndonConcept ProblemSolving BusinessPlanDeployment TotalProductiveMaintenance ScheduledShipping Receiving LevelVehicleOrderSchedules SupplyChainManagement InternalPull Delivery SimpleProcessFlow TemporaryMaterialStorage FixedPeriodOrderingSystem OrderParts HealthandSafetyPriority TeamConcept Values Vision Mission ShopFloorManagement Standardization标准化 EarlyMfg andDesignIntegration DFM DFA LeanDesignofFacilities Equipment ToolingandLayout ControlledExternalTransportation ContinuousImprovementProcess TaktTime Numberofvehiclesrequiredpertimeperiod此阶段需要生产台数 Weekly周Monthly月Yearly年 TaktTimeisConstant TAKTTIME是不变的 TaktTime Determinesthespeedoftheline决定流水线速度Thetimeavailabletoproduceacomponentorsingleunit 生产一个部件或一辆车的时间Determinedbythenumberofvehiclesrequiredbytheendofeachdaytomeettheproductiontarget 由需要达到的每日生产目标的车辆数决定 OperationalTimePerPeriod某阶段生产时间 ManagementByTaktTimeTaktTime管理 ILoveLucyVideoPartII ILoveLucy StartvideoatChocolateAssemblyLine 录象从巧克力的生产线开始 ILoveLucyVideoPartIIGroupDiscussion小组讨论 WhatGMSStandardizationPrincipleconceptsdidwe not seeinthevideo 在录象看到或没看到哪些GMS的标准化原则Discussasanopenforum notbyteams论坛讨论 非小组讨论 ILoveLucyVideoDiscussion Whatdidweseeinthevideo 从录象可我们看到 LackofStandardizedWork 缺乏标准化工作Nodocumentedstandardizedworkonjob车上没有标准文件化Nostandardizedworktouseasbasisfortraining没有标准化工作作为培训基础Noqualitystandardforcompletedchocolate巧克力做完后没有质量标准LackOfManagementByTaktTime 缺乏生产节拍管理TaktTimearbitrarilychanged主观改变生产节拍NocommunicationorplanningofTaktTimechange生产节拍改变没有协商或计划Novisualindicationofworkstationbeginningandend从头到尾都没有工位的目视化标识Others NowaytocallforhelpNowaytostoplineorpreventdefectsfromleavingstation ILoveLucy ExampleofUnleanChocolateFactory不精益的巧克力工厂例子TakttimesloweddownTAKTTIME减慢Cycletimenotadjustedtothetakttime周期时间与TAKTTIME不符 CycleTime Lucy Ethel ActualTaktTime TeamMember CycleTime 5 4 3 2 1 Time ManagementByTaktTimeTaktTime ExampleofUnleanChocolateFactory不精益的巧克力工厂TaktTimeArbitrarilySpeedUpTAKTTIME随意加快CycleTimeNotAdjustedtoTaktTime周期时间与TAKTTIME不符 CycleTime Lucy Ethel TaktTime TeamMember CycleTime 5 4 3 2 1 Time Overburden 负载过重 ManagementByTaktTimeTaktTime管理 ManagementByTaktTimeTaktTime管理 WhenTaktTimeChangesArbitrarily Safety Quality EfficiencySuffer TAKTTIME随意改变 安全 质量 效率就会出问题 TaktTimeChangesMustBeCommunicated Planned TaktTime的改变必须经过协商或计划 JustthinkofpoorLucy ExampleofLeanChocolateFactory精益的巧克力工厂TaktTimeIsConstant BasedonDemandTAKTTIME基于需求恒定CycleTimeIsAdjustedtoTaktTime周期时间与TAKTTIME一致 CycleTime Lucy Ethel TaktTime TeamMember CycleTime 5 4 3 2 1 TaktTimebasedondemandTAKTTIME根据需求 Time ManagementByTaktTimeTaktTime管理 8hoursx60minutes8小时x60分 100UnitsScheduled100辆计划 480mins 47mins Breaks480分 47分 休息 4 33mins 4 33分 100Units100辆 OPTIMUM TAKTTIME x 1 07DowntimeLoss1 07停线损失 107UnitsNeededCapacity107辆产量 107Units107台 433minutes433分钟 4 04mins 4 04分钟 ACTUALTAKTTIME 实际费时 OFWASTE 107CAPACITY107产量 100UnitsREQUIRED需求100辆 7UNITS7辆浪费 PLANTLOSS 工厂损失 TheEffectsofWaste Downtime OPTIMAL TAKTTIME最佳节拍 7 OVERSPEED DowntimeLoss ACTUALTAKTTIME实际节拍 CycleTime 433100 4 33 433 30100 4 04 AndonStops OperatorOverburdenQualityIssuesOtherProcessIssues 5 Machine EquipmentDowntime 2 TheEffectsofWaste Downtime 浪费后果 停线 PointA FPS PointB FPS PointC FPS StartStd Workatmatchedreferencepoints与控制点一致 FinishStd Workatwhenreferencepointsmatchedatnextstation与下一工位控点一致 UsetheFPSAsaReferencePointtoMeasuretheTaktTime用定点停作为测量节拍的控制点ThinkoftheFPSas thebeginningofStandardizedWork intermsofTIME the startofthestopwatch 在时间上定点停为 标准化工作的起点 秒表的开始 PurposeofFixedPositionStop FPS 定点停目的 ManufacturingProcessValidation QualitySystemManagement In ProcessControl Verification QualityFeedback Feed forward StandardizedWork Work placeOrganization ProblemSolving ContinuousImprovementProcess TotalProductiveMaintenance ControlledExternalTransportation ScheduledShipping Receiving LevelVehicleOrderSchedules SupplyChainManagement InternalPull Delivery SimpleProcessFlow TemporaryMaterialStorage FixedPeriodOrderingSystem OrderParts HealthandSafetyPriority PeopleInvolvement Values Vision Mission ShopFloorManagement Standardization标准化 EarlyMfg andDesignIntegration DFM DFA LeanDesignofFacilities Equipment ToolingandLayout DefinitionofVisualManagement目视化管理的定义 Aprocessinwhichstandardsandactualconditionbecomequicklyvisualintheworkplace 标准与实际情况在工作场所视觉化的程序 VisualManagement目视化管理 VisualManagementKeyConcepts目视化管理主要概念 MAKESTANDARD OUTOFSTANDARDCONDITIONSCLEAR VISIBLE 使标准及非标准明晰及可视化 x x VisualManagementKeyConcepts目视化管理主要概念 STATUSATAGLANCE一目了然的状态 GUIDELINE SHOULDNOTTAKEMORETHANONESECONDTOGRASPANYSITUATION 方针 不超过一秒钟了解情况 VisualManagementKeyConcepts目视化管理主要概念 CommunicateInformationtoDriveQuickDecisionsforAction 互通信息迅速下决定采取行动 WearPPE Problem I mOK WalkHere OnTarget I montime VisualManagement目视化管理 MaketheShopFloorTalktoYou 使车间也会说话 APictureIsWorthAThousandWords 百闻不如一见 Visualizationvs VisualManagement目视化与目视管理 NiceCharts Verypretty BeCarefulOfVisualization注意目视化 图表真美观 是的 这个信息说明有问题了 Pretty 好看 Useful 有用 1 2 3 9 10 11 5 4 6 31 30 28 29 23 24 25 16 17 18 7 8 13 19 20 26 27 14 15 21 22 ClearOutOfStandardConditions突出异常情况 12 TRIM1 1 2 3 4 5 SAFETY安全 QUALITY RESPONSIVENESS质量 响应 X StatusAtAGlance Examples CommunicateInformation Examples Showphotosofnormal Walk Don tWalk lightversusStackLighttoshowhowmuchtimeisleft用图片指示常见 行走 禁走 灯与一堆灯表示剩下多少时间对比 FPS FPS Reorder 9pcs 25 02 023L 25 02 023L WorkstationAddressSign Label Label Label Label Label Label Label Label Green Start Mark Red Finish Mark BestPeoplePractices ProductAssemblyDocument KeyPointChart Manifest RequiredPersonalProtectiveEquipment OperationCer