伟创力制造系统介绍

ABasicIntroductiontoFMS伟创力制造系统FMS介绍AwarenessSessionforDL直接员工认知课程,FlexManufacturingSystem,BanishWastes,CreateValue,FlexE2EValueStream,2,ABriefIntroductiontoFMSFMS简介,TPS,DFT,&Lean丰田生产系统,需求流程技术,&精益生产IntegratingLean&DFTFMSFMS是精益生产&需求流程技术的集成,3,TPS*:PresentDayStructure丰田生产系统的结构,Quality,Cost,Delivery品质,成本,交期ShortenProductionFlowbyEliminatingWaste通过消除浪费缩短生产流程JustInTime准时生产RightPartattheRightTimeintheRightAmount只在正确的时间生产正确的产品和数量ContinuousFlow连续流PullSystems拉动系统LevelProduction分级生产Built-InQuality(Jidoka)过程品质控制(自动化)ErrorProofingPokaYoke防错法VisualControls目视控制OperationalStability操作稳定性StandardizedWork标准化作业RobustProducts&Processes强大的产品&工艺TotalProductiveMaintenance全员生产性维护保养SupplierInvolvement供应商参与Kaizen改善5S/VisualManagement5S/可视化管理HighlyMotivatedandCreativePeople高主动性和创造性的人员,*ToyotaProductionSystem,4,DFT*inFlexToday伟创力目前实施的需求流程技术,*DemandFlowTechnology需求流程技术,5,/,Value价值CorrectlySpecifyValueofProduct/ServicewithCustomerinmind从正确识别产品/服务的价值,始终考虑客户的需求,/,ValueStream价值流IdentifytheValueStreamandremovealltheWastes识别价值流,消除浪费,/,Flow流程MaketheProductandValueFlowSmoothly理顺产品关系和价值流,/,Pull拉动ProduceonlytothePullofCustomerDemand以客户需求拉动生产,/,Perfection完成WastesEliminationasanOngoingProcesstowardsPerfection浪费消除,流程趋于完善,TheUniversalLeanPrinciples普遍的精益原则,6,TheOriginofFMS:FlexManufacturingSystem伟创力制造系统的起源,ToyotaProductionSystem丰田生产系统,DFT需求流程技术,LEAN精益生产,FlexManufacturingSystem伟创力制造系统,7,FlexManufacturingSystem(FMS)伟创力制造系统LeadTimeImprovement+BanishWastesDriveValueCreation缩短生产周期+消除浪费以驱动价值创造,LeanisamanufacturingphilosophythatrecognizesWASTEastheprimarydriverofcycletime,andemploystechniquestocontinuallydriveoutthewasteinprocesses.精益生产是这样一种制造业哲学,它认为生产周期,员工的操作方法是造成浪费的主要原因,并致力于消除这些浪费,PRODUCTSHIPMENT出货,TotalLeadTime生产周期,BusinessasUsual正常工作,Waste浪费,CUSTOMERORDER客户订单,LeanManufacturing精益制造,PRODUCTSHIPMENT出货,CUSTOMERORDER客户订单,LeadTime(Shorter)生产周期(更短),WhyLeadTimeiscrucialtobecomeLean?为什么生产周期在精益生产中如此的至关重要,9,CycleTimeandWaste生产周期和浪费,TypesofWaste*1七种浪费Transportation运输Inventory库存Motion动作Waiting等待Overproduction过量生产Over-processing不必要的过程Defects缺陷,*1Prompter:Whois“TIMWOOD”?敦促者:谁是”TIMWOOD”,Waste浪费,Waste浪费,MUDA*=WasteMUDA=浪费,*Japanese,10,1.Overproduction过量生产Makingmore-earlier-fasterthanthenextprocessorcustomerneedsit相对于下一工序或客户过早过快生产-Justincaselogic以防万一的逻辑-Unbalancedworkload工作量不平衡-Improperscheduling不适当的计划2.Defects缺陷NotdoingworkRighttheFirstTime没有做到第一次就把工作做对-NotusingPoka-yoke*1没采取防错法-LackofStandardization,inconsistentworkmethods缺乏标准化,不一致的工作方法-Ineffectivecommunication无效的沟通Littleinvestmentintraining缺乏培训3.Inventory库存Anysupplyinexcessofone-pieceflow一个流之外的任何供给品-Oftentheresultof“Overproduction”常常是”过量生产”的结果-Unbalancedworkload工作量不平衡-Improperscheduling不适当的计划-Unreliablesuppliers不可靠的供应商,7TypesofWaste七种浪费,*1-alsocalledmistakeorerror-proofing,11,7TypesofWaste七种浪费,4.Over-processing不必要的过程Processingbeyondthecustomers(internalorexternal)requirements过程超过客户(内部或外部)的要求-Poorknowledgeofspecsorcustomerrequirements缺乏对客户规格或要求的知识-Inconsistentworkmethods(non-standardization)不一致的工作方法(非标准化)-Ineffectivecommunication无效的沟通Examples:举例:Manuallycleaningproductbecauseofdirt用手清除产品上的尘土100%visualinspectionatend-of-line线末100%目视检验5.Transportation运输Inefficientmovementofpeople,materialsandinformationintheorganization人员,物料和信息的低效率的移动-Poorlayout差的工厂布局-Inefficient“flow”低效的流动Carryinglargeinventories大量库存Exposesproducttopotentialdamage/lossduringtransportation产品在运输过程中遭受潜在的损害/损失Examples:Anywheresequentialoperationsarebroken任何连续作业中断的地方-Materialstoredtoofarfromworkstation物料存储离工作站太远Toomanyconveyors,forklifts,pallettrucks,etc.过多的传送带,铲车,叉车,12,7TypesofWaste七种浪费,6.Waiting等待Waitingforman,machine,materials,information,etc.等待人,设备,物料,信息等-Unbalancedworkload工作量不平衡-Unplanneddowntime无计划的停机时间Poorworkplacediscipline工作场所无纪律Examples:举例:Lookingfortoolstorepairmachines寻找工具维修设备Firstpiecewaitingfortheentirebatchtofinish第一件等待整批完成Peopleidlebecauseofnomaterialstoworkon因为缺料造成的人员空闲Waitingforinstructionstoproceed等待继续的指示7.Motion动作Unnecessarymovementofpeople,partsormachineswithintheprocess生产过程中,不必要的人员,工件或机器的移动Poorlayout不好的工厂布局InefficientWorkplaceOrganization工作场所缺乏组织LackofStandardization,inconsistentworkmethods缺乏标准化,不一致的工作方法Increaseoperatorfatigueleadingtootherwastese.g.defects增加作业员疲劳造成浪费,如缺陷Ergonomicissuescausinghealthe.g.repetitivemotioninjuries,etc.工效问题对健康的影响,如重复的动作性伤害,13,Understandthedifferenttypesofwaste理解不同的浪费种类Identifythem识别浪费Carryoutyourprocessaccordingtoprocedure按照程序实施你的方法ProperhandlingofPCBandmaterials恰当的处理物料Followthetakttime,worktocycletimeoftheprocess跟随节拍时间工作以形成过程的周期时间Reporttosupervisorifyouspotanyofthe“waste”,like“Iamwaiting”当你发现任何浪费应该报告给你的主管,HowcanIcontributetoeliminatewaste?怎样才能消除浪费,14,FlexManufacturingSystem(FMS)伟创力制造系统(FMS)FMSCharacteristicsFMS的特点FMSToolsandTechniquesFMS的工具和技术,15,WhatFMSis什么是FMS,Anintegratedsystemofprinciples,operatingpractices,andelementsthatdrivetherelentlesspursuitofbusinessexcellencethroughwasteidentification,eliminationandprevention.Peoplemakesithappen.FMS是一个集成了众多生产原理,生产实践的综合系统,它通过浪费的识别,消除和预防以求对卓越事业的不懈追求.其中人是最关键的因素.Outcome:ValueCreationfortheCompanyandCustomer结果:为公司和客户创造价值Outcome:AJourneyTowardsPerfection结果:是追求完善的旅程,LEAN,FMS,16,CharacteristicsFMSwantstoachieve典型的FMS想要达到,People:人员:-Multifunctionalteamsindesignandproduction具备复合功能的设计和生产团队Peoplehavewidevarietyofskills(flexibility)人员具备多种技能(柔性)-Teamsperformwholetasks通过团队执行任务Tools:工具:Low/minimalsetuptimes最少的设立时间Availability&Maintainability有用性和可维护性Productionprocess:生产过程-Demandpullinsteadofschedulepush需求拉动代替计划推动-MinimalInventories最小库存,Fast,FlexibleFlow,17,CharacteristicsFMSwantstoachieve,Quality:品质-Informationcollectedduringproduction生产过程中的信息收集-Problemsaresolvedduringproduction生产过程中解决问题Volumeflexibility:产量的机动性-Switchingbetweenproductsiseasy易于更换产品进行生产-Productionloadsareleveled生产负荷分等级Organization:组织-Optimizethechain:assemblerandsupplierworkcloselytogether优化供应链:组装员工和供应商密切协作,Fast,FlexibleFlow,18,FMSTools&TechniquesFMS工具和技术,19,FMSToolsandTechinquesFMS工具和技术,Amongothers,theseareFMStoolsandtechniquesthatwillhelpustoeliminatewastesandincreaseFlextronicsSuccess:以下这些FMS工具和技术将帮助我们消除浪费和增加FLEX的成功:1.ValueStreamMapping价值流程图-Toidentifyvaluestreamandwaste用于识别价值流和浪费,20,ContinuousFlow连续流-Toreduceoverall7sourcesofwaste用于减少7种浪费,CellularManufacturing细胞制造-Toreduceoverall7sourcesofwaste用于减少7种浪费,Kaizen改善Itsatechniqueforcontinuousimprovement持续改善的技术,21,FromThis从这里.,ToThis到这里,EliminateWaste,MaintaintheDiscipline,5S-Basicstepforthewasteelimination消除浪费的基本步骤-Toimprovesafetyandproductivity提高安全性和生产力,22,Pullsystem拉动系统Tomakevalueflowsatpullofthecustomer根据客户的需求建立价值流,SingleMinuteExchangeDie(SMED)快速换模Aprocessforequipmentchangeoverandset-uptimereductioninunder10minutes.设备换模和设立的时间缩短至十分钟的方法,23,PokaYoke防错Itsatechniquetopreventhumanmistakes防止人类错误的技术Example:Forgetfulness,misunderstanding,wrongidentificationetc.例:健忘的,误解,错误辨认,TotalProductiveMaintena