WCM审核标准ppt课件

精选,1,WORLDCLASSMANUFACTURING,PLANTAUDITclarifyevaluationstandpointsandlevels;andestablishasystemof(atleast)everyfourmonthson-siteauditsbyseniormanagers.Thisisindispensableforeliminatingaccidents.,精选,14,Safety(Proactive),1.Safetystep6,2.SafetyRCA+10.Employeesatisfaction3.Systemtocreatemotivation9.Bodyage4.Intrinsicsafetydesignfor,equipment5.Intrinsicsafetydesignforworkshop14,6.Safetystep7,8.Healthadvice7.Healthcampaign,精选,15,Safety(Proactive),1.Safetystep6:Teaminitiatedsafetyactivities,2.SafetyRCA+TWTTP+humanerroridentificationatoneofthreephases,(perception,judgmentandaction)anditspropercountermeasures3.Systemtocreatemotivationtorecordallkindsofnearmisses,unsafeconditionandacts.,15,4.Intrinsicsafetydesignforequipmentandprocess5.Intrinsicsafetydesignforworkshopandplant,6.Safetystep7:Systemtomakepeoplenotabletomakemistakes7.Healthcampaign,8.Healthadvicetoincludewell-beingprograms9.Checkingbodyageandactualage,10.Employeesatisfactionwithhealthandsafety,精选,16,Level4,Level5,6.Teaminitiatedsafety*Proactiveapproachtosafety,7.Fullyimplemented,2,safetymanagementLevel63,4,5ThesevenlevelsofsafetyLevel7,16,Level1,Level2,Level3,1.Settingsafetyorganization,2.Modelareasselection*Safetymatrix*SafetyEWOtoaccidents,medications,5.Autonomoussafety4.Furtherdetailrootcausesanalysis,*SafetyEWOtonearmisses,unsafeconditionsandacts3.Stepbystepextension*Modelareas:Step4zeroaccidents,zeromedications,1,Expansionanddevelopment,精选,17,17,Thesevenlevelsofsafety1.Settingsafetyorganization*Appointedpersonforsafety*Reportsofaccidents,medicationsandcountermeasures*Safetypyramid*Registerandcomplianceanalysisofnationalsafetyrequirements2.Modelareasselectionandcreationofknow-howtoeliminateaccidentsandmedications*Safetymatrix*Classification(AA,A,B,C)*Modelareasselection,developmentofSafetystep13:zeroaccidents*SafetyEWOappliedtoaccidents,medications*Visiblesafetystandards*Riskassessment3.Stepbystepextension*ManagementSMAT*Modelarea:Safetystep4,Zeroaccidents,Zeromedications,精选,18,18,*AASafetystep13:zeroaccidents*Formalrecordedriskassessmentscarriedout,reviewedandupdated*100%adheredSMATaudit*Contractorinvolved*Occupationalhealthprogram4.Furtherdetailrootcausesanalysis*SafetyEWOapplieduptonearmisses,unsafeconditionsandunsafeacts*SafetyEWO+TWTTP5.Autonomoussafety,operatorSMAT*Dynamicriskassessments*Modelarea:Safetystep5*AA:Safetystep4,*A,:Safetystep13,精选,19,6.Teaminitiatedsafety.Proactiveapproachtosafety*Furtherdetailedrootcausesanalysis(recognitionjudgmentandaction)*Nolosttimeaccidentsforthelast3years*Nounsafeconditions*Healthadviceavailableforthelast3years,*,Modelarea:Safetystep6AA:Safetystep5A:Safetystep4B:Safetystep13,7.Fullyimplementedsafetymanagement*Nolosttimeaccidentsforthelast5years*Almostnomedications*Almostnounsafeacts*Employeesatisfactionwithhealthandsafety*Modelarea:Safetystep7*AA:Safetystep6*A:Safetystep5*B:Safetystep4*C:Safetystep1319,精选,20,CriteriatoEvaluateAchievementLevelSafety/Hygieneunsafetools,equipment;unsafeprocedures,system;poorattitude,behavior;lackofcare,attention;personalconditions)andcountermeasurestoavoidrepeatsforthesimilarinjuryinthesimilarareasareimplemented.Professionalsafetytoolsareinplaceandused(Responsibilitymatrix,riskassessment,incidenttrendanalysis,managerialSMATs,standardsgapanalysis),Safetyimprovementactionplaninplace,displayedfromthemodelareas.Housekeeping5Sinmodelareasandagoodstandardelsewhere.ResponsibilitymatrixwithnamedpersonswithH+Sresponsibilities.Managementsitesafetyinspectionsscheduledanduptodate.Riskassessmentprocessinplaceandjobsafetyinformationavailable.ManagementSMATscheduledisplayedanduptodate.Sitesafetysteeringgroupestablishedandfunctional.Evidenceisdisplayedaboutthesafetycommunicationsystemwithintheplant.Registerofsafetywarningreceiptandlocalactionplan.Basicoccupationalhealthsysteminplace(eyesightandhearingregularchecks,etc.).,精选,22,CriteriatoEvaluateAchievementLevelSafety/Hygienetakesemergency,actionagainstthem,Performgeneral,Processproblems,(focus:process)Machinecapability(focus:machine),Understandspropertiesof,materialsbeinghandled;performscorrectadjustmentandsetting,processinspectionEquipmentinspectionforquality,Establishcleaningand,Basicconditions,topreventdeterioration(focus:machine),Understandsprocessperformance,andfunctions;operatesprocesscorrectly,checkingstandardsAddresscontaminationsourcesandinaccessibleplacesPerforminitialcleaning,1,2,3,4,5,6,1,2,3,精选,59,ClassificationofAMmachines,59,精选,60,AM(Reactive),1.5G,60,6.Breakdownmaps,7.AMstep1,2.5W+1H,5Why10.Correctevaluation3.7WCMtools9.AMstep34.Maintenancetheory8.AMstep25.Machine,classification,精选,61,61,AM(Reactive)1.5G2.5W+1H,5Why3.7WCMtools4.Maintenancetheory5.Machineclassificationbasedoncostdeployment(Breakdownlossesduetolackofbasiccondition)6.Breakdownmaps7.AMstep1:Inspectionbyinitialcleaning8.AMstep2:CountermeasuresagainstcontaminationsourcesSpecificissuesforeachspecificshopeg.1.Paintshop:foreignbody2.Machining:cuttingchips,coolant3.Welding:spatters9.AMstep3:CILRAMcalendar,10.Correctevaluationofbenefitandcostofeachstep,精选,62,AM(Preventive),1.Machineclassification,2.4categoriesof,operators,10.Correct,62,6.AMstep6,analysis,evaluation3.AMstep49.Jobcovermatrix4.Quickkaizen8.Processdataanalysis5.AMstep57.Machinedata,精选,63,AM(Preventive),1.MachineclassificationbasedoncostdeploymentP,Q,C,D,Sand,Manalysis,2.Fourcategoriesofoperators*,3.AMstep4:equipmentinspectionforquality,3.1Managementofoperatingstandardsforzerodefects,3.2ExtensiveuseofvisualcontrolsandminimizationofCILRtimeincludinginspectionofquality,63,4.Quickkaizen,5.AMstep5:generalprocessinspection,5.1Changeovertimereduction(changeoverSOP)5.2Adjustmentandsettingtimereduction5.3In-comingmaterialchecking5.4SOPforstartupandshutdown,5.5Countermeasuresagainsthumanerrors,精选,64,6.AMstep6:Selfworkplacemanagement6.1Workpieceflow,WIPmanagement6.2Arrangementofspares,tools,etc.6.3Handlingtransportequipment,etc.7.Machinedataanalysis8.Processdataanalysis,9.Jobcovermatrix3x3x3,6x6x3dependingontheabsenteeism,rate10.Correctevaluationofbenefitandcostofeachstep64,精选,65,65,FourlevelsofoperatorsskillLevelI:newregularemployees(onetwoyears),seasonalworkers,temporaryworkersLevelII:regularemployees,cancopewithabsenteeismLevelIII:coreemployeesLevelIV:teamleaderslevel,IngeneralmorethanregularemployeesRobotizedlineeverybodyIII,IVMaintenanceShopeverybodyIVAssemblymorethan60%III,IV,精选,66,AM(Proactive),1.AMstep7,2.Eliminationofwasteand,losses,10.Careful,evaluation3.Productiondataanalysis9.Designin4.Man-machinechart8.Reliabilityandmaintainabilitydesign5.Layoutmodification7.Designin6.CreationofMPinformation66,精选,67,AM(Proactive),1.AMstep7:fullyautonomousmanagement2.Eliminationofworkplacewasteandlosses3.Productiondataanalysis4.Man-machinechart5.Layoutmodification,67,6.CreationofMPinformation7.Safetydesign,visualcontrol,8.InvolvementinQAdesign,reliabilityandmaintainabilitydesign,flexibility,design,operationabilitydesign(ergonomics),9.Designin(operatorinvolvementatthedesignstagesofEPM,EEM)10.Carefulevaluationofbenefitandcostofeachstep,精选,68,Level4,Level5,Level6,5.AMstep5:generalprocessinspection,6.AMstep6:Developmentoffullyautonomousoperatorsresponsiblefordailyproduction,7.AMstep7,2,3,5Thesevenlevelsofautonomousmaintenance4Level7,68,Level3,3.Classificationofoperatorsinto4levels(I,II,III,IV)Level22.ImplementationofAMstep1-3Level11.Machineclassification,4.AMstep4:Equipmentinspectionforquality,1,Expansionanddevelopment,精选,69,1.Machineclassificationbasedoncostdeployment,*Modelmachinesselection,2.ImplementationofAMstep13,*Modelmachines,*AMStep13:achievingzerobreakdownduetolackofbasiccondition,after3months,*CILR:90%reduction,ThesevenlevelsofautonomousMaintenance,69,*CarefulevaluationofB/Cofeachstep*Evaluationofthegrowthoftheoperators,3.Classificationofoperatorsinto4levels(I,II,IIIandIV),*IV:Teamleaderlevel.Furtherlearningopportunitiesforcompetence,development,*III:Coreoperator,*II:Multitaskoperator4x4x3*I:Normaloperator,精选,70,70,4.AMstep4:Equipmentinspectionforquality*Modelmachines:step4(qualitychecking,quickkaizen,etc.)*Alltop50%ofAAmachines:step1-3*Trainingroomavailable.*CarefulevaluationofB/C5.AMstep5:Generalprocessinspection*Modelmachines:step5*Alltop50%ofAAmachines:step4*Therestof50%ofAAmachines:step1-36.AMstep6:Developmentoffullyautonomousoperatorsresponsiblefordailyproduction*Modelmachines:step6*Alltop50%ofAAmachines:step5*Therestof50%ofAAmachines:step4,*A,:step1-3,精选,71,7.AMstep7:DevelopmentofengineeringoperatorsfromIVclassoperatorsInvolvementofoperatorsforEPMandEEM*Modelmachines:step7*Alltop50%ofAAmachines:step6,*A,:step1-3(4,5),71,精选,72,Trainingroomavailable.CostandbenefitanalysisprovesbenefitofAMstep4.,(4-1)AutonomousMaintenanceEvaluationLevels,0.NoactionTherearenoactivitiestoinvolveoperatorsindailymaintenanceandimprovement.,ReactivetoPreventiveforthemodelmachinesModelmachinesforAM,fromtheAAmachinesofwhichbreakdownlossesarethemajoronesduetothelackofbasicconditions,havebeenchosenandStep1Step3havebeenimplementedtocorrectstandards.Visualmanagementisintroduced(e.g.safety,tools,manuals,oillevels,gauges,).VisualCILR(Cleaning,CriteriatoEvaluateAchievementLevelAutonomousActivities,72,Inspection,Lubrication,Refastening)scheduledisplayedatthemachineandfollowed.AMcalendarononepageestablished.Regularstepauditsconducted,visualizedandfollowedup.,2.PreventiveforthemodelmachineswhereAMcanbejustifiedStep4formodelmachines.Ifstep4cannotbeeconomicallyjustified,modifyStep4todeletepartofStep4andincludenewelementssuchasFIorQCbyoperatorstotakecareequipmentrelatedissuessothatStep4canbejustifiedandoperatorsstillgrowandenjoylearning.Step1Step3foralltop50%ofAAclassmachineshavebeencompleted.KPIbeingregularlymeasuredbyoperators.,精选,73,CriteriatoEvaluateAchievementLevelAutonomousActivities,3.PreventiveforthemajormachinesIfeconomicallyjustified.Step5forthemodelmachines.Ifstep5cannotbeeconomicallyjustified,modifyStep5todeletepartofStep5andincludeotherlossessuchaschangeoverlosses,startupandshutdownlosses,etc.orFIbyoperatorstotakecaremoreofprocesssothatStep5canbejustifiedandoperatorsstillgrowandenjoylearning.Step1Step3(4)toallAAclassmachines.Step1Step3toAclassmachines.,73,Cleaningtime(greaterthan90%reductionagainstbaseline).Inspectiontime(greaterthan90%reductionagainstbaseline).,Lubrication(movedfromPMworktoAMworkforthosepointsmanageablebyoperators).,KPIsbeingregularlymeasuredbyoperators.,精选,74,74,CriteriatoEvaluateAchievementLevelAutonomousActivities4.ProactiveforthemodelprocessesIfeconomicallyjustified,Step6formodelprocesses.Ifstep6cannotbeeconomicallyjustified,modifyStep6todeletepartofStep6andincludeotherlossessuchasWIPorFIbyoperatorstobecomeresponsibleforhis(her)processandguaranteequalityandoutputwiththerightpaceathisprocesssothatStep6canbejustifiedandoperatorsstillgrowandenjoylearning.Step5forAAclassmachines.Step1-3(4)toAclassmachines.Autonomystartstotakeplacefrommodelmachines,graduallyAAclassmachinesandthenuptomajormachineswitheconomicaljustification.5.ProactiveforthemajorareasIfeconomicallyjustified,Step7formodelmachines.Ifstep7cannotbeeconomicallyjustified,modifyStep7todeletepartofStep7andincludenewelementssuchasinvolvementofoperatorsinEPMandEEMtotakecareofproductionproblemscomingfrompoordesignoftheproductand/orequipmentsothatStep7canbejustifiedandoperatorsstillgrowandenjoylearning.Step6forAAclassmachines.Step1-3(4,5)forAclassmachines.Autonomystartstotakeplacefrommodelmachines,graduallyAclassmachinesandthenuptoBclassmachineswitheconomical,justification.,精选,75,Step4,Step5,Step6,JITpartssupply,Standardi-zation,Cycletimestabilization,4-2WorkPlaceOrganizationStep7,Step1,Step2,Step3,Initialcleaning,Tidyingupprocess,Tentativestandard,Productcharacteristicseducation,Reactive,Preventive,Proactive75,精选,76,WPO(Reactive),1.5G,2.5W+1H,5Why10.Linebalancing3.7WCMtools9.Videomonitoringmethod4.Minimalmaterialhandling8.WPOstep35.Pacemonitor7.WPOstep26.WPOstep176,精选,77,WPO(Reactive),1.5G,2.5W+1H,5Why3.7WCMtools,4.Conceptofminimalmaterialhandling5.Pacemonitor,6.WPOstep1:tidyingup,77,7.WPOstep2:3Manalysis(Muri,Mura,Muda)8.WPOstep3:SOP,9.Videomonitoringmethod10.Linebalancing,精选,78,WPO(Preventive),1.Motioneconomy,2.7IEtools10.Pickingmethods3.Onepieceflow9.Twovideocameramethod4.Threeobstacles8.WPOstep65.Noforklift7.WPOstep56.WPOstep478,精选,79,79,WPO(Preventive)1.Principlesofmotioneconomy(goldenzone,strikezone)2.The7IEtools*Processanalysis*Operationeffectiveanalysis*Motionstudy*Timestudy*Linebalancingandsequencing*Materialhandling*Layoutimprovement3.Onepieceflowproduction4.ThethreeobstaclesofWPO*Rollerconveyors*Hangerconveyors,*Ceilingcranes,精选,80,5.Noforkliftsinworkplaces,6.WPOstep4:qualitychecking,7.WPOstep5:synchronizationbetweenoperationandmaterialfeeding8.WPOstep6:LCA,9.Twovideocameramethodforcomparisonbetweentheoneofexcellent,skillsandanewcomer,10.variouspickingmethods,80,精选,81,WPO(Proactive),1.WPOstep7,81,WIP,2.Layout10.IPS3.Visibility9.DFA4.Wiringandpiping8.Ergonomicsdesign5.Toolsandjigs7.IEwithIT6.Avoidanceof,精选,82,WPO(Proactive),1.WPOstep7:Standardworksequence2.Layout,3.Visibility,4.Wiringandpipingforflexibility,82,5.Toolsforeasytouseandjigsalongwitheasetowork6.AvoidanceofWIP7.IEwithIT,8.Ergonomicsdesign,9.DFA(manual),minimaltooling,stability10.IPS,精选,83,ClassificationofAA,A,BandCworkplaces,精选,84,Level4,Level5,Level6,5.ImplementationofWPOstep6,6.Implementationof,WPOStep7.NVA:lessthan30%,Level77.Involvementof,operatorsforEPMandEEM,2,3,4,5Thesevenlevelsofworkplaceorganization,84,Level3,3.ImplementationofWPOstep4Level22.ImplementationofWPOstep1-3Level11.WPOclassification,4.ImplementationofWPOstep5,1,Expansionanddevelopment,精选,85,1.WPOclassification*Modelareasselection,*WPOstep1-3,2.ImplementationofWPOstep13,*Modelareas,*DevelopmentofWPOstep13:achieving3050%productivity,improvementby3Mapproachandre-linebalancing*CILR:90%reduction*CarefulevaluationofB/C,ThesevenlevelsofworkplaceOrganization,85,*Evaluationoftheoperatorsappreciation,3.ImplementationofWPOstep4,*Modelareas:WPOstep4(qualitychecking+Qgateconcept)*CarefulevaluationofB/C,*Alltop50%ofAAareas:WPOstep1-3*Trainingroomavailable.,精选,86,4.Classificationofoperatorsinto4levels(I,II,IIIandIV).ImplementationofWPOstep5*Modelareas:WPOstep5*Alltop50%ofAAareas:WPOstep4*Therestof50%ofAAareas:WPOstep1-3,*A,:WPOstep1,3,86,5.ImplementationofWPOstep6*Modelareas:WPOstep6*Alltop50%ofAAareas:WPOstep5*Therestof50%ofAAareas:WPOstep4*A:WPOstep1,36.ImplementationofWPOstep7*Modelareas:WPOstep7*Alltop50%ofAAareas:WPOstep6*Therestof50%ofAAareas:WPOstep5*A:WPOstep4,5*B:WPOstep1,3,7.InvolvementofoperatorsforEPM,精选,87,87,CriteriatoEvaluateAchievementLevelAutonomousActivities(4-2)WorkPlaceOrganizationEvaluationLevels0.NoactionTherearenoactivitiestoinvolveoperatorsindailyassemblyworkimprovement.ReactiveModelareasforAAfromtheAAareasofwhichlossessuchasidleness,walking,transportation,searching,setupandadjustment,andproductionofdefectivesaresubstantialduetothelackofproperworkplaceorganization,havebeenchosenandStep1Step3havebeenimplementedtocorrectstandards.Asystemforauditingthatthestepshavebeencorrectlyfollowedisinplace.2.FocusmoreonqualityStep4formodelareas.Step1Step3forallAAclassareashavebeencompleted.CostandbenefitanalysisprovesbenefitofAA.3.OptimumjobassignmentStep5forthemodelareas.Step1Step4toallAAclassmachines.Step1Step3toAclass,areas.,精选,88,4ReviewandimprovementofstandardsStep6formodelareas.Step5forAAclassareas.Step1Step4toAclassareas.,CriteriatoEvaluateAchievementLevelAutonomousActivities,88,5.CycletimestabilizationStep7formodelareas.Step6forAAclassareas.Step1Step5forAclassareas.Autonomystartstotakeplacefrommodelareas,graduallyAclassareasandthenuptoBclassareas.Involvementofoperatorsatthedesignstage.FeedbacktoEPM.,精选,89,Builda,periodic,tivemainte-nancesystem,Step7Maintenancecostmanagement,Establishmentof,aplannedmaintenancesystem,(trendmanagement)maintenance,Phase1,Phase2,Step3,Step4,Step5,Phase4Step6Buildapredic-,5.ProfessionalmaintenancePhase3,89,Eliminationofforceddeteriorationandpreventionofaccelerateddeterioration,(breakdownanalysis),Step1,Step2Reversedeterioration,ofmaintenancestandards,Countermeasuressystemagainstweakpoints,Establishmentofthemachineand,lengthenedequip-mentlife,Reactive,Preventive,Proactive,精选,90,PM(Reactive),1.5G,2.5W+1H,5Why10.SMP3.7WCMtools9.PMStep34.Maintenancetheory8.PMStep25.Machineclassification7.PMStep16.MeasurementofOEE,OPE90,精选,91,PM(Reactive),1.5G,2.5W+1H,5Why3.7WCMtools,4.Maintenancetheory,91,5.Machineclassificationbasedoncostdeployment,breakdownmaps6.MeasurementofOEE,OPEandlossstructure7.PMstep1:Preventionofforceddeterioration8.PMstep2:BreakdownEWO,9.PMstep3:Visualmachineledgerwithcomponentclassificationand,PMcalendar,10.SMP,精选,92,PM(Preventive),1.5Sinmachineworkshop,2.Equipmentdrawings,management,10.Useof,92,6.PMstep5,maintenance,highspeedcamera3.Sparepartmanagement9.QM,PPA4.Machineclassification8.MTTRanalysis5.PMstep47.Component,精选,93,PM(Preventive),1.5Sinmachineworkshop,2.Equipmentdrawingsmanagement3.Sparepartmanagement,4.Machineclassificationbasedoncostdeployment+P,Q,C,D,SandM,analysis,93,5.PMstep4:Correctivemaintenance,creationofMPinformation6.PMstep5:EstablishmentofTBM,totalmaintenancecostreduction7.Componentmaintenance,8.MTTRanalysisandpropercountermeasurestoshortenit9.QM,PPA,10.Minorstoppagereduction,useofhighspeedcameraforreducingminorstoppages,精选,94,PM(Proactive),1.Breakdownanalysis,94,operation,6.FTA,processFMEA,7.FeedbacksystemtoEPMandEEM,2.PMstep610.Sparepartmanagement3.PMStep79.RCM4.Realtimemanagement8.Reliabilitydesign5.Unmanned,精选,95,PM(Proactive),1.Breakdownanalysisofbrokencomponents2.PMstep6:CBM,optimummaintenance,3.PMstep7:CMMS,maintenancecostmanagement4.Realtimemanagement5.Unmannedoperation,95,6.FTA,processFMEA,equipmentFMEA7.FeedbacksystemtoEPMandEEM8.Reliabilitydesign,maintenancedesign9.RCM,10.Sparepartmanagementfromdesignstage,精选,96,Level5,6.PMstep7:CMMS,Level77.Wellestablishedmaintenancesystem,2,Thesevenlevelsofprofessionalmaintenance43Level6,5,96,Level33.PMstep4:MovementtocorrectivemaintenanceLevel22.ImplementationofPMst