德尔福-精益制造(ppt 33).ppt

OverviewPage1,Lean/DMSOverview,OverviewPage2,Lean(Exercise)精益（练习）,Exercise:Bytable/groupcomeupwithyourdefinitionof揕ean练习：按课桌/小组给出您对“精益”的定义,WhatisLean?什么是精益？,OverviewPage3,WhatisLean?什么是精益？,OverviewPage4,Lean精益,leanadj.精益：形容词1a:lackingordeficientinflesh.b:containinglittleornofata:无肉或少肉b:少脂肪或无脂肪2:lackingrichness不富裕3:deficientinanessentialorimportantqualityoringredient在必要性、重要性、质量或成分方面稀缺4:charac-terizedbyeconomyofstyleorexpression文体或措辞简练syn.thin,skinny,lanky,scrawny,gaunt,bony,emaciated,svelte,lank同义词：薄、极瘦、过分瘦长、骨瘦如柴、瘦削的、似骨的、消瘦的、细长的、瘦长的ant.fat,fleshy,overweight,flabby,obese,plump,chunky,corpulent,soft反义词：肥胖的、多肉的、过重的、不结实的、过分肥胖的、丰满的、粗短的、肥大的、软的,OverviewPage5,Lean精益,WhatisLean?-Womack什么是精益1.Definevaluepreciselyfromtheperspectiveoftheendcustomer从最终用户的角度准确地定义价值2.Identifytheentirevaluestreamforeachproductorproductfamilyandeliminatewaste确定每一种产品或产品系列的整个价值流，消除浪费3.Maketheremainingvaluecreatingstepsflow理顺创造价值的步骤4.Designandprovidewhatthecustomerwantsonlywhenthecustomerwantsit只在客户需要时设计和提供他们所需的东西5.Pursueperfection追求完美,OverviewPage6,Lean精益,AtDelphi,Leanis.Abusinessstrategyformaximizingprofitbyenergizingpeopletorespondtocustomerdemandintheshortestpossibletimebyeliminatingwasteineverythingwedo.,在德尔福公司，精益表示一种经营战略，它激励人们在所做的任何事情中消除浪费，在尽可能短的时间内对客户需求作出反应，从而使利润最大化。,2020/6/10,OverviewPage7,MassProductionvs.LeanManufacturing,WithLeanProductionYouCanGet:,7of30,90%ReductioninProductionTime,90%ReductioninInventories,50%ReductioninErrorsReachingCustomers,50%ReductioninScrap,50%ReductioninJobRelatedInjuries,Theamountofhumaneffort,time,space,tools,andinventoriesneededtodesignandprovideagivenserviceorgoodcantypicallybecutinhalfveryquickly,andsteadyprogresscanbemaintainedfromthispointonwardtocutinputsinhalfagainwithinafewyears.LeanThinking,Womack&Jones,OverviewPage8,WhatisDMS?什么是德尔福制造系统,OverviewPage9,ChangeinManufacturing制造业的演化,HenryFord亨利福特Assemblylinemassproduction装配线大批量生产Produceinhighvolumewithlowvariety生产数量多、品种少Singleskill单一技术,ToyotaProductionSystem(TPS)丰田公司制造系统Just-In-Time?Production(produceonlywhatisneeded)“准时生产制”（只生产所需要的）PullSystem拉动系统Produceenoughvolumetomeetcustomers?needs生产足够的数量以满足客户的需要Highvarietytomeetcustomerswants多品种以满足客户的要求,OverviewPage10,COMMONManufacturingSystemtoDelphiDivisionsVisionandOperatingPrinciplesSixInterdependentElementsThesixinterdependentelementsprovidethebasicframeworkofthemanufacturingsystem.Theyarethefocusofouractivities:Developingprofoundknowledge,planningandimplementation,andcontinuousimprovement.德尔福各分部共同的制造系统前景展望和运行原则六个相互依存的要素六个相互依存的要素构成了该制造系统的基本结构。它们是我们活动的中心：拓展丰富的知识、规划和实施以及不断改进。,WhatisDMS?什么是德尔福制造系统,OverviewPage11,Transform&ContinuouslyimproveouroperationstoaQualityNetworkbased,globallydominantmanufacturer转变并持续地改进我们的业务从而使其成为基于质量网络的在全球处于主导地位的制造厂商。ReduceTotalManufacturingCosts降低总的制造成本ReduceCustomerResponseTime减少对客户的反应时间ReduceInventory减少库存ReduceNon-ValueAddedActivities减少非增值活动IncreaseProductivity提高生产效率ImproveQuality提高质量ReduceStructuralCosts降低结构成本Engagetheworkforceintheprocess让员工参与这一过程,DMSObjectives德尔福制造系统目标,OverviewPage12,OperatingPrinciples运行原则,DefinetheFundamentalBasisoftheManufacturingSystem确定制造系统的主要基础EnsurethattheHealthandSafetyofallourpeopleisourpriority.确保所有员工的健康和安全是我们的首要任务AggressivelyimproveCustomerresponsetime.积极缩短对客户的反应时间ImplementQualityattheSource.从源头处保证质量CreateaLearning,Supportive,andCooperativeCulture.创造一个相互学习、相互支持和相互协作的企业文化CompetitivelymanufactureatanyvolumeandbeFlexibletoanyquest.在任何制造批量下都具有竞争力并能灵活地满足客户需求RelentlesslypursuetheEliminationofWaste.不懈努力，消除浪费,EstablishprocessmeasurementsthatcontributetoBusinessGoals.建立有助于实现业务目标的过程衡量指标DrivetheTransformationProcessthroughKnowledgeableandInvolvedLeadership.通过知识渊博和全身心投入的领导人员推动变革进程DefineandUnderstandRolesandResponsibilities.确定并理解岗位和责任OptimizetheManufacturingSystemthroughbalancedImplementationoftheInterdependentElements.通过均衡地实施六个相互依存的要素来优化制造系统,OverviewPage13,CorrectionOverproductionMaterialMovement/conveyanceMotionWaitingInventoryProcessing,7TypesofWastes7种类型的浪费,改正过度生产物料的移动和运输动作等候库存加工过程的浪费,OverviewPage14,Definition:ProducingMoreThanNeededProducingFasterThanNeeded,WasteofOverproduction过度生产的浪费,定义:生产超过了需求生产快过了需求,OverviewPage15,Characteristics特点:InventoryStockpiles库存积压ExtraEquipment额外的设备ExtraStorageRacks额外的仓储架ExtraManpower额外的人力AdditionalFloorSpace更多的工作场地,Causes原因:IncapableProcesses过程能力低下LackofCommunication缺乏交流LongToolChanges工具更换周期长LowUptimes计划工时利用率低LackofStable/ConsistentSchedules缺乏稳定/连贯的计划安排,WasteofOverproduction过度生产的浪费,OverviewPage16,Definition:ReworkofaProductorServicetoMeetCustomerRequirements,WasteofCorrection改正的浪费,定义:为满足客户的要求，对产品或服务进行的返工。,OverviewPage17,Characteristics特点:ExtraTimeRequiredbyWorkforcetoInspect/Rework/Repair工人需要额外的时间来检查/返工/修理MissedShipments/Deliveries错过了装运/交货时间OrganizationBecomesReactive(FireFighting,ExpeditingVs.PreventionOrientation)使组织变得被动(疲于“救火”，而不是采取各种预防措施),Causes原因:IncapableProcesses过程能力低下OperatorControlError操作者控制失误InsufficientTraining缺少足够的培训,WasteofCorrection改正的浪费,OverviewPage18,Definition:Anymovementofmaterialthatdoesnotdirectlysupportaleansystem.,WasteofMaterialMovement/Conveyance材料移动/传送的浪费,定义:任何不直接支持一个精益系统的材料移动。,OverviewPage19,Characteristics特点:ExtraForkTrucks额外的叉车MultipleStorageLocations多处储存地点ExtraFacilitySpace额外的设施空间IncorrectInventoryCounts不正确的存货清点OpportunityforDamage/FloorLoss存在损坏/丢失物品可能,Causes原因:UnleveledSchedules计划安排不平衡LongChangeOverTimes更换品种时间长LackofWorkPlaceOrganization工作场地缺乏组织ImproperFacilityLayout设备布局不当LargerBufferandBanks缓冲库存区过大,WasteofMaterialMovement/Conveyance材料移动/传送的浪费,OverviewPage20,Definition定义:Anymovementofpeopleormachineswhichdoesnotcontributevaluetotheproductorservice.任何对生产和服务没有带来价值的人员或机器的运动。,WasteofMotion动作的浪费,OverviewPage21,Characteristics特点:LookingforTools寻找工具ExcessiveReaching/Bending过度伸展/弯腰Machines/MaterialTooFarApart(WalkTime)机器/材料距离过远（步行的时间）ShuttleConveyorsBetweenEquipmenttoCarryParts零件在设备间传送带上的来回传送Extra揃usy?MovementsWhileWaiting等候期间的额外“忙乱”动作,Causes原因:Equipment,Office&PlantLayout设备、办公室和工厂的布局不当LackofWorkPlaceOrganization工作场地缺乏组织PoorPerson/MachineEffectiveness人员/机器效率不高PoorErgonomicDesign人机工程方面的设计不好InconsistentWorkMethods不一致的工作方法LargeBatchSizes加工批量过大,WasteofMotion动作的浪费,OverviewPage22,Definition:IdleTimeThatIsProducedWhenTwoDependentVariablesAreNotFullySynchronized.,WasteofWaiting等候的浪费,定义:当两个相关的变量不完全同步时产生的停顿时间。,OverviewPage23,Characteristics特点:PersonWaitingforMachine人员等候机器MachineWaitingforthePerson机器等候人员OnePersonWaitingforAnotherPerson一个人等候另一个人UnbalancedOperations(Work)不平衡的操作（工作）UnplannedEquipmentDowntime计划外停机,Causes原因:InconsistentWorkMethods不一致的工作方法LongMachineChangeOverTimes机器设置时间长PoorMan/MachineEffectiveness人员/机器效率不高LackofProperMachines缺乏合适的机器LackofEquipmentResources缺乏设备资源,WasteofWaiting等候的浪费,OverviewPage24,Definition:Anysupplyinexcessofprocessrequirementsnecessarytoproducegoods.,WasteofInventory库存的浪费,定义:任何超过生产产品过程所需要的供应。,OverviewPage25,Characteristics特点:ExtraSpaceonReceivingDock在进货仓库中占据额外的空间StagnatedMaterialFlow物流停滞MassiveReworkCampaignsWhenProblemsSurface当出现问题时，不得不进行大规模的返工RequiresAdditionalMaterialHandlingResources(People,Equipment,Racks,Storage,Space/Systems)要求更多的材料处理资源(人力、设备、货架、仓库、空间/系统)SlowResponsetoChangesinCustomerDemands对客户要求的改变反应迟缓,Causes原因:IncapableProcesses过程能力低下LongChangeOverTimes更换品种时间长ManagementDecisions管理决策不当LocalOptimization局部最优化InaccurateForecastingSystems不准确的预测系统,WasteofInventory库存的浪费,OverviewPage26,DEFINITION:Effortwhichaddsnovaluetoaproductorservice.Enhancementswhicharetransparenttothecustomers,orworkwhichcouldbecombinedwithanotherprocess.,WasteofProcessing加工过程的浪费,定义:对产品或服务附加的无效的工作，或可以结合在另一过程的工作。,OverviewPage27,Characteristics特点:ProcessBottlenecks工作过程出现瓶颈LackofBoundarySamplesorClearCustomerSpecifications缺乏边界样品或明晰的客户规格要求EndlessRefinement没完没了的修饰RedundantApprovals过多的批准程序ExtraCopies/ExcessiveInformation额外的复印件/过多的信息,Causes原因:EngineeringChangesWithoutProcessChanges工艺过程没有随着工程的更改而改变NewTechnologyUsedinOtherProcesses在其他工艺过程中使用了新技术DecisionMakingatInappropriateLevels在不适当的层次上制定的决策IneffectivePoliciesandProcedures无效的政策和程序LackofCustomerInputConcerningRequirements对客户的有关要求缺乏了解,WasteofProcessing加工过程的浪费,OverviewPage28,Game:FindtheWaste,OverviewPage29,OperatingPrinciples运行原则,EstablishprocessmeasurementsthatcontributetoBusinessGoals.建立有助于实现业务目标的过程衡量指标,EnsurethattheHealthandSafetyofallourpeopleisourpriority.确保所有员工的健康和安全是我们的首要任务AggressivelyimproveCustomerresponsetime.积极缩短对客户的反应时间ImplementQualityattheSource.从源头处保证质量CreateaLearning,Supportive,andCooperativeCulture.创造一个相互学习、相互支持和相互协作的企业文化CompetitivelymanufactureatanyvolumeandbeFlexibletoanyquest.在任何制造批量下都具有竞争力并能灵活地满足客户需求RelentlesslypursuetheEliminationofWaste.不懈努力，消除浪费,DefinetheFundamentalBasisoftheManufacturingSystem确定制造系统的主要基础,DrivetheTransformationProcessthroughKnowledgeableandInvolvedLeadership.通过知识渊博和全身心投入的领导人员推动变革进程DefineandUnderstandRolesandResponsibilities.确定并理解岗位和责任OptimizetheManufacturingSystemthroughbalancedImplementationoftheInterdependentElements.通过均衡地实施六个相互依存的要素来优化制造系统,2020/6/10,LeanMetricsUptimeMaintenance(MERV)Scrap%Rework%CapacityUtilizationInternalProductivityManufacturingExpenseTotalProductionCycleTimeInventoryTurnsQualityandSafetyMetricsRRPPMRecordableAccidentRateLostWorkDayCaseRate,KeyMetrics,30of30,OverviewPage31,OperatingPrinciples运行原则,EstablishprocessmeasurementsthatcontributetoBusinessGoals.建立有助于实现业务目标的过程衡量指标,EnsurethattheHealthandSafetyofallourpeop