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1、LMSLMSApril 2008Chicago, IllinoisLean Six Sigma SummitManaging the Corporate Change for your DeploymentManaging the Corporate Change for your Deployment LMSLMSAdvance RelentlesslyAdvance RelentlesslyLMSLMSLMSLMSLMSLMS1. Why we do LMS2. Evolution of LMS / Structure3. 展开需要什么 What is needed for Deploym

2、ent4. What is LMS and how it Works5. Examples of LMS at work6. 对顾客好处 Advantages to Customers7. Advantages to Suppliers8. Advantages to Lear9. What we have learned10.One Final result.LMSLMSbehaviorLMSLMSBestPracticesLessonsLearnedLearManufacturingExperiencesToyotaProductionSystemLear Manufacturing Sy

3、stem(LMS)LMSLMS Systems Approach to Lean Deployment推广/使用 Manufacturing System 2 Foundations 2个基础 4 Pillars 4根柱子 基础、柱子和所有要素都是相辅相成的 Foundations, Pillars & all LMS Elements are Interdependent Create Total Lean Behavior that provides results 导向行动/活动oriented activity.Lear Manufacturing SystemLMSLMSLMS“全部

4、全部 Lean 行为行为”内务管理内务管理质量第一质量第一物物 料料 流流工厂布置工厂布置Lear 人人产品设计产品设计基础基础柱子柱子LMSLMS训练 Training作业者支撑 Operator Support参与 Employee Involvement健康、安全/ 人类工程学 Health & Safety / ErgonomicsLear PeopleLMSLMS Six Sigma Training 4 month intensive certified Black Belt 2 month 被鉴定的certified Green Belt 6 month certified Ma

5、ster Black Belt Lean 熟练者熟练者Facilitator Training 3 month training 证明 Certification via “Model Area” In-Plant Training Kaizen events used to teach and apply Events facilitated by Plant Lean Facilitator and or Lean Master 培训档案保存Training records maintained by plantsLMSLMS LMS works 来自彻底的作业者第一 from insid

6、e out that is, from the operator first and foremost作业者履行真的价值附加作业，必须每次成功OperatorsOperators perform the true value added operations and must be successful every time真实附加价值作业和必须时刻成功LMSLMS Our people are involved: 产品投放的三个阶段 In all three stages of product 投放launch 最前面的设计、投产和持续改善 Upfront design, 投入 launch

7、 and Continuous Improvement 工作站设计、平面布局 Designing of work stations, layouts and product Ergonomic and Health & Safety 关怀 concerns (Virtual Cad) Process and product changes (Design for Manufacturing)LMSLMSThis is our 高于一切的责任over-riding responsibility.We create a safe and 工作环境改造语言ergonomically sound, 伤

8、害injury free workplace for all our employees through LMSi绝不伤害工作地 LMSLMSLear PeopleProduct DesignDesign For Six Sigma (DFSS) Design For Lean (DFL)Common Hardware / ArchitectureLMSLMSLean DesignOptimize Valuethrough DesignReduce Wastethrough DesignDFSS (Foundation)q The use of DFM/A early in the desig

9、n process is necessary because .q Any effort to reduce cost after the design stage can only influence the remaining 30 percent of product cost.q The that DFM/A has is the . A reduction in the part count results in fewer interfaces between parts and a DFM/ADFM/ADFM/ADFM/A ？通过设计减少浪费通过设计最佳价值为制造设计LMSLMS

10、 DFSS, part of our overall Six Sigma culture, is used in the product design process to reduce overall process and product variation.LMSLMSProduct design teamsunderstand and employLMS principles in order to 保证 ensure that ourproduct can bemanufactured in an Lean environment.This includes packaging, p

11、resentation and flow principles that ensure operator success.LMSLMS07 GM Truck & SUV07 GM Truck & SUVCommon proven designs use common hardware and architecture to reduce costsLear Flexible Seat ArchitectureLear Flexible Seat Architecture06 Ford Fusion06 Ford Fusion06 Mazda 606 Mazda 606 Ford Mustang

12、06 Ford Mustang06 Lincoln Zephyr06 Lincoln Zephyr06 Mercury Milan06 Mercury Milan06 Ford Explorer06 Chevy Impala06 Chevy Monte Carlo06 Buick - Lucerne06 Buick - Lucerne12 million units produced to dateLMSLMSHousekeepingLear PeopleProduct Design5S / Workplace OrganizationVisual ManagementTotal Predic

13、tive Management (TPM)Standardize Work后勤后勤LMSLMSDevelop Housekeeping Standardand PhilosophyInvolve andtrain the employeesTake theassessmentDevelop a corrective action planMotivate and engagethe employeesBuild a cross functional team Improve the HousekeepingFind the best practicesWORLD CLASSHOUSEKEEPI

14、NGLMSLMSA LMS 基石基石cornerstone. All improvements flow from World Class Housekeeping. It must be in place in order to execute LMS“LMSLMSVisual management tools control processes so that the process speaks to the observer. From labeling & signage to data & metrics reviewLMSLMSEquipment, tools and facil

15、ities must be in optimal operating conditionin order to execute LMS. TPM is used to ensure that capital is maintained without wasting resourcesLMSLMSStandardized work reduces process variation and ensures consistency in our products, processes and delivery LMSLMSHousekeepingQuality FirstLear PeopleP

16、roduct DesignQuality at the Source (Jidoka)Problem Solving (PDCA)Six SigmaError ProofingManufacturing Execution Systems (MES)LMSLMSQuality at the Source(Jidoka) ensures problems are dealtwith in station and are not passed on to downstream operations, repair loops and most important our customersLMSL

17、MSBasic Problem Solving methodology understands that every change to the process creates other changes and must be managed with a discipline methodI. Identify ProblemII. Analyze CauseIII. Formulate PotentialCountermeasuresI. Develop Implementation PlanII. Communicate PlanIII. Execute PlanI. Monitor

18、Progress of Implementation PlanII. Modify Plan if NecessaryIII. Monitor ResultsI. Evaluate ResultsII. Standardize Effective Countermeasure(s) or Start PDCA againPlan-Do-Check-Act, 5 Why and 8-D methodologies are applied on shop floorLMSLMSSix Sigma, a disciplined approach using data is interlinked with Lean to reduce defects and variation in all processes.Lean LinkSix SigmaSix SigmaProjectsProcesses Common GoalsLEANPhase II: Process MeasurementP