康明斯目视管理法(1)

1、康明斯目视管理法Cummins Visible Controls 1Cummins 目视管理 Visible Controls 目的 Objectives阐述目视管理: 目标，定义，和标准 Describe Visible Controls: goal, definition, and criteria 了解如何运用 Understand how to use them讲解4种做法 Define the 4 categories展示与持续改进的联系 Show connection to Continuous Improvement Process2Cummins 目视管理 Visible Co

2、ntrols 与CPS*的联系 CPS Connection隐藏问题，不能使问题受到重视并得到解决。我们必须能够很快地标识问题，并立即做出反应。问题点必须可以一目了然。 CPS 员工手册 1991，24页 *CPS-康明斯生产系统“Hidden problems will not get attention and will not be fixed. We must be able to identify problems quickly and respond to them immediately. Trouble spots must be obvious at a glance.”

3、CPS Employee Manual, 1991, pg. 243Cummins 目视管理 Visible Controls . 注意！ATTENTION！下面两种方法对于信息运用管理可能会有很大的区别： How information is organized is perhaps the most distinguishing feature between 信息共享 目视交流 Information Sharing Visible Communication4Cummins 目视管理 Visible Controls 目视管理目标 Visible Controls Goal1. CPS

4、 质量目标是： “使过程成效指标和问题均目视化” A CPS quality objective is to “make performance to processes and problems visible.”2. 持续改进是我们的生存之道 Continuos Improvement is a way of life3. 建立发展一个部门区域间交互责任的体系 Developing a system of overlapping responsibilities between functional area 5Cummins 目视管理 Visible Controls 目视管理 VISI

5、BLE CONTROL DEFINITION 目视管理就是信息展示，全面直观地、方便地 能看见，以便对其做出反应，进行调整控制。 A visible control is defined as a display of information devised to be in full view or readily seen in order to allow reaction or regulation to the source or cause of information.6Cummins 目视管理 Visible Controls 基本准则 Essential Criteria 使

6、重要的信息以最快的速度方便地传递到决策和措施制定的地方 They are used to facilitate the transfer of important information as quickly as possible at the point where decision and action can be made.1、简洁陈述 Simplicity of presentation 2、可视测评 Visibility of measurements情况目视通报到每位员工 situation are visible to everyone 目标和责任目视通报到每位员工 goal

7、 and rules are visible to everyone 7Cummins 目视管理 Visible Controls 基本准则 Essential Criteria3、每位员工进行参与 Everyones involvement 4、基础信息数据的真实收集 Undistorted collection of primary information 5、重要数据的直接测评（至关重要的几个） The straightforward measurement of whats important (The Vital Few)6、对紧急情况有全面的了解掌握 Achieve an over

8、all feel of urgency 7、针对变异有完善计划和受训练的反映 Planned and disciplined response to abnormalities8Cummins 目视管理 Visible Controls 行GO停STOP我该如何做？ What should I do?9Cummins 目视管理 Visible Controls 出口Exit 96目视信息-不好 Visible Information -Bad Example10Cummins 目视管理 Visible Controls 目视信息-好 Visible Information-Good Examp

9、le.出口Exit 9611Cummins 目视管理 Visible Controls 共同负责 Shared Responsibility工厂质量水平 Plant Level公司目标 Company Goals:*世界级 World class*CPS*通告Inform visitors班组板块区Teams Territory班组目标Group Goal:*用户/供应商 customer/supplier*成本/质量/发运 cost/quality/delivery*问题 problem独立工作站Individual Workstation工序说明 Operation Specific:*工

10、艺文件 Process doc.*标准工作图示 Std work charts*维护 Maintenance*环境管理 Housekeeping12Cummins 目视管理 Visible Controls 工厂质量水平 Plant Level 团队班组板块区TeamsTerritory 用户Customer 支持 Support 方法 Methods规范 Specification用户 Customer工厂测评 Plant measure过程测评 Process measures供应商 Supplier维护 Maintenance 安全 Safety独立工作站 Individual Work

11、station供应商 Supplier 计划 Plans安全Safety13Cummins 目视管理 Visible Controls 目视管理准则The Rule of Visible Controls 班组必须审核和认可目视管理 The team has to review and approve any visible control“提交目视管理文件进行公开评议使员工获得认知，提供员工发表建设性意见的机会”“submitting a visible control document to a process of public scrutiny -result in better ow

12、nership of the knowledge and opportunities for constructive criticism.”14Cummins 目视管理 Visible Controls 公开式传达信息Openness of Communication问题状况的明确展示使每位员工知道目前过程的状态“Visible display of problem status lets everyone know the current status of the process.”度假, 一周后返回On vacation Return in 1week15Cummins 目视管理 Vi

13、sible Controls 生产计划展示 例1 Handout Solution for Situation 1 -Production Schedule for Plant B, Example #116Cummins 目视管理 Visible Controls 生产计划展示例2 Handout Solution for Situation 1 -Production Schedule for Plant B, Example #217Cummins 目视管理 Visible Controls 人力计划举例 Handout Solution for Situation 1 -Workfor

14、ce Planing A工厂 Plant A B工厂 Plant B18Cummins 目视管理 Visible Controls 四种展示 The Four Categories目视生产控制 Visible Production Control目视质量控制 Visible quality control过程指示 Process indicators进程显示 Making Progress Visible改进 Improvement ： 节拍 cycle time实际 Actual: 3.5 min reduction19Cummins 目视管理 Visible Controls 生产管理 P

15、roduction Control(过程状态一目了然 understanding the process at a glance.)看板或拉料卡显示材料状态 Chanson or Pull Cards showing material status 工作标准化 Standardized work charts瓶颈工序标识出 Bottleneck operations identified工序流程图 Process flow charts预先确定场所 Predetermined locations整洁、工装和设备定置摆放 clear, designated tool& equipment loc

16、ations20Cummins 目视管理 Visible Controls 生产管理 Production Control材料存储标识完善 well marked material storage 材料过量堆积 overflow areas警示灯显示问题或异常情况 Andon displays to indicate problems or abnormal situations生产量计数 Production count status 发交状况 Delivery status料箱（架）限制零件装载量 Containers limiting the amount of parts21Cummi

17、ns 目视管理 Visible Controls 料架满装指示举例Example of Production ControlInstructions for filling a container错误 No 正确 Yes满装线Fill line22Cummins 目视管理 Visible Controls 警示灯板 Andon (a lighting panel)发生故障传送信息的装置 Which is an “information transfer device for trouble occurrence”.同时可指示停止或故障解除警示Also reference to as stop

18、alarms, uptime lights23Cummins 目视管理 Visible Controls 生产管理警示板 Production Control Board -Andon Board目标 345Target实际 345Actual时间损失 8minLoss time最新消息：工作站 3材料短缺， 工作站 6有质量问题Status update:Station 3 has a material shortage, Station 6 has a quality problem 6789101234524Cummins 目视管理 Visible Controls 生产警示灯有如下表示

19、：Example of Production: Andon Lights-红色 Red : 生产线停止Line Stop -黄色Yellow: 请求支持援助 Worker has called for help-绿色Green: 正常 Normal operation25Cummins 目视管理 Visible Controls 警示灯有如下表示：Example : Andon Lights-红色Red: 设备故障 Machine trouble -白色White: 生产终止 end of production run-绿色Green: 材料短缺停产 no work shortage of m

20、at.-兰色Blue: 有问题 defective unit-黄色Yellow: 要求调整 set-up required26Cummins 目视管理 Visible Controls 过程指示 Process Indicators (用于监控工作进程的设施 devices for monitoring work progress)设备机油消耗 Machine oil consumption班组培训矩阵表(技能水平/培训项目) Team training matrix (skill level/training)安全成效 Safety results 内部环境管理维护成效 Housekeepi

21、ng results库存周转 Inventory turns色彩编码任务 时间安排卡片 Color coded job scheduling cards在制品 Line side storage 节拍 Tat time, cycle time调整时间 Set-up TimeSPC 图 SPC charts27Cummins 目视管理 Visible Controls 过程标示举例: 发动机挂旗Example of process indicators:Engine Flags 红色 - 发动机质量问题要拆检 Red - Engine Quality Teardown黄色 - 缺“自制”件 Ye

22、llow - Shortage of “made in works” part兰色 - 缺“外协”件 Blue -Shortage of “bought out finished “ part绿色 - 发动机准备做试验 Green -Engine ready for test白色 - 等待检查 White -Awaiting inspection 28Cummins 目视管理 Visible Controls 质量管理 Quality Control (质量状况一目了然 understand quality status at a glance) 用户质量水平 Customer Quality

23、 Levels工序控制纪录 Process Control RecordsSPC图 SPC chartsCPC情况 CPC status (CPC triangles)量检具检定状况 Gauge calibration status接受/不可接受标样 Boundary Samples referencing acceptable/non-acceptable quality供应商质量成效 Supplier results规定明确的不合格品区 Clearly defined non-conforming area工艺文件 Process Documentation检查计划 Inspection

24、plans 29Cummins 目视管理 Visible Controls 工作场地一目了然A VISIBLE WORKPLACE产品陈列Product display用户反馈Customer Feedback成效展示Results displayed30Cummins 目视管理 Visible Controls 工作场地一目了然A VISIBLE WORKPLACE1814131211101098716172619543211542031Cummins 目视管理 Visible Controls 32Cummins 目视管理 Visible Controls 33Cummins 目视管理 V

25、isible Controls 34Cummins 目视管理 Visible Controls 35Cummins 目视管理 Visible Controls 36Cummins 目视管理 Visible Controls 37Cummins 目视管理 Visible Controls 38Cummins 目视管理 Visible Controls 39Cummins 目视管理 Visible Controls 40Cummins 目视管理 Visible Controls 41Cummins 目视管理 Visible Controls 42Cummins 目视管理 Visible Contr

26、ols 工作场地一目了然 A VISIBLE WORKPLACE谈论视觉图像信息却不用图片，似乎有些似是而非。这就是展示车间目视管理图片的原因。 It would be somewhat paradox to speak of visual communication without relying on an image. This is the reason for presenting a visual workplace.上张图示不是固定不变的逐条要遵循的实际例子，每个工厂有各自不同的实际操作运行情况。没有理由完全按照图示中每个项目去实施。其他内容或展示可能更适合具体的情况。这里主要是

27、提供目视交流、管理的一种思路。The workplace depicted is not a practical example to be followed literally. Each firm has its own constraints and operating structure. There is no reason automatically to include everything appearing in this sketch. Conversely, other elements-or other forms of presentation-maybe more

28、suitable for certain situation. In this portrayal, the intent is to present significant visual communication themes.43Cummins 目视管理 Visible Controls 工作场地一目了然 A VISIBLE WORKPLACE班组板块 The Teams Territory1.板块标识 Identify territory2.标识活动、资源和产品 Identify activities, resource,& product.3.班组园地 Identify the te

29、am4.地面标记 Marking floor5.标识工装和工位器具 Marking of tools and racks6.技术区域 Technical area7.交流和休息区域 Communication & rest area8.信息和指示 Info. & instruction 9.清扫工具 Neatness (broom)目视文件 Visual Doc.10.生产指导和技术程序Manufacture Instruction & tech. procedure44Cummins 目视管理 Visible Controls 工作场地一目了然 A VISIBLE WORKPLACE目视生产

30、管理 Visual production control11.计算机终端 Computer terminal12.生产计划 Production schedule13.维修计划 Maintenance schedule14.零标识 Identification of components目视质量管理 Visual quality control15.设备监控信号 Machine monitor signals16.SPC17.记录指标展示 Display Indicators18.目标、结果和差距Objectives, results, and differences进展 Rendering

31、Progress Visible19.改进活动 Improvement activities20.公司方针、计划和任务 Company policy, project & mission 45Cummins 目视管理 Visible Controls 实施改进 Making Improvements（目视板可使每个员工追踪改进工作的进展）(Display so that anyone can follow improvement work as it progresses)用户满意 Customer satisfaction 用户/供应商合作协议Customer/supplier workin

32、g agreements项目和状况 Projects and status改进活动 Improvement activities之前/之后 Before/After培训计划 Training matrices改进板 Improvement boards问题解决过程 Problem solving process status库存降低腾空场地 Floor space freed up due to inventory reduction 预防性维护计划 Preventative maintenance schedule46Cummins 目视管理 Visible Controls 合适的搬运摆放

33、作业指导Instructions for Proper Stacking Procedure不在正确 No 正确Yes47Cummins 目视管理 Visible Controls 预防问题重新设计Re-design for prevention of problem 目视管理的实施Levels of Visible Controls Implementation工艺文件 Process documentation环境维护管理 Housekeeping duties图表-发交 ,员工培训计划 Charts - parts shipped, - operator training matrice

34、s检查计划 Inspection plans不合格品报告 Reject reports色斑材料区 Color striped material zonesSPC 图 SPC charts控制限 Boundary samples发动机试验 Engine test活塞环颜色码 piston ring color code特殊力矩复检 specialized torque overchecks预防 PREVENTION发现 DETECTION停线 灯machine down lights装配红灯 assembly red lights2预通道无线系统 2-way radio system最初展示运行

35、状态Initial display of operational status质量信息和规范Quality information &specification工作环境探测异常Work environment for abnormality detection问题可视或可见警示Visual or audible alerts to problem防错 Failsafing自动Automation48Cummins 目视管理 Visible Controls “标准是一个参照点, 提供给班组追随的目标, 同时也提供了出发的起点.”“A standard is a point reference that simultaneously provides the group with a point to adhere to and a point of departure.” 通过信息展