德尔福精益制造

Lean/DMSOverview1第一页，共三十四页。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？2第二页，共三十四页。WhatisLean?什么是精益？3第三页，共三十四页。Lean精益lean

adj.

精益：形容词1a:lackingordeficientinflesh.b:containinglittleornofat a: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4第四页，共三十四页。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.Identifytheentirevaluestreamforeachproductorproductfamilyand eliminatewaste 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5第五页，共三十四页。Lean精益AtDelphi,Leanis...Abusinessstrategy

formaximizing

profitbyenergizingpeople

torespondtocustomerdemandintheshortestpossibletime

byeliminatingwaste

ineverythingwedo.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。6第六页，共三十四页。MassProductionvs.LeanManufacturingWithLeanProductionYouCanGet:

7of3090%ReductioninProductionTime

90%ReductioninInventories

50%ReductioninErrorsReachingCustomers 50%ReductioninScrap 50%ReductioninJobRelatedInjuriesTheamountofhumaneffort,time,space,tools,andinventoriesneededtodesignandprovideagivenserviceorgoodcantypicallybecutinhalfveryquickly,andsteadyprogresscanbemaintainedfromthispointonwardtocutinputsinhalfagainwithinafewyears.

LeanThinking,Womack&Jones第七页，共三十四页。7WhatisDMS?什么是德尔福制造系统8第八页，共三十四页。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9第九页，共三十四页。

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10第十页，共三十四页。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11第十一页，共三十四页。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12第十二页，共三十四页。CorrectionOverproductionMaterialMovement/conveyanceMotionWaitingInventoryProcessing7TypesofWastes

7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13第十三页，共三十四页。Definition:ProducingMore

ThanNeededProducingFasterThanNeededWasteofOverproduction

过度生产的浪费定义:生产超过了需求生产快过了需求

14第十四页，共三十四页。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15第十五页，共三十四页。Definition:ReworkofaProduct

orServicetoMeet

CustomerRequirementsWasteofCorrection

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。16第十六页，共三十四页。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17第十七页，共三十四页。Definition:Anymovementofmaterial

thatdoesnotdirectlysupporta

leansystem.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。18第十八页，共三十四页。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19第十九页，共三十四页。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20第二十页，共三十四页。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21第二十一页，共三十四页。Definition:IdleTimeThatIsProducedWhenTwoDependentVariablesAreNotFully

Synchronized.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。22第二十二页，共三十四页。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23第二十三页，共三十四页。Definition:Anysupplyinexcess

ofprocessrequirementsnecessarytoproducegoods.WasteofInventory库存的浪费定义:任何超过生产产品过程所需要的供应。

24第二十四页，共三十四页。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25第二十五页，共三十四页。DEFINITION:Effortwhichaddsnovaluetoaproductorservice.Enhancementswhicharetransparenttothecustomers,orwork

whichcouldbecombinedwithanotherprocess.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。

26第二十六页，共三十四页。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27第二十七页，共三十四页。Game:FindtheWaste28第二十八页，共三十四页。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29第二十九页，共三十四页。LeanMetricsUptimeMaintenance(MERV)Scrap%Rework%CapacityUtilizationInternalProductivityManufacturingExpenseTotalProductionCycleTimeInventoryTurnsQualityandSafetyMetricsRRPPMRecordableAccidentRateLostWorkDayCaseRateKeyMetrics

30of305/8/2023第三十页，共三十四页。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31第三十一页，共三十四页。InterdependentElements

相互依存的要素EmployeeEnvironment&Involvement员工环境于参与BusinessObjectivesScrapJan.Apr.Jul.Dec.UptimeGoalOnTimeDeliveryGoalGoalEmployeeInformationCenterJan.Apr.Jul.Dec.Jan.Apr.Jul.Dec.Ourimprovementteam抯effortshavehelpedusmeetourgoals.WorkplaceOrganization工作场地组织PULLCARDSTRASHTOWELSGLOVESTOOLSFlowManufacturing流动制造CoatingMachiningWeldingPressingOurintegratedlineisbalancedtomeetcustomerdemand.Ourpeopleareflexible,andWIPisdownduetosinglepieceflow.Nowthatwedoquickchangeovers,wecanruneveryparteveryday.Quality质量ErrorProofingTwo-pointInspectionCONTROLWARNINGJigThelightgoesonifthemachinefails.jam