精益制造质量管理系统持续改进模块省名师优质课获奖课件市赛课一等奖课件

不停改进CONTINUOUSIMPROVEMENT

定义：一个基于标准化，经过一系列小改进来到达改进程序。Definition:Aprocessbasedonstandardization,wherebyimprovementismade,throughaseriesofsmallimprovements.

目标:不停向前挑战更多目标而且经过降低浪费在安全、人员参加、质量、响应和成本方面取得进步。Purpose:

ToalwaysadvanceaheadtowardsanevermorechallengingtargetandmakeprogressinSafety,PeopleInvolvement,Quality,Responsiveness,andCostthroughtheeliminationofwaste.

第1页1TheContinuousImprovementCycleStandardizationImprovementStandardizationStandardizationStandardizationImprovementImprovement上面这张图表显示出每次改进之后，都会带来暂时不稳定，直到建立并应用新标准。只有当情况真正稳定了，新不停改进才能实施。Thediagramaboveshowshoweachtimeanimprovementisimplemented,itcreatestemporaryinstability.Therewillbeashortperiodofinstabilityuntilnewstandardsareset,andapplied.Onlyoncethesituationistrulystable,cannewimprovementsbeimplemented.

改进改进改进标准化标准化标准化标准化不停改进CONTINUOUSIMPROVEMENT循环不停改进第2页2

不停改进要素

ContinuousImprovement

1暗灯原理

AndonConcept2业务计划实施BusinessPlanDeployment3全员生产设备维护TotalMaintenanceSystem4设施、机器、工具和规划精益设计

LeanDesignofFacilities,Equipment,ToolingandLayout5不停改进流程ContinuousImprovementProcess6早期制造设计整合EarlyMfg.DesignIntegration(DFM/DFA)7问题处理ProblemSolving不停改进CONTINUOUSIMPROVEMENT第3页3不停改进CONTINUOUS

IMPROVEMENT要素1：Andon原理Element1:AndonConcept定义:一个生产现场工序控制系统(人工或自动开启)，能在异常情况发生时传递需要帮助信息并进行相关信息交流。DEFINITION:

Anoperationalfloorprocesscontrolsystem(thatcanbeactivatedmanuallyorautomatically).tocommunicatetheneedforassistancewhenabnormalconditionsoccuraswellascommunicaterelevantinformation.目标:授权作业，为预防缺点出现或传递到下一个工序,或操作迟后于工作节拍，员工拉暗灯呼叫援助，立刻进行问题处理。并促使管理层和支持部门亲临车间查看问题,采取办法。PURPOSE:

Toempoweroperationstopreventtheoccurrenceorpassingofdefectstothenextprocessandcallforassistancewhenbehindinworksequence;prioritizeandinitiatetheproblemsolvingprocess;drivemanagementandsupportgroupstogoandseetheproblemsonthefloorandtakeactionandcommunicateoperationalinformation.

第4页4不停改进CONTINUOUSIMPROVEMENT要求Requirements1.把相关信息显示于众Visuallydisplaysrelevantinformationforanyoneto

2.使用固定仃位点Fixedpositionstopsexists/marked

3.单线系统,当使用时,由单一拉线锁定

oneropesystem,whenapplicable,andinterlockedbyasinglepull

4.Andon区域布置应便于管理层和支持部门亲临现场发觉问题

Andonareaconfigurationsareestablishedtodirecttheorganization(support)toseetheproblems

Andon原理AndonConcept第5页5不停改进CONTINUOUSIMPROVEMENTAndon原理AndonConcept5.从质量检验,检验和返修缺点处取得相关缺点处理反馈信息

allowsfeedbackfromqualitychecks,inspectionandrepairfordefecthandling6.经过建立andon板来监控andon呼叫(拉动次数和仃线次数)

monitorsandoncallsbyestablishedandonzone(numberpullsandlinestoptime)

7.能够要求/提醒员工执行标准/常规活动

abletorequest/remindpeopletoperformstandard/routineactivities8.提供用于突出颈瓶现象和问题区域信息和数据(计机算报表无法表达)

providesinformationanddatathatcanbeusedtohighlightbottlenecksandproblemareas(notavailableoncomputerprintout)

第6页6不停改进CONTINUOUSIMPROVEMENT要素2：业务计划实施Element2:BusinessPlanDeployment

定义:一个能使整个组织机构制订目标、计划,并共同完成企业目标方法。DEFINITION:

Aprocessthatenablesthetotalorganizationtosettargets,integrateplansandremainfocusedtoachievecompany-widegoalsandmanagechange.目标:使全体员工步调一致,共同努力创造一个不停改进文化。PURPOSE:

Toalignandintegrateallemployeestoworktogether,totakeactionandtodevelopacultureofcontinuousimprovement.第7页7不停改进CONTINUOUSIMPROVEMENT业务计划实施BusinessPlanDeployment

要求Requirements1.使用标准年度计划表,其包含目标,方法,指标,责任人,时间进度,签字和签字框

Useastandardannualplanformatthatincludes:objectives,method,target,responsiblepersons,timing,signoffandsignatureblock2.制订年度计划最少应落实到工段级

Makeannualplanstoatleastthedepartment/unitlevel3.在新年计划实施前,向员工通报企业目标

Communicatethecompanygoalstoemployeesbeforethestartofthenewyear

plan

4.年度计划应贴在显眼处且定时检验

Postannualplansinvisiblelocationsandcheckregularly第8页8不停改进CONTINUOUSIMPROVEMENT业务计划实施BusinessPlanDeployment

5.采取计划,实施,检验,行动(PDCA)格式执行业务计划实施

UsethePlan,Do,Check,ActcycletocarryoutBusinessPlanDeployment6.利用正式协商程序和部门间横向协调会以及签字栏确保各方同意此计划

Useaformalprocessofnegotiationandcrossfunctionalinter-departmentalmeetingsandsignoffblockstoassurebuyin第9页97.计划补充或改变应用不一样颜色直接写在计划上,不得涂改

Writeadditionsorchangestotheplanwithdifferentcolor,directlyontheplan.Noerasing

8.为了评定相对目标计划进展情况应在不一样层次定时进行评审

Holdscheduledreviewsoftheplanatalllevelstoevaluatetheprogressoftheplantothegoals

9.跟踪PDCA(计划,实施,检验,行动)表和5大目标应是可视

VisualizationshouldfollowthePlan,Do,Check,Actionformatandfollowthefivegoalcategories

10.培训全部员工业务计划实施基本标准

TrainallemployeesinthebasicprinciplesofBusinessPlanDeployment不停改进CONTINUOUSIMPROVEMENT业务计划实施BusinessPlanDeployment

PDCAGrasptheSituation把握情况第10页10业务计划实施--年度计划BusinessPlanDeployment-AnnualPlan

BPDCategory:2.Quality质量Department:Paintshop油漆车间不停改进CONTINUOUSIMPROVEMENT第11页11不停改进CONTINUOUSIMPROVEMENT要素3：全员生产设备维护Element3:TotalProductiveMaintenance定义:维修、生产和工程部门共同参加设备和工具标准化维护活动，提升设备和工具使用效率。DEFINITION:Anactivitytomaximizeequipment,toolingandmachineproductivitythroughthesharingofstandardizedmaintenanceresponsibilitiesbetweenmaintenance,production,andengineering.目标:经过设备拥有权划分,明确职责和培训员工技能,从而到达降低成本,提升生产能力和改进质量和安全。PURPOSE:Toreducecosts,improveplantthroughput,qualityandsafetythroughownership,accountability,andthedevelopmentofmulti-functionalemployees.

第12页12不停改进CONTINUOUSIMPROVEMENT全员生产设备维护TotalProductiveMaintenance

要求Requirements1.把设备拥有权分至工程,生产和维修部门

Assignownershipofallequipmenttoengineering,production,andmaintenance

2.设置全部设备标准,包含工程部,生产部和维修部门责任

Standardssetforallequipmentthatincludesresponsibilitiesofengineering,production

andmaintenance第13页13不停改进CONTINUOUSIMPROVEMENT全员生产设备维护TotalProductiveMaintenance

3.工程部,生产部和维修部门必须在启动阶段一起验收用于常规生产设备(比如确认零件清单,制订清理流程建立维修标准等)

Engineering,production,andmaintenancetogethermustbuyoffandprepareequipmentforstartofproductionatlaunchtime.(i.e.confirmpartslists,producecleaningcharts,buildstandardmaintenance,etc)4.定时管理回顾/审计全员设备维护系统

Regularmanagementreviews/auditsoftotalmaintenancesystem5.制订停机时间,交接班时间以及计划性TPM行动计划

DevelopTPMactionplansfordowntimeandscheduledtimes,splitshiftsforTPM第14页14不停改进CONTINUOUSIMPROVEMENT全员生产设备维护TotalProductiveMaintenance第15页15不停改进CONTINUOUSIMPROVEMENT定义:借签从来精益生产成功例子，并把它们作为完成企业目标、标准、和关键要素，对设施、设备、工具和布局设计进行不停改进。Definition:Thecontinuousimprovementofthedesignoffacilities,equipment,toolingandlayoutsutilizingthemostsuccessfulhistoricalandfutureexamplesofleanmanufacturingasabasistoachievecompanygoals,principlesandkeyelements.目标:经过对工作环境改进，实施SGM通用制造系统关键要素，进而到达企业目标和标准。Purpose:TofacilitatetheimprovementoftheworkenvironmentandcultureneededtoattainthecompanygoalsandprinciplesbyintegratingthekeyelementsoftheSGMGeneralManufacturingSystem.

要素4：设施,设备,工具和布局精益设计Element4：LEANDESIGNOFFACILITIES,EQUIPMENT,TOOLINGANDLAYOUT第16页16不停改进CONTINUOUSIMPROVEMENT

要求Requirements1.使能表达当前已认可和推荐简易工艺图/布局标准化

Standardizesimpleprocessdiagrams/layoutstobedevelopedandmaintainedreflectingthemostcurrentacceptedandrecommendedprocesses/layouts2.反馈机制应到位以使现有设施,设备,工装和布局使用者能把他们当前经验和提议通知制订评定标准控制人员(应包含质量,物料,生产,维修,人事和工程部门)

Feedbackmechanismsareinplaceforusersofexistingfacilities,equipment,toolingandlayouttocommunicatetheircurrentexperiencesandrecommendationstothecontrolleroftheevaluationcriteria.(Shouldinvolvequality,material,production,maintenance,personnelandengineering）

设施,设备,工具和布局精益设计LEANDESIGNOFFACILITIES,EQUIPMENT,TOOLINGANDLAYOUT第17页17不停改进CONTINUOUSIMPROVEMENT3.有设施，设备，工具和布局不停改进计划

Havecontinuousimprovementplanoffacilitiesequipmenttoolingandlayouts4.含有一整套当评定标准需更改时需经相关部门首肯流程

Processexiststocommunicateandgainapprovalfromanyrelateddepartmentwhenevaluationcriteriarequiresmodifications5.设备维护能力

Maintainabilityofequipment

设施,设备,工具和布局精益设计LEANDESIGNOFFACILITIES,EQUIPMENT,TOOLINGANDLAYOUT第18页18改进前：油漆车间与车身车间之间、油漆车间与总装车间之间连接处没有封闭，外界灰尘、小昆虫进入油漆车间。改进后：在油漆车间内部增加隔墙，将与两车间机运接口两条积放链及接口处封闭起来，使两接口处与油漆车间内部分离开。不停改进CONTINUOUSIMPROVEMENT设施,设备,工具和布局精益设计LEANDESIGNOFFACILITIES,EQUIPMENT,TOOLINGANDLAYOUT第19页19不停改进CONTINUOUSIMPROVEMENT要素5：不停改进流程Element5:ContinuousImprovementProcess

定义:一个改进过程，经过认识、接收、创造和使用不停改进，来到达新业务挑战和目标，毁灭浪费。DEFINITION:Animprovementprocessthatcreatesandutilizesthemindsettounderstandtheneedandrecognizeandacceptchangeinordertomeetnewbusinesschallengesandtosupporttheongoingefforttoidentifyandeliminatewaste.

目标:改变现实状况，不停进步。PURPOSE:Toremainflexibleandprofitableinthefaceofchangingbusinessconditions.

第20页20不停改进CONTINUOUSIMPROVEMENT不停改进流程ContinuousImprovementProcess

怎样改进？要求Requirements1.在全部运作层次和功效中建立和培训一套标准连续改进流程EstablishandtrainastandardContinuousImprovementProcessinalloperationallevelsandfunctions

2.跟踪和监控所作改进办法

Followupandmonitorimprovements

3.使改进标准化

Standardizeimprovements第21页21不停改进CONTINUOUSIMPROVEMENT不停改进流程ContinuousImprovementProcess

4.建立一套激励快速反馈机制以勉励员工参加

Establishaquickmotivatingfeedbackprocessthatencouragestheinvolvementofthepeople5.在每一区域建立CIP小组(冲压,油漆,车身,总装等)

EstablishCIPshopsineacharea(Press,Paint,Body,Assembly,etc.)

6.实施针对CIP活动合理化提议程序,提议程序应考虑全部提议且能作出快速反应

ImplementasuggestionprogramthatrecognizesCIPactivities.Thesuggestionprogramshouldrecognizeallideasandprovideaquickresponse

7.含有小组目标

Haveteamleveltargets8.使用标准作业单(SOS)作为CIP工具

UseStandardizedOperationSheetsasatoolforCIP

第22页22不停改进CONTINUOUSIMPROVEMENT定义:在产品设计和工序开发早期阶段把设计和生产制造有机地结合起来。DEFINITION:

Theutilizationofthecombinedinputofdesignandmanufacturingoperationsintheearlieststagesofproductandprocessdevelopment.目标:利用现有和过去经验确保新产品/工艺生产过程简单化。

PURPOSE:

Tobuilduponcurrentandpastexperiencestoassurethatnewproducts/processesenablesthesimpleprocessingandassemblyofproducts.

要素6：制造和设计尽早结合(DFM/DFA)Element6:EarlyManufacturingandDesignIntegration(DFM/DFA)第23页23不停改进CONTINUOUSIMPROVEMENT

要求Requirements1.总体计划(比如四阶段)应包含谁,做什么,何时等且含有计划好审核时间

Masterschedule(e.g.4Phase)isapplied(toincludewho,whatandwhen)andincorporatesscheduledreviewpoints2.工厂必须配置专门资源(生产和工程)保持DFM/DFA小组使用是当前加工工艺文件

Dedicatedplantresources(productionandengineering)existswhichmaintaincurrentprocessingdocumentationusedbytheDFM/DFAteam制造和设计尽早结合(DFM/DFA)EarlyManufacturingandDesignIntegration(DFM/DFA)第24页24不停改进CONTINUOUSIMPROVEMENT3.工厂(生产,工程和维护)产品制造从制造样品阶段开始,统计他们在样品研制阶段发觉问题然后为常规生产开发必要工艺

Theplant(production,engineeringandmaintenance)buildsproductstartinginprototypestage,documentstheirfindingsanddevelopsthenecessaryprocessesforregularproduction4.产品和工序必须含有即刻传递质量改进效果能力,而不是象先前那样只是统计

Productandprocessingmustbecapableofimmediatelydeliveringimprovedqualityresultscomparedtothepreviousmodelwithadocumentedhistoryofevents

制造和设计尽早结合(DFM/DFA)EarlyManufacturingandDesignIntegration(DFM/DFA)第25页25不停改进CONTINUOUSIMPROVEMENT要素7：问题处理Element7:ProblemSolving定义:确认、分析和消除当前标准或期望值和实际情况差异，而且防止根本原因重复出现一个方法。DEFINITION:

Astructuredprocessthatidentifies,analyzes,andeliminatesthediscrepancybetweenthecurrentsituationandanexistingstandardorexpectation,andpreventsrecurrenceoftherootcause.目标:确定根本原因，预防问题重复出现，实施对策,不停改进。PURP