德尔福精益生产Leanmanufacturing的培训

德尔福精益生产Leanmanufacturing的培训Lean/DMSOverviewLean(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？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。WhatisDMS?什么是德尔福制造系统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

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。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。

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。

Characteristics特点:ProcessBottlenecks工作过程出现瓶颈LackofBoundarySlesorClearCustomerSpecifications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Game:FindtheWasteLeanMetricsUptimeMaintenance(MERV)Scrap%Rework%CapacityUtilizationInternalProductivityManufacturingExpenseTotalProductionCycleTimeInventoryTurnsQualityandSafetyMetricsRRPPMRecordableAccidentRateLostWorkDayCaseRateKeyMetrics

21of309/22/2023OperatingPrinciples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