JIT-准时化(日本培训资料)

KAIZENinJust-In-TimeProductionSystem

在准时化生产系统中的改善ToyotaProductionSystem丰田生产方式Jay-eye-teaJIT1ReductionofProductionLeadTime减少生产周期Source:SannoCollege“Seisan-shiTextbook”

“Whatissue/conceptwillbemostimportanttoyouinthe1990’s?”

在九十年代对你而言最重要的概念是什么OrderReceiptDeliveryProductionProductionLeadTimeFastproductionflow快速的生产流程23Ｓｕｐｐｌｉｅｒ供应Ｃｕｓｔｏｍｅｒ客户ＣｕｓｔｏｍｅｒＳｕｐｐｌｉｅｒManufacturerManufacturer生产Dealer经销DealerPartsExcessinventory剩余库存Difficulttoforecast

customerdemand难以预期客户需求PartsPushsystem推进系统Pullsystem4ByToyotaMotorCompany丰田汽车公司Theconceptofproducingorconveyingonlythoseunitsneeded,atallstagesofproduction.justwhentheyareneeded,injusttheamountneeded,Just-In-Time(JIT)system

准时化生产系统在所有的生产阶段生产和运输的概念——需要的时间提供所需数量5Now

LookatsomeexamplesofKAIZEN

inToyota现在，来看下丰田改善的一些案例6Thisreferstothethoughtfuluseofdeviceswhicheliminatesoperator’scarelessmistakes.这是指排除操作者纰漏,周全地使用设备Note注意:“Poka”-----Carelessness;Absent-mind粗心、心不在焉“Yoke”-----Elimination消除Fool-proof(Poka-yoke)

傻瓜防（防错）7Mistakes错误Makemistakesforcounting,measuring,worksequence,setting,etc.在计算、测量、工作顺序、设定等方面犯错误“Iforgotthingstodo.”

我忘记作了“Imissedthemonitoring.”我错过了监测“IdidsomethingwhichIshouldnotdo.”我做了些不该我做的8Wrongoperations误操作23%Negligence疏忽(Forgetfulness遗忘)48%Source:“Poka-yokeactivities“KaneboChem.,1991KaneboChemical佳丽宝化学,

1989AnalysisofCarelessness

分析粗心0%100%(

)(

)其他阀操作准备组装开关操作通讯确认 输入设备测定9Screwdriverslipsandscratchestheproduct.螺丝刀划伤、刮伤产品Source:“Poka-yokeDaizukan”Nikkan-kogyo1987Poka-yokeExample1防错例Neverslips未划伤10Source:“Poka-yokeDaizukan”Nikkan-kogyo1987Fool-proofdevice保险装置Poka-yokeExample2防错例BendingMachine折弯机Non-defective无缺陷Defective有缺陷11Kumasi,Ghana12VisitJapanesehome?

拜访日本家庭13Somethinginshoes14Poka-yokeExercises

防错练习15Exercise练习1Brush刷?ByunknownWhereisabrush?刷子在哪里

Insidethetank?在槽里?16Poka-yokeSolution防错方案ByunknownThebrushistiedwitharope.用绳子系着刷子17Exercise练习2Theworkerstirstheliquidinatankandaddsomeadditives.工人在搅拌槽中液体时添加添加剂“DidIalreadyaddadditives?”我已经添加了吗18Poka-yokeSolution防错方案Beforestirringtheliquid,putadditivesincups.在搅拌之前，将添加剂放在杯中19Jidokareferstotheabilityofproductionequipment,includingasinglemachine,tosenseamalfunctionofthemachine.自动化是指生产设备的能力（包括单台机器）和设备的故障Autonomation(Jidoka)

自动化AutonomousAutomation20Stop!停Idon’tknow.我不知道Simple

automation简单自动化Jidoka自动化Autonomation(Jidoka):

自动化Automationwithahumantouch

自动化以人为本21VideorecordedatToyotaTechnoMuseumVideo22Loomwithnon-stopshuttlechange不停穿梭的织布机,1924

(SakichiToyoda,57yearsold丰田佐吉，五十七年岁)In1929,PlattBrothersofEnglandrequestedtechnologylicensingagreementfromToyota.1929年，普拉特兄弟要求英国从丰田获得技术许可Automaticloom,typeGPhototakenat

ToyotaTechnoMuseum23Lasttopic最后话题ThebiggestKAIZENinToyota?在丰田最大的改善24Thegoalofsingleminuteset-upmovementistoreducetheset-uptimetolessthan10minutes.单分钟设置运动目标就是至少减少10分钟的建立时间Singleminuteexchangeofdie(SMED)快速转模法

Singleminute快速转模法25StampingMachine烫金机Oldstyle老式的Modernstyle现代13.1tons吨PhototakenatToyotaTechnoMuseum26Question问题27Makeaknot,butyoumustholdbothendsoftherope.打个结，但必须抓住绳子的两端28Demonstration演示129Demonstration演示230TheTrickoftheMagic

魔术把戏AdvancedPreparation先进的准备预先准备31Maskingtape封口胶纸Paintanarrow画箭头Trashcan垃圾桶Spreadsheet电子表格Source:TheJapanHRAssociationExample练习(1)32AdvancedPreparation

预先准备33Canyouputyourtie

within5seconds?

你能在5秒钟内系领带3410minuteslooktooshorttoreplace

bothupperandlowerdies

看起来十分钟同时更换上下磨具时间太短TimeSavings节省时间35U-shapedwasherU形垫圈Nutandbolt螺母和螺栓Pear-shapedholes梨状孔Source:H.Hirano“MedemitewakaruJITSeisanHoshiki”Nikkan-kogyoShinbun,1990Example练习(2)36DemonstrationVideorecordedatToyotaTechnoMuseum37KAIZENinToyota

丰田改善AsingleKAIZENeffectmaybesmall,butwithcontinuousaccumulatedeffort,itcanproducegoodresults.单一改善的影响可能很小，但不断努力积累，它可以产生良好的结果。38Toyota’sspirit

丰田的精神Squeezeoutalastdropoutofadriedtowel.挤出干毛巾最后一滴WasteElimination消除浪费39Wastefromover-production生产过剩的浪费Wasteofwaitingtime等待时间的浪费3.Transportationwaste交通浪费4.Processingwaste过程浪费6.Wasteofmotion多余动作7.Wastefromprod