精益六西格码.ppt

1、6-SIGMA LEAN,培训资料,目录 / Contents,什么是六西格码精益生产？ What is 6 Sigma Lean ? 为什么要进行六西格码精益生产？ Why 6 Sigma Lean ? 什么是七大浪费？ What is 7 + 1 waste? 我们该如何排除浪费？ How can I contribute to eliminate waste? Jidoka Jidoka 5S 5S 设备效率 OEE 快速换线 SMED,Basic beliefs of “Lean”,员工安全 Safety(People),不忽略每一个步骤的过失 A defect should not

2、be passed on at any step. 零缺陷品质制度必须规划并建立 Zero defect quality must be designed and built in.,运输 Delivery(JIT),成本 Cost (MUDA),什么是六西格码精益生产? / What is 6-Sigma Lean ?,员工是公司最重要的资产 People are the most important asset of the company. 计划安全的工作环境 Design Safe work places.,质量保证 Quality(Jidoka),无论何时何处都根据需要的数量进行生产

3、 Make products only when and where needed in the quantities needed,消除所有浪费和排除不必要的存货 All waste must be banished and unnecessary inventory eliminated.,Customer Satisfaction,为什么要六西格码精益生产？/ Why 6-Sigma Lean ?,满足客户需求 To meet customer demands. 客户只会为有价值的行为买单 Customer is willing to pay for only value-added a

4、ctivities. 没有价值的行为会增加生产的成本 Non-value added activities add cost to manufacturing. 要想在竞争激烈的商业环境下生存，就必须最充分地利用资源 To survive in this competitive business environment, there is a need to maximise utilisation of resources. 保持公司的收益 Sustained profitability of the company.,对于公司 For the Company,对于个人 For You,为了

5、旭电的安全工作 Job security for Solectron Penang. 集中你的时间成就有价值的分派任务 Focus your time and effort on valuable tasks. 停止步行/检查/查找/重做和其他一些无价值的行为 Stop walking, checking, searching, reworking and other non-value activities. 加入到工厂的成功当中 Involved in the success of the Plant. 你的技能和领导能力的提高从而得到认可 Your skills and leadersh

6、ip development and the opportunity to be recognized.,客户愿意付钱, 并使产品发生转变或给产品增加价值的行为才是有价值的生产活动 Activities that transform the products, or add value to the products which the customer is willing to pay for. 例如 / Examples： 贴装元件 Mounting components on the board; 集成电路程序烧制 Programme IC 印刷电路板放入盒子 Secure PCB t

7、o the chassis; 手工插装元件 Handload the components; 波峰焊操作等 Wave solder the PCB etc,什么是有附加值的活动？/ What are Value-Added (VA) activities ?,什么是可增加附加值的行为？/ What are ValueEnabled (VE) activities ?,不增加附加值但是必须要做的事情 Activities which are non-value added but necessary today 例如/ Examples: - 视觉检查与测试 - Visual inspectio

8、n and testing - 为了组装操作在小范围拿取工具和原料 - Small movements to reach for tools or materials for assembly etc;,什么是浪费？/ What is waste ?,做不增加产品附加值的工作 Work which does not increase the value of the products 例如 / Examples - 错料返修 - Rework due to the use of wrong parts; - 补焊 - Touch-up; - 当机器运转时，操作工等待的时间 - Operator

9、 waiting-time while machine is running; - 找料，计算 - ARF, looking for parts, counting; - 走动 - Walking etc.,什么是七大浪费？/ What is “7 + 1 Waste” ?,Over production过量生产 Over processing多余的工作程序 Inventory库存 Motion多余动作 Transportation运输 Rework返修 Waiting等待 Intellect waste 人才浪费,生产过剩 / Overproduction,客户何时需要，需要什么是我们的生产

10、目的 Our goal is to produce only what the customers want, when they want it. 过量生产是一种最大的浪费，它能够导致更多的浪费，诸如多余动作，等待，运输，返修; Over production is the worst type of waste as it leads to further waste, such as motion, waiting, transportation, rework. 例如/ Examples:- 为了周末的野餐,而带了一周的食物 - Bring one weeks worth of foo

11、d for a weekend picnic; - 存货的返修 - EC rework for inventory; - 提前36小时备好料 - Kit 36 hours before parts are needed; - 后道工序运作得比前道工序快 - Run bottom side faster than top side etc,等待材料和机器操作时不做任何事 Doing nothing while waiting for materials or machine to complete a process. 机器和人力利用率低下 Under utilise machine or ma

12、npower 实质浪费时间会降低生产运作 Essential waste time can be filled with productive activities 重新平衡生产线会减少等待时间 Rebalance activities to remove waiting time. 例子 / Examples- 提早到达, 等待开会 - Arriving an hour early for a meeting; - 开会迟到, 所以其他与会人员等待 - Coming late for a meeting while the rest are waiting for you; - 板子等待压配

13、合 - Boards awaiting press-fit; - 手工组装的操作员等待板子 - Handload operators waiting for boards etc.,等待 / Waiting,运输 / Transportation,工艺过程中不必要的物料和人力移动 Unnecessary movement of parts or people between processes. 差劲的物流安排导致不必要的材料运输 Poor logistics layout that cause unnecessary transportation of materials. 能造成运输损坏或

14、是产品质量问题等 Can create handling damage and cause production rejects such as knock-off, dropped boards etc 例如 / Examples: - 传送带太长或工艺间隙太远 - Conveyor is too long or gap between process is too far apart; - 在两站之间不必要的存货, 板子送去清洗和 5DX等 - Unnecessary inventory between stations, boards sent to wash and 5DX etc,库

15、存 / Inventory,原料放置不动不能增加附加值 Materials that are sitting idle do not add value. 库存与现金紧密相联 Inventory ties up cash (million/billion USD) 库存可能是仓库里的原料或是生产线上的在制品 Inventory can be raw materials in warehouse/store or WIP on the line. 大量库存会增加成本，并提高损坏，丢失，被盗等的可能性 High inventory increases the potential for highe

16、r operation costs, scrap, loss, theft etc 差的生产线5S Poor 5S on the line 例如 / Example: - Stock up a months supply of Maggie Mee when the supermarket is nearby; - Absenteeism that causes inventory to pile up at certain operations; - Combo boards traffic jam; - Overflow of inventory at parking lots etc,多

17、余的工作程序 / Over Processing,客户不需求的工艺作业是一种浪费 Processing beyond what the customer requires is a waste. 可能是由于缺乏标准, 或不了解客户的需求, 或知识不知道规范 May be due to a lack of standards or lack of knowledge of customers requirements or simply do not know the specifications. 多余的工作程序不能增加附加值, 因为客户并不打算为之付钱 Overprocessing does

18、 not add value as customer is not going to pay for it. 例如 / Example： 咖啡里加太多的糖 Put too much sugar for coffee 焊料过多 Extended stirring of solder paste 将已经清洗干净的镜子再清洗一次 Cleaning the mirror over and over again even though the mirror is already clean.,多余动作 / Motion,在一个工序中不必要的物品或人员移动 Unnecessary movement of

19、parts or people within a process 差的工作站规划,差的5S. Poor work station layout, poor 5S. 安排人员或物品围绕工作站, 改善 5S, 并消除动作浪费 Arrange people or parts around station, improve 5S and eliminate motion waste.,例如 / Example : 手工组装的元件远离操作员 Handload components are placed far from the operator; 常用的工具远离工作站等 Frequently used

20、tools are far away from workstation etc.,返修/Rework,每个人尽力第一次就做好 Everyone do it right the first time. 返修可能是由原料，机器或人为引起的 Can be caused by materials, machine or people. 返修需要额外的资源并且增加生产成本 Requires additional resource to rework, add cost to product. 废料，高成本(数百万美元) - 50%的板子需要去返修 Scrap, high cost (millions U

21、SD) 50% of boards go to the Hospital ! 使客户不安 Upsets customers 例如 / Examples ： 集成元件极性错误 IC installed with wrong orientation; 用错机器程序等 Using wrong machine program etc,才能、智力 / Talent & Intellect,未采用人们的意见和行为 Untapped peoples ideas and action 优秀的返修工去做手工插件组装 Well trained rework operator put to handload ope

22、ration 操作员浪费时间找料，点料 Operators wasting time searching for components, counting parts 好主意未被采纳执行 Good idea not communicated for implementation,我该怎样排除浪费？/ How can I contribute to eliminate waste ?,了解不同类型的浪费 Understand the different types of waste 了解以下的行为,将有助于消除浪费 Understanding the following Lean concept

23、s can help you to eliminate waste. 识别它们 Identify them 根据流程工作 Carry out your process according to procedure 正确的处理印刷电路板和原材料 Proper handling of PCB and materials 根据目标时间工作 Follow the takt time, work to cycle time of the process 发现浪费时,向主管汇报 Report to supervisor if you spot any of the “ waste”, like “ I a

24、m waiting”,Jidoka (Autonomation),Autonomation 是任何时候异常状况发生时停止生产的原则 Autonomation is the principle of stopping manufacturing process whenever an abnormality occurs. 异常状况是背离标准的 An abnormality is any form of deviation from the standard 例如 / Examples ： 质量问题，低合格率，元件丢失等 Quality problems, low yield, missing

25、component etc 机器参数： 温度太高等 Machine parameters temperature too high etc 气管漏气 Air leaking from air pipes 不依照计划生产 Production not according to plan,当发现异常问题停止生产并通知管理员，管理员会找到原因和知道解决方案并解决异常事件 When an abnormal event is observed, stop and call the supervisor. The Supervisor will find the cause and provide the

26、 solution to solve the abnormality.,什么是 5S? / What is “5S” ?,A place for everything and everything is in its place.,排除工作场所不需要的工具材料 Eliminate all non-essential tools, materials from workplace,组织好需要的工具材料 Organise all necessary tools, materials 分配到最佳的工作场所 Assign an optimal area in the workplace,有规则的打扫工

27、作场所和设备 Regularly clean the workplace and equipment,发展标准流程和检查表,以维持有序/整洁/实用的工作场所 Develop standard procedures and checklists to maintain an orderly, clean & functional work area,贯彻 5S 体系, 确保工作场所良好，5S将成为公司文化的一部分 Implement systems to ensure the workplace is improved and 5S becomes part of the culture,Eli

28、minate Waste !,5S不是一次的事情，它是一条纪律 5S is not a one time event, it is a discipline. 纪律给你带来所有好的习惯，做正确的事 Discipline is having the habit of doing the right thing right. 习惯是知识，技能和愿望的交叉点 Habit is the intersection of knowledge, skills and desire.,“追求优秀不是一件行为而是一种习惯” - 亚里斯多德 “We are what we repeatedly do. Excel

29、lence is not an act but a habit.” - Aristotle,知识 Knowledge 怎样取做 What to do 为何去做 Why do it 目标条件 A target condition,技能 Skills 怎样去做 How to do it,愿望 Desire 将去做 Will to do it,什么是 5S? / What is “5S” ?,设备的所有效率 / OEE (Overall Equipment Effectiveness),OEE 衡量设备的损失, 例如： OEE measures machine losses, such as: 速度

30、的降低 Reduced speed 停顿 Breakdowns 换线 / 产品切换 Change over 等待 Idling and minor stops 报损和返工 Scrap and rework Start up losses,我能为改善OEE做什么? / How can I help to improve OEE ?,理解指标, 了解操作 Understand the indicators and know the performance level 参加并遵守换线程序,以减少换线时间 Participate and follow change over procedures to

31、 reduce change-over time 交叉培训以胜任不同操作,以减少等待和停止 You are cross-trained to support multiple operations to reduce idling and minor stops 遵循标准的工作流程, 以减少导致返工和报损的错误 Follow standard work procedures to eliminate errors that lead to rework and scrap 根据目标时间操作,以减少等待和停止 Perform according to takt time to reduce id

32、ling and minor stops 发生异常时通知主管,以减少设备停止时间 Inform supervisors when abnormality is observed to reduce machine breakdowns 计划好工作,以减少等待/搬运/停工的浪费 Plan your work to eliminate waiting, transportation, downtime waste during the conversion 预测导致设备停止的原因 Anticipate the condition that caused the machine to stop,你知

33、道一辆赛车在大奖赛中换4个轮胎需要多少时间吗? Do you know how much time is taken for a racing car in the Grand Prix to have all 4 tyres changed? 你认为你将要花多少时间去换4个轮胎? How long do you think you will need to change 4 tyres? 你知道需要多少时间换一个生产线吗? Do you know how much time is taken to convert one line? 我们能进一步改善我们现在的换线时间吗? Can we fu

34、rther improve our current conversion time ? 你知道哪些因素会造成换线过程中的浪费吗? Do you know what are the elements and waste in the change-over process ? 我们能改善它吗? Can we improve it ?,快速换线 / SMED (Single Minute Exchange of Die),为什么快速换线对我们重要？/ Why SMED is important to us ?,在客户不断变化的需求下,我们不得不小批量生产,在指定时间内交给客户。迅速的change-

35、over 让我们有灵活性去实现这个目标 With the changing demands of our customers, we have to build products in smaller quantities, deliver to customers the quantity within the time they want the products. Fast change-over gives us the flexibility to meet this objective. 最少的change-over时间能让我们的设备有更多的时间去生产好的产品 Minimising change-over time will give our equipment more time to produce good parts in the shift / day . 有竞争力，能够满足客户需求，从而保持公司的利润. Be competitive and satisfy customers requirement to sustain profitability .,Change Over 的重要