1、6西格瑪流程能力 (西格瑪改善) Six Sigma Process Capability (Sigma Kaizen)重點縮短制造周期 Focus on lead-Time reduction to :增加客戶忠誠度和市場份額 Increase customer Loyalty and Market Share取得銷售和收益雙增長 Achieve Growth in Sales & Earnings 保持競爭優(yōu)勢 Sustain the Competitive Advantages 提升利益相關(guān)者價值Improve Stakeholder Value 改善突破法 Kaizen Bre

2、akthrough Methodology準(zhǔn)時化Just inTime準(zhǔn)時化有效使用Efficient Use of 員工 People 設(shè)備 Equipment 物料 materials 占占地 Space 均衡生產(chǎn) Production Smoothing 提升工藝流程能力 Improve Process Capability 盡量減少變化 Minimize variation 控制異常 Manage abnormality 驅(qū)動成本下降 Drives cost reductionJidoka自働化自働化精益生產(chǎn)系統(tǒng) Lean Production system及時生產(chǎn) Just-In-T

3、ime Is. 這樣的生產(chǎn)系統(tǒng) A manufacturing system which produces: 按客戶所需進行生產(chǎn) What the customer wants 按客戶要求數(shù)量生產(chǎn)In the quantity the customer wants 按客戶要求時間生產(chǎn)When the customer wants it 利用最少的While using the minimum: 原料 Raw materials 設(shè)備 Equipment 工人 Labor 廠房 Space核心概念和工具Key Concepts and Tools 符合節(jié)拍時間Pace to Takt time

4、單件流 One-piece flow 拉動系統(tǒng) Pull systemLean Production system節(jié)節(jié)拍時間的重要性拍時間的重要性 Importance of Takt Time客戶需求Customer requirements凈操作時間 Net operating time將運作和客戶需求同步Synchronizes operations to customer demand 防止過量生產(chǎn) Prevents overproduction 建立流動生產(chǎn)的工具 Tool for creating flow確定最佳生產(chǎn)人數(shù) Determines optimal staffing推動

5、產(chǎn)能分析和設(shè)備利用率 Drives capacity analysis & equipment utilization必須定期更新以適應(yīng)需求的變化Must be updated periodically as demand changes單件流單件流 One-piece flow超市運作 Supermarket Operation過道 AisleEDCBAIHGFABCDEFGHI按需生產(chǎn) Produce to Actual Customer Demand拉動系統(tǒng)拉動系統(tǒng) Pull System實施拉動系統(tǒng)實施拉動系統(tǒng) Implement Pull system線旁供貨LSS線旁供貨L

6、SS收集看板Pick-up Kanban供應(yīng)商Supplier物料超市Supermarket投遞生產(chǎn)看板Drop Production Kanban原料RM成品FG生產(chǎn)計劃板Schedule board生產(chǎn)看板ProductionKanban現(xiàn)場送料員Water Spider及時生產(chǎn)的要素及時生產(chǎn)的要素 JIT Elements 小巧便宜機器Small, inexpensive machines in process order 單件流生產(chǎn), 反時針方向One-piece flow production, counterclockwise 人機正確結(jié)合Ergonomically-correct

7、 operations 站立操作, 邊走邊做Standing operations, moving while working 拉動系統(tǒng)訓(xùn)練Pull system discipline 定義和實施“標(biāo)準(zhǔn)化作業(yè)”“Standard operations” defined and implemented 及時生產(chǎn)的好處及時生產(chǎn)的好處 JIT Benefits 消除生產(chǎn)過程浪費Eliminates waste in production processes 縮短運作周期時間Reduces lead times 不能容忍生產(chǎn)異常Creates a system which is intolerant

8、of production abnormalities 準(zhǔn)時化Just inTime準(zhǔn)時化有效使用Efficient Use of 員工 People 設(shè)備 Equipment 物料 materials 占占地 Space 均衡生產(chǎn) Production Smoothing 提升工藝流程能力 Improve Process Capability 盡量減少變化 Minimize variation 控制異常 Manage abnormality Jidoka自働化自働化Jidoka is 減少不良品A method for reducing defects設(shè)備自動化，提高生產(chǎn)率Equipment

9、 autonomation to improve productivityJidokaA. 減少不良品的工具或方法 Tools or Methods to Reduce Defects 發(fā)現(xiàn)不良品的產(chǎn)生 Detect defects when they occur 防止不良品進入下一道工序 Prevent defects from passing to next operation 識別不良品產(chǎn)生根源 Identify root causes of defects 消除根源 Eliminate root causes 減少或消除不良品 Reduce or eliminate defectsJi

10、doka Elements 目視控制 Visual Control 5S 信號燈 Andon 異常反應(yīng)Abnormality Response/Reaction 作用 / 責(zé)任Roles and responsibilities 停工指引Line stop guidelines 西格瑪改善 Sigma Kaizen (DMAIC) 基本品質(zhì)工具Basic QC Tools 先進統(tǒng)計工具Advanced Statistical Tools 措施 Countermeasures 防錯措施Mistake-proofing (Poke-Yoke) 手動操作 Manual Work 自動操作Automa

11、tic machine work 新標(biāo)培訓(xùn)New Standard Operations and training 技巧矩陣, 表現(xiàn)量度Skill matrix and performance 自働化 Autonomation 人機分離 Separate person from machineJidoka Elements目控 Visual Control 5S 信號燈Andon零件展示 Parts presentation工具展示Tool presentation包裝線Pack line信號燈 Andon標(biāo)準(zhǔn)化工作 Standard work異常反應(yīng)過程異常反應(yīng)過程 Abnormality

12、Response Process發(fā)現(xiàn)問題React to problem Q C D S 衡量影響Measure impact提醒同事 Alert team標(biāo)準(zhǔn)化后, 訓(xùn)練員工Train affected associates in new standard operations MANEFFECTMACHINEMATERIALMETHOD找出原因Find root cause提出改善, 進行試驗Develop and test improvement Check 2BGauge 4試驗成功, 更改運作Update standard operations with tested improve

13、mentJidokaB. 設(shè)備自働化 Equipment autonomation 人機分離 Separate operator work from machine work改善前 Before: 操作員監(jiān)控機器工作 Operator watches machine run改善后 After: 操作員裝卸零件 Operator loads and moves 自動關(guān)閉 Auto shut-off “自動退件” 自動卸貨 “Hanedashi” auto unload 操作員進入下一道工序 Operator moves to next operationJidoka Benefits 改善產(chǎn)品質(zhì)

14、量Increases production quality 提升生產(chǎn)力Increases productivity 保證準(zhǔn)時交貨Ensures on-time delivery 準(zhǔn)時化Just inTime準(zhǔn)時化有效使用Efficient Use of 員工 People 設(shè)備 Equipment 物料 materials 占占地 Space 均衡生產(chǎn) Production Smoothing 提升工藝流程能力 Improve Process Capability 盡量減少變化 Minimize variation 控制異常 Manage abnormality Jidoka自働化自働化均衡生

15、產(chǎn)是均衡生產(chǎn)是 Production Smoothing Is.調(diào)整生產(chǎn)速度, 滿足客戶變化Adapting production rates to variations in customer demand產(chǎn)品數(shù)量變化Variation in volume產(chǎn)品種類變化Variation in product mix每日平均需求 = 生產(chǎn)目標(biāo)Average Daily Demand = Target Production數(shù)量Quantity時間 Time客戶需求 Customer Demand均衡生產(chǎn)均衡生產(chǎn) Production Smoothing產(chǎn)量的變化 Variation in Vol

16、ume均衡生產(chǎn)均衡生產(chǎn) Production Smoothing天 Day每月計劃: (3,200個)Monthly Schedule(3200 units)5152010型號A Model A1600 個 units型號C Model C800 個 units型號B Model B800 個units天 Day每日計劃 (160個) Daily Schedule (160 units) 生產(chǎn)模式: Production pattern AABCAABC80140 4080240 4080340 40802040 40種類變化 Variation in Mix均衡生產(chǎn)的好處均衡生產(chǎn)的好處 Production Smoothing Benefits 保持一致優(yōu)良品質(zhì)Maintains a consistent, high product quality 減少資金投入需求Reduces the requirements for capital investment 降低員工成本Reduces staffing costs 保證準(zhǔn)時交貨Ensures on-time delivery 及時Ju