丰田精益生产手册中英文对照版课件

1、1,Lean Hand Book 精益生产手册,2,Defect : X 1/10 缺陷降低90% Inventory : X 库存减半 Productivity : X 2 生产效率翻倍 Lead Time : X 生产周期减半 Scrap : X 1/10 报废降低90% Space : X 面积减半,Goal : Add Value & Eliminate Waste Relentlessly for Our Customers 目标: 减少浪费&创造价值 全心全意为客户服务,ETE (End to End) Productivity Improvement 端到端(从头到尾)产能提高 ETE Zero Defect (Quality, TPM, OEE & etc.) 端到端(从头到尾)零缺陷（质量，全面生产维护，全局设备利用率等） Inventory Reductions 降低库存 Lead Time Reductions 缩短生产前置期 Crew Size Optimization 优化人员数量 Space Reduction 减少使用面积,Double the Good

2、好的加倍 Halve the Bad 坏的减半 Double the Speed 改善速度加倍,Kaizen Workshop Goal 改善目标,No Money 不投入更多金钱 No Space 不占用更多面积 No Manpower 不使用更多人力,3,Standard Work & Standard Combination Sheet 标准化作业 & 标准作业合并表,1) Standard work defined 标准作业定义 a) Takt time defined 节拍时间的定义 b) Work sequence defined 工序的定义 c) Standard WIP defined 标准在线库存定义 d) Cycle time defined 周期时间定义 e) No of operators defined 操作员数量的定义 f) Safety 安全性 g) Multi skill 多技能 2) Standard work combination sheet defined 标准作业合并表定义 a) Manual time 手动时间 b) Auto time 机器

3、(自动)时间 c) Walking time 走动时间 d) Waiting time 等待时间 3) Is the Quality check legend defined on each process on std work sheet? 标准作业合并表上，有定义每个流程中的品质管控的关键点吗？,3 Key Elements 3项关键要素,4,3 Types of Standard Works 3种标准作业,5,3 Types of Standard Works 3种标准作业,Type 1 : Standard Work to support machine (90%) & man (10%) combination task. 类型1：标准作业适用于90%的机器作业和10%的手动作业的组合作业方式。 Type 2 : Standard Work to support man (90%) & machine (10%) combination task. 类型2：标准作业适用于90%手动作业和10%机器作业的组合作业方式。 Type 3 : Standard Work (also

4、 called as Work Standard) to support task carried out once signal is triggered. 类型3：标准作业（也叫做作业标准）适用于当信号产生时才去执行相应任务的作业方式。,No Std Work means no Kaizen Std Work is the Mother of all Kaizen 没有标准作业就没有改善标准作业是改善之母,6,How to start the Takt Time Calculation Based On Customer Demand 怎样根据客户需求计算节拍时间,Step 1: Calculate Takt time Based on Customer Demand 第一步：根据客户需求计算节拍时间 Example 例如: Customer Demand per Month 792K. Working hour per day is 22 hours, 20 days a month. 客户每月需求量是792K。每天工作小时是22小时，一个月20天。,Takt Time calc

5、ulation shall display all the variable and units to make clarity to all. 计算节拍时间时要显示所有变量及单位，便于大家理解。,7,How to start the Takt Time Calculation Based On Product and Process Design怎样根据产品和制程设计计算节拍时间,Step 2: Calculate Process Takt time Based on Product and Process Design 第二步：根据产品和制程设计计算节拍时间 Based on Step 1, Takt Time is 2 second to produce 1 pcs. 根据步骤1，节拍时间是每 2 秒生产 1 件产品。,8,How to start the Takt Time Calculation Based On Product and Process Design怎样根据产品和制程设计计算节拍时间,Scenario 1: Product design is 6 pcs pe

6、r one PCB panel. The Process Takt Time will be every 12 second a panel. Besides, your process design is using a pallet to place 4 panels, then your Process Takt Time is 48 second a pallet. If 2 line running, process Takt time will be 96 sec. 情节1：产品设计为每块PCB板由 6 块小板组成，节拍时间是每块PCB板 12 秒; 制程设计治具同时放置 4 块PCB板，则制程的节拍时间是 48 秒/治具。如果同时有 2 条生产线生产，制程的节拍时间则为 96 秒。,Scenario 2: If Top and Bottom product running on same line at the same time, Takt time shall be half = 48sec 情节2：如果正反面产品同时在一条生产线生产，节拍时间则为一半，48秒。,As

7、 such the Process Takt Time Calculation as following: 制程节拍时间计算如下： = Takt Time X Product Up x Process Up X Number of Line = 2 sec X 6 products per panel X 4 Panel per pallet X 2 Lines = 96 sec,9,What is Standard WIP 什么是标准WIP,Various types of WIP in our manufacturing process 生产过程中存在各种类型的WIP Standard WIP 标准WIP Process WIP 制程WIP Process To Process WIP 制程与制程间WIP Station To Station WIP 工位与工位间WIP,10,What is Standard WIP 什么是标准WIP,WIP means INVENTORY. INVENTORY is Basically bad. WIP就是库存。库存从根本上说是“不好”的。 St

8、andard WIP is the Ideal or Should be conditions for WIP 标准WIP是理想WIP或者是WIP的应有状态。 However, before you fully achieved Standard WIP Quantity, you might need to go through various stages to understand your process Muda and bottle neck 然而，在完全达到标准WIP数量前，你需要经过不同的阶段了解制程中的浪费和瓶颈。 Key Note from Sensei: 老师的重要提示： To understand the above WIP definitions, go to The Genba and perform your own work towards Establishing the right WIP quantities. This is the Only way you can understand the definition. 要理解WIP定义，你需要去

9、到现场在工作中实践正确的WIP数量。这是让你理解这个定义的唯一方法。,11,What is Standard WIP 什么是标准WIP,The purpose of Standard WIP is: 标准WIP的目的： Separation between machine job and man job 区分机器作业和手动作业 Ensures quality requirements 确保质量要求 Ensures smooth flow based on Takt time 确保基于节拍时间的连续流 Example 1: 例子1 WIP in the reflow oven for curing with process time 6 min and Takt time 30 sec. 在回流焊炉中固化的WIP，制程时间 6 min，节拍时间 30 sec. Standard WIP in the curing oven = Process Time / Takt Time 回流焊炉的标准WIP = 6 min / 30 sec = 12 Pcs,12,What is Standard WIP 什么是标准WIP,Example 2: 例子2 WIP in the tester at backend assembly with process time 60 sec and Takt Time 30 sec. 后段组装线测试机的WIP，制程时间 60 sec，节拍时间 30 sec. Standard WIP in the Test station = 60 sec/ 30 sec 测试工位的标准WIP = 2 pcs In other words, Standard WIP in order to fulfill the above 1), 2), 3) functions, It is the compulsory WIP in the machine / process before establish standard work for the process. 换句话说，标准WIP能够确保上述1),2),3)达成，在建立标准作业前，标准WIP是机器和制程强制的W

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