1、1,NOS簡介 精實生產 & 七大浪費,Fundamentals of NOS 7 Wastes + Launch Workshop agenda for PCN (CS CHANGSHIN VIETNAM CO .LTD+PCN) (Oct.2 ,2002) ( IY ),2,What is meant by Lean Manufacturing 什麼是精實生產,Today, there are many terms being spoken within the industry：今天, 在工業界裡有很多的專有名詞被提到: Kanban 看板 Pull Systems 後拉式系統 Batc
2、h-of-one Production 單批生產 Andon 燈號警示裝置 Total Productive Maintenance (TPM) 全面生產維護 Kaizen 改善Worker Empowerment 對員工授權,3,Lets define Lean Manufacturing 讓我們對精實生產下定義,Many people refer to the Toyota Production System when discussing Lean Manufacturing 當討論精實生產時，很多人都會談到Toyota的生產系統For our discussion, we will d
3、efine lean manufacturing as the“ process of identifying and eliminating waste within our operations including manufacturing, engineering and administration ”. 為討論方便，我們定義精實生產為：在作業中確認並消除浪費的一種過程,包括製造、工程與管理等的作業。,4,Evolution of the Manufacturing System 生產體系的演進發展,The process of manufacturing and supplying
4、 products has evolved from simple craft production to a fast-paced, global-oriented arena. 製造產品與其供應的過程已從簡單的手工技藝發展到快速以及以全球化為導向的競技場。,Craft 手工- Mass 大量- Lean 精實生產,Time and Resources force Transition時間與資源 迫使變革,Less individual control; 較少的個人控制,去除個人英雄 Responsibilities distributed over many people. 把責任分散給許
5、多人,5,Customer demand is the universal driver in change 客戶的要求主導所有變革,Conditions that were satisfactory yesterday are not acceptable. Tomorrows demands will be even greater. 昨天滿意的狀況今天已不再被接受，明天的需求亦將更巨大,Product Shipment 產品出貨,Product Shipment 產品出貨,Waste浪費,Time時間,Time時間 (shorter更短),Lean Manufacturing helps
6、 to shorten the timeline between the customer order and the product shipment 精實生產縮短了客戶定單與產品交貨之間的時間,6,Why make the change to Lean Manufacturing ? 為什麼精實生產會造成如此改變,Lean Manufacturing implementation has been shown to aid companies in the following areas：實施精實生產已知可以替公司帶來以下方面的幫助： Improved productivity 提升生產力
7、 People not wasting effort on non-value added tasks 人們不會浪費努力在沒有增加價值的活動上 Predictable and stabile environment 可預測與穩定的環境 Greater Quality Assurance 更佳的品質保證 Tools designed to achieve defect elimination, not detection 工具的設計是為了達成不良的排除，而非察覺不良 Greater Flexibility 更大的彈性 Quicker response to changes in customer
8、 orders 更快速反應客戶訂單的變化 Reduce Cost 降低成本,How should we determine what “ waste ”is： 如何判斷什麼是”浪費”,Waste defined：浪費的定義Waste (wast)n. anything that takes time, resources or space but does not add to the value of the product or service delivered to the customer. 任何需要時間、資源或空間但卻未增加產品價值或帶給客戶服務的事物,8,Launch Works
9、hop Agenda,Value Add: changing shape, form, function of material to meet customer requirements 增加價值：改變物料的外觀、形狀與功能以符合客戶要求。 Non-value Add: activities that add cost but not value to the product (WASTE) 無增加價值：增加產品成本卻沒有增加價值的動作(浪費)。,9,While products made in each factory may be different, the typical waste
10、s found in 類似的！ factories are similar： 雖然每個工廠所製造的產品不同，但所發現的浪費典型都是,Correction 修改 Transportation 搬運 Motion 多餘的動作 Over-production 過量生產 Over-processing 多餘的製程 Waiting 等待 Inventory 存貨,10,Waste of Defects 品質不良之浪費(LWA),Definition 定義: producing product that must be touched up, reworked, or scrapped 製造產品時須經過修
11、改，重做，或銷毀 Effects 影響: time, effort, $ 時間/努力/金錢Causes 原因: unclear or no standard, incorrect machine settings, etc. 不清楚或無標準，機器設定錯誤，等等Examples 實例 :,11,Waste of product Rework/Rejects 重工及退貨的浪費,When defects occur at one station, operators at subsequent stations waste time waiting, thereby adding cost to t
12、he product and adding production lead time. 任何一個工作站發生品質不良，下一個工作站的作業員將浪費時間等待，從而增加產品的成本和生產的時間。 Furthermore, rework may be required or the defective products are scrapped. 此外，也會產生重工或是報廢。 If a defect occurs in assembly, additional labor is required to disassemble and additional parts are required to rea
13、ssemble. 如果不良發生在成型，必須額外的人力拆卸, 再加上新的零件/裁片重新組裝回去.,12,Waste of Waiting 等待之浪費(LWA),Definition 定義: people, machinery, or product “sleeping” 人，機器，或產品 “睡著了”Effects 影響: time, space, effort, potential obsolescence, $ 時間，空間，努力，潛在性之過時損失，金錢Causes 原因: unclear or no standard, layouts, etc. 不清楚或無標準，現場擺設，等Examples
14、實例:,13,Waste of Waiting 等待的浪費,People and/or Machines Waiting on Product 人員或機器等待製品,14,Waste of Waiting (Cont.) 等待的浪費(續),Time 時間 Processing Time 製程時間 = 1 minute分鐘/ unit 單位,A,B,C,D,A,A,A,A,B,B,B,B,C,C,C,C,D,D,D,D,0,1,2,3,7,15,Waste of Transportation 搬運之浪費(LWA),Definition 定義: movement of product from on
15、e place to another (by hand carry, by cart, by conveyor, by truck, etc.)產品由甲地移動到乙地(不管是用手提，手推車，輸送帶，或卡車等等)Effects 影響: time, cost, equipment, effort, potential for quality issues 時間，費用，設備，努力，淺在的 品質問題Causes 原因: factory layout, cell design 廠房擺設，群組設計Examples 實例 :,16,Waste of Conveyance 搬運的浪費,For Example：例
16、如Raw material being stored away from the place of use. 原物料從庫存區到使用地距離過長 Result：結果We must inform tracking personnel where to pick up material 我們必須通知搬運原料的員工到何處領料。We will need additional storage location other than point of use我們需要在使用區之外再增加額外的庫存區 . We need additional material movement personnel and equi
17、pment 我們需要增加額外的材料搬運人員與設備 .,17,Waste of Over-processing 多餘流程的浪費(LWA),Definition 定義: Performing operations that are not required to manufacture or assemble the product to the customers quality expectations 進行非製造所必需的作業或不是客戶要求與品質有關的組裝 Effects 影響: time, cost, effort, $ 時間，費用，努力，金錢Causes 原因: unclear or no
18、 standard 不清楚或無標準Examples 實例:,18,Waste of Motion 動作之浪費(LWA),Definition 定義: ergonomic or extra movement by people or machines 因人或機器所產生的人體工學問題或多餘動作Effects 影響: time, ergonomic problems, effort, $ 時間，人體工程學問題，努力，金錢Causes 原因: cell layout, machine set-up 群組擺設，機器設定Examples 實例 :,19,Waste of Motion 多餘的動作,What
19、ever time not spent in adding value to the product should be eliminated as much as possible.任何時間沒有花費在增加產品價值上的都應盡可能除去. Movement does not necessarily indicate value-added work. 搬運不必然是指增加價值的工作.,Categories of Work 工作種類Value Added-something the customer will pay for 增加價值-客戶會付錢Incidental-something which h
20、as to be done附帶的非作不可的Waste-provides no value or service浪費- 未提供價值或服務,“Eliminate Waste：Reduce Incidental Work ”“消除浪費：降低附帶的工作“,20,Waste of Over-production 過量生產之浪費(LWA),Definition 定義: Creating more than or ahead of customer requirement 製造超量或超前客戶需求 Effects 影響: time, transportation, space, effort, $, pote
21、ntial quality issues: leads to all other forms of waste 時間，運輸，空間，努力，金錢，潛在品質問題：導致其他的浪費產生Causes 原因: unstable work environment (downtime, quality issues, “JIC”, etc.) 不穩定之工作環境(停線，品質問題，看情況/不及時，等)Examples 實例:,21,Waste from Over-production 過量生產而來的浪費,Created by producing goods above the amount required by
22、the market.因生產的貨物超過市場需求所造成,22,Waste of Inventory 庫存之浪費(LWA),Definition 定義: excess material (raw, WIP, finished) 過量之材料(原料，半成品，成品)Effects 影響: lead time, working capital tied up, effort, transportation, $, potential quality issues, covers up problems 生產週期，週轉資金緊縮，努力，運輸，金錢，潛在品質問題，掩蓋問題Causes 原因: unclear o
23、r no standard, incorrect machine settings, etc.不清楚或無標準，機器設定錯誤Examples 實例:,23,Waste of Excess Inventory 過多存貨的浪費,As shown with Over-production, excess inventory requires extra cost to handle and maintain. 如過量生產一樣，過多的存貨會產生多餘的處理及維持成本 Excess inventory also covers problems in the operation 過多的存貨會掩蓋生產操作的問題
24、,原物料,成品,24,Now that we understand the different types of waste, let us go to the workplace and hunt out some real life examples. 現在我們已經了解各種不同形式的浪費，讓我們到現場，找出一些實際生活中的例子。,25,Waste Hunt Search for WASTE in all work areas 在所有的工作場所找出浪費,26,Waste Elimination Tool & Method 消除浪費 - 工具及手法,1. 刪除 eliminate：不必要的2. 合併 combine：劃分過細或重複的3. 重組 rearrange：調整先後次序4. 簡化 simplify：多餘的,
