1、Standardization 标准化,员工参与,标准化,制造质量,缩短制造周期,持续改进,Quality Feedback/ Feed- forward,Standardized Work,Visual Management,Work- place Organization,Problem Solving,Continuous Improvement Process,Total Productive Maintenance,Scheduled Shipping / Receiving,Supply Chain Management,InternalPull / Delivery,Simple
2、 Process Flow,Temporary Material Storage,Fixed Period Ordering System/Order Parts,Team Concept,People Involvement,Open Communication Process,Standardization 标准化,Vision/ Mission,Management by TAKT Time,Shop Floor Management,Qualified People,Product Quality Standards,Quality System Management,Lean Des
3、ign of Facilities,Equipment, Tooling and Layout,Early Mfg. and Design Integration (DFM / DFA),Small Lot Packaging,Controlled External Transportation,Standardization标准化,What is it? 是什么？ Group Discussion小组讨论,Standardization is a dynamic process by which we set standards of terminology, principles, met
4、hods, and processes within our organization. 标准化是指在我们的组织内部对各种术语、原则、方法及工艺建立标准的动态过程。,Definition of Standardization 标准化的定义,Standardization 标准化,The purpose of standardization is to reduce variation and stabilize, so as to achieve a base from which to grow and improve. 标准化的目的是减少变化与维持稳定，在此基础上进步与提高。,Purpos
5、e of Standardization 标准化的目的,Standardization标准化,Standardization 标准化,Why Is Standardization Important? 为什么标准化很重要？,SAFETY 安全,QUALITY 质量,COMMON DIRECTION 共同方向,PRODUCTIVITY 产量,What Happens When We Do Not Have Good, Clear Standards? 若没有良好、明晰的标准会怎样？,Example: 2000 U.S. Presidential Elections: Variation in V
6、oting Machines & Methods Caused Major Election Controversy,事例：2000年美国总统大选： 投票机器与方式的不一致导致重大选举纷争,Standardization 标准化,“THE WEDGE” TO STABILIZE BEST PRACTICE “楔子”楔牢最优方法,Continuous Improvement 不断改进,Change 改变,Standardization 标准化,A Standard Is The Best Current Practice Based On Many Peoples Experience & Le
7、ssons Learned, so 标准是基于多数人的经验教训得来最优现行方法，所以,DONT SHORTCUT THE STANDARD! 切勿缩短标准！,BAD THINGS COULD HAPPEN, ESPECIALLY SAFETY & QUALITY PROBLEMS 不良的事故会发生，尤其是安全及质量问题。,IF YOU DONT LIKE THE STANDARD, TRY TO CHANGE IT, BUT NEVER SHORTCUT IT. 若你不满意这个标准，试着改变它，切勿走捷径。,Standard,Shortcut,What Happens When We Do N
8、ot Follow Standards? 如果不遵照标准会怎样？,EVERY YEAR PEOPLE DIE FROM NOT FOLLOWING LOCK-OUT PROCEDURE,U.S SUBMARINE HITS JAPANESE FISHING BOAT - SURFACING PROCEDURE NOT FOLLOWED,EXXON VALDEZ OIL SPILL CAPTAIN DID NOT FOLLOW STANDARDS,GERMAN PLANE CRASHES IN SWITZERLAND AIR TRAFFIC CONTROL PROCEDURES IGNORED,
9、每年都有人死于不遵循关阀规定,美国潜艇击沉不遵守海面规定的日本渔船,德国忽视空中飞行条例在瑞士坠毁,船长不遵循标准导致EXXON 瓦尔迪兹石油泄露,STANDARDIZATION EXERCISE 标准化练习,Think of any example inside or outside work where standards not being followed led to a bad situation 想想工作中或其它不遵守标准导致不良事件发生的例子。Discuss as a team and report Take 5 minutes 小组讨论、汇报-5分钟,Always Remem
10、ber The Priorities 牢记的重点,Safety 安全 People 员工 Quality 质量 Responsiveness 响应 Cost 成本,Importance 重要,For Example, Sometimes We Have To Sacrifice Efficiency To Achieve Safety,例如：有时我们必须为了安全而牺牲效率,MAKE RULE 制订条例TEACH RULE 讲授条例KEEP RULE 遵守条例,DO THE RIGHT THING! 做合理的事情,LEAD BY EXAMPLE! 榜样领导,Standardization On
11、A Broader Scale Leads to Communization更大范围的标准化以达到共有化,One “Language” 同一语言Common Principles 通用原则Common Methods 通用方法Common Processes 通用程序,Standardization vs. Commonization 标准化与共有化,If one family made a recipe for their Kimchi, then it would be Standardized. 如果一个家庭为其泡菜定个菜谱，就是标准化。But all families are stil
12、l different so we are not Commonized (sometimes common is not appropriate). 但是每个家庭做法不一样则没有达到共有化。（有时共同的并非是正确的）,Manufacturing Process Validation,In-Process Control & Verification,Visual Management,Management by TAKT Time,Problem Solving,Continuous Improvement Process,Total Productive Maintenance,Level
13、 Vehicle Order Schedules,Supply Chain Management,Temporary Material Storage,Health and Safety Priority,People Involvement,Values,Vision/ Mission,Shop Floor Management,Standardization 标准化,Early Mfg. and Design Integration (DFM / DFA),Lean Design of Facilities,Equipment, Tooling and Layout,Scheduled S
14、hipping / Receiving,Workplace Organization 工作场地布置,What is it? 指什么？ Group Discussion 小组讨论,WPO Motto: 工作场地布置口号 “A place for everything and everything in its place” 所有工作的场地，所有工作井井有序。,Workplace Organization, 5S 工作场地布置, 5S,Put order to the workplaceby making Standards that allow“out-of-standard” conditio
15、nsto be visible! 制定标准使工作场地井井有序， 并使非标准的东西暴露出来。,Where is Workplace Organization Important?哪些工作场地布置重要？,On the shop floor. . . 车间地面. . . in the office! 办公地点,How is workplace organization done? 怎样布置工作场地？,Workplace Organization 工作场地布置,5S,5 Self Discipline/Cont. Improvement 不断改进,4 Sustain/Maintain 维护,2 Sor
16、t/Standardize 整顿,1 Sift/Clear 整理,3 Sweep/Clean 清扫/清洁,Sift/Clear 整理,Divide the needed and not needed items at the job site, and quickly remove the unneeded items.区分开工作场所中必要和不必要的东西，迅速将不必要的东西清除。Areas of Focus 重点区域,Tools工具,2) Inventory/Storage库存/储存,3) Equipment 设备,Keep needed Items 保留必要东西,Remove unneede
17、d Items (waste) 清除不必要东西（废料）,The Most Difficult thing for us to do 这是最难做到的,1 Sift/Clear (),Red Label Campaign,Sift/Clear 整理,1 Sift/Clear (),If In Doubt Throw It Out! 毫不犹豫扔掉,Sort/Standardize 整顿,A Place for everything . . . and everything in its place 所有工作的场地，所有工作井井有序。The location of equipment, tooling
18、 and material should be clearly defined, displayed and maintained. 各种设备、工具、材料明确区分，放置，维护。,L850 Hose30 pcs.,Small Bolts小螺栓 700 pcs,Med. Bolts中等螺栓 500 pc.,Large Bolts大螺栓 300 pcs.,L850Rubber Hose 橡胶管,2 Sort/Standardize (),1 Sift/Clear (),Sort/Standardize 整顿,Make A Standard! 制定标准,2 Sort/Standardize (),1
19、Sift/Clear (),Sweep / Clean 清扫/清洁,3 Sweep (),2 Sort (),1 Sift (),“Sweeping” is checking! 清扫既是检查！,Check,Sustain/Maintain 维护,Identify Tasks 确定任务 Assign Responsibility 划分责任 Set Targets 设定目标,Safety/5S Checks Must Be Performed Everywhere and At Every Level Of The Organization! 安全/5S检查应该人人处处开展！,Standards
20、are worthless if there is no system to check! 如果没有系统检查， 标准即毫无用处。,Self-Discipline/ Continuous Improvement 自律/不断改进,5 Self Discipline/Cont. Improvement 自律/不断改进,4 Sustain/Maintain 维护,2 Sort/Standardize 整顿/标准,1 Sift/Clear 整理,3 Sweep/Clean 清扫/清洁,It is everyones responsibility! 这是每个人的职责！,5S EXERCISE5S练习,Ho
21、w would you use the 5S process to improve the situation below?你怎样用5S程序来改善下图的情形？Utilize ALL 5Ss 利用所有5S程序Discuss as a team and report Take 10 minutes 小组讨论、汇报10分钟,5S EXERCISE,INSERT WORKSHEET 插入工作表,Anything outside the standard is WASTE! 所有标准外的东西都是浪费！,WPO is a key means of visualizing and eliminating w
22、asteWPO是暴露及消除浪费的主要途径,Why workplace organization? 为什么要场地布置？,Why workplace organization? 为什么要场地布置？,Example of Cabinet 5S橱柜5S范例,Cabinet “Before 5S” 5S之前的橱柜,Cabinet “After 5S” 5S后的橱柜,Example of 5S,Manufacturing Process Validation,Quality System Management,In-Process Control & Verification,Visual Managem
23、ent,Andon Concept,Problem Solving,Continuous Improvement Process,Business Plan Deployment,Total Productive Maintenance,Controlled External Transportation,Scheduled Shipping / Receiving,Level Vehicle Order Schedules,Supply Chain Management,Simple Process Flow,Temporary Material Storage,Health and Saf
24、ety Priority,People Involvement,Values,Vision/ Mission,Shop Floor Management,Standardization 标准化,Lean Design of Facilities, Equipment, Tooling and Layout,Early Mfg. and Design Integration (DFM / DFA),Standardized Work 标准化工作,The documented, current best methodto Safely and Efficiently perform worktha
25、t meets the necessary level of Quality. 为了达到一定的质量标准，以文件化 及最可行的方法来安全有效地开展工作,Without Standardization 没有标准化,With Standardization 有了标准化,Standardized Work 标准化工作,Standardized Work 标准化工作,Standardized work is used when there is a definable, repeatable process. 当工序明确可重复时，采用标准化工作,Standardized Work Can Be Perf
26、ormed Everywhere! 随处都可以开展标准化工作!,Everyone can perform standardized work! 每个人都可以进行标准化工作！,Employees Should Be Involved In Developing Standardized Work They Know The Job The Best! 员工应该加入标准化工作开展因为他们最了解工艺！,Standardization 标准化,Improvement 改进,Standardized Work (标准化工作),Standardized Work Is A Baseline for Con
27、tinuous Improvement! 标准化工作是不断改进的基线 ！,Standardization 标准化,Standardization 标准化,Standardization 标准化,Improvement 改进,Improvement 改进,Each Individual Has Good Ideas If We Do Not Document The Best Methods Then We Are Not Fully Utilizing The Teams Brainpower and We Will Never Improve Or We May Actually Get W
28、orse! 每个人都有好主意如果我们不把最好方法文件化，则不可能充分利用团队的智能，不但不能取得进步，甚至会越来越糟糕！,Would You Want To Get Into A Plane Where The Crew Did Not Exactly Follow A Standardized Check Process? Even Though They Have Performed It Hundreds Of Times! 你会不会乘坐乘务员不履行标准检查程序的检查的飞机？-即使他们重复操作过无数遍。,Check Fuel (检查汽油) Check Tires (检查轮胎) Check
29、 Instruments (检查仪表盘),Continuous Improvement,Standardization,There Is a Real Balance Between Standardization and Continuous Improvement. 标准化与不断改进之间有个天平。 We Must Control TheBalance to Be Sure That We Are Neither to Strict With Standardization, Nor Too Flexible.我们必须控制这个天平以确保 既不要死守也不要脱离标准化,BUT,Lego Exer
30、cise,Standardized Work Basics,Cycle Time,001L,Actual Takt Time,5”4”3”2”1”,Time,Standardized Work Basics,Make Waste Visible!暴露浪费！,Work Flow Diagram 工作流程表,Time Chart 时间表,Waste of Motion! 动作浪费,Non-Value Added!非增殖时间,Value Added 增殖时间,Wait Time! 等待时间,Provides an overview of the elements and their times in
31、 the correct sequence for one job,Identifies important key points using symbols,Ensures standard across shifts via sign-off,Documents changes to the Standardized Work,Documents work location,Visualizes worker movement via sketch.,Symbol,MOVING LINE STANDARD OPERATION SHEET,Group / team,JOB NAME,Oper
32、ation:,S,Element Name,y,s,Work,m,t,element,b,e,Registered,Handwork/Model,o,p,Number,l,Total handwork / walking by model sec.,Cycle time sec.,Volume %,Weighted average,Return,Walk,(R3) (R2),(R4),(IR),(L3),(L1),(L4),(R1),(L2),(IF),(E),(CF),(CR),(T),C,Quality,Checks,Safety for Operator,Critical,Process
33、,for,CR,T,L4,IR,L3,IF,L2,L1,CF,E,SUB,MAT,Location LH,Frequency,CR,T,R4,IR,R3,IF,R2,R1,CF,E,SUB,MAT,Location RH,Frequency,Cycle Time Chart,weighted average cycle time,Option or Model,Time,Volume %,s,Walk Time,walking,Actual Takt Time,Signature Team Ldr Superv. Shift Mgr.,Shift A Shift B Shift C,Revis
34、ions,Mo./Yr.,Sign.,What Change,Confirmation of Adherence,Date,Signature,Visualizes A.T.T. Vs. Cycle Times of the job via the Cycle Time Chart,Elements Of Good Standardized Work ( ),Symbol,MOVING LINE STANDARD OPERATION SHEET,Group / team,JOB NAME,Operation:,S,Element Name,y,s,Work,m,t,element,b,e,Re
35、gistered,Handwork/Model,o,p,Number,l,Total handwork / walking by model sec.,Cycle time sec.,Volume %,Weighted average,Total,Return,Walk,(R3) (R2),(R4),(IR),(L3),(L1),(L4),(R1),(L2),(IF),(E),(CF),(CR),(T),C,Quality,Checks,Safety for Operator,Critical,Process,for,CR,T,L4,IR,L3,IF,L2,L1,CF,E,SUB,MAT,Lo
36、cation LH,Frequency,CR,T,R4,IR,R3,IF,R2,R1,CF,E,SUB,MAT,Location RH,Frequency,Cycle Time Chart,weighted average cycle time,Option or Model,Time,Volume %,s,Walk Time,walking,Actual Takt Time,Signature Team Ldr Superv. Shift Mgr.,Shift A Shift B Shift C,Revisions,Mo./Yr.,Sign.,What Change,Confirmation
37、 of Adherence,Date,Signature,Elements Of Good Standardized Work 标准化工作要素,Use as basisfor training& Problem Solving 作为培训 问题解决的基点,Must supportthe user & beposted visually 有利于操作者或张贴 到明显处,User involvedin development 操作者参加改进,Always respectStd. Work of others 尊重他人的标准化工作,Perform regular checksof Std. Work 定
38、时检查 标准化工作,Final Notes on Standardized Work 标准化工作后注,Final Notes on Standardized Work 标准化工作后注,The True Test of Good Standardized Workis When Someone Does Not Come to Work and the Job Still Gets Done Safely, Efficiently and with Quality 真正经得检验的标准化工作是当有人缺席时仍能 安全、有效、高质地完成工作,What Do I Do?,Quality System M
39、anagement,In-Process Control & Verification,Quality Feedback/ Feed- forward,Standardized Work,Visual Management,Work- place Organization,Andon Concept,Problem Solving,Business Plan Deployment,Total Productive Maintenance,Scheduled Shipping / Receiving,Level Vehicle Order Schedules,Supply Chain Manag
40、ement,InternalPull / Delivery,Simple Process Flow,Temporary Material Storage,Fixed Period Ordering System/Order Parts,Health and Safety Priority,Team Concept,Values,Vision/ Mission,Shop Floor Management,Standardization 标准化,Early Mfg. and Design Integration (DFM / DFA),Lean Design of Facilities, Equi
41、pment, Tooling and Layout,Controlled External Transportation,Continuous Improvement Process,Takt Time =,Number of vehicles required per time period 此阶段需要生产台数,Weekly 周 Monthly 月 Yearly 年,Takt Time is Constant! TAKT TIME是不变的！,Takt Time: Determines the speed of the line 决定流水线速度 The time available to pr
42、oduce a component or single unit.生产一个部件或一辆车的时间 Determined by the number of vehicles required by the end of each day to meet the production target.由需要达到的每日生产目标的车辆数决定,Operational Time Per Period 某阶段生产时间,Management By Takt Time Takt Time管理,I Love Lucy Video Part II ,I Love Lucy,(Start video at Chocolat
43、e Assembly Line)录象从巧克力的生产线开始,I Love Lucy Video Part II Group Discussion 小组讨论,What GMS Standardization Principle concepts did we (not) see in the video? 在录象看到或没看到哪些GMS的标准化原则Discuss as an open forum not by teams 论坛讨论非小组讨论,I Love Lucy Video Discussion,What did we see in the video: 从录象可我们看到： Lack of Sta
44、ndardized Work: 缺乏标准化工作No documented standardized work on job 车上没有标准文件化No standardized work to use as basis for training 没有标准化工作作为培训基础No quality standard for completed chocolate 巧克力做完后没有质量标准Lack Of Management By Takt Time: 缺乏生产节拍管理 Takt Time arbitrarily changed 主观改变生产节拍No communication or planning of Takt Time change生产节拍改变没有协商或计划No visual indication of workstation beginning and end 从头到尾都没有工位的目视化标识Others:No way to call for helpNo way to stop line or prevent defects from leaving station,
