1、MANUFACTURING TRAINING UNIT WCM Approach basic WCM 方法 基础 Fiat Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach_basic 2 1950 1980 1991-92 1986 2006 传播 丰田生产体系 （TPS ） 书 2005 2007 书 菲亚特WCM 菲亚特 汽车生 产体系 启动 2 个试点工厂获 得初步成果： Tychy （波兰） 、Melfi （意大 利） WCM 向FGA 和 集团扩展，始 于2006 年 所有FGA 工 厂参与；FPT
2、 工厂马瑞利 ；依维柯参 与 第一铜质工 厂 Shigeo Shingo 转 换成英语，传播 丰田思想 of Taichi Ohno 丰田生产体系（ TPS ）发展 精益思想 (Womack/ Jones) 改变世界的机器 (Womack/Jones) 菲亚特走出危机 ；识别利用WCM 模型建设菲亚特 汽车生产体系 施恩伯发布了世 界级制造：简化 应用的经验 KAIZEN （ 持续改善） 起源于丰田 KAIZEN 译成 英文 WCM 首次在美国 应用：通用电气 ；川崎北美等。 发现生产率差异， 日本和欧美之间差 异达40% KAIZEN 活动开始 在西方运用 通过第一个示 范区域建立信 心&
3、开始运行 JIT TQC TIE TPM 重振 菲亚特 2008 菲亚特集 团& 供应 商的FAPS FGA 其他工 厂铜质奖， 全面扩展到 供应商 FGA 银奖， 扩展到克莱 斯勒，与其 他WCM 协会 的其他公司 合作 2009 WCM 协会： 菲亚特集团 和外部公司 此模型的历史 Part 1 Part 2 Genesis and development of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM management criteria overview Part 4 Part 5 WCM in
4、FIAT Group today Audit 体系 and WCM Association 菲亚特 集团的 FAPS Fiat Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach_basic 3 方法 焦点 目标 价值 成本部署 TQC TIE TPM JIT 人员参与、价值创造、客 户满意 度 费 库 生产率 质量改进 技术效率 服务水平 全面工业工程 全面质量控制 全面生产维修 准时生产 场 质 维护 零浪费 零缺陷 零库存 1 2 3 4 零故障 WCM 框架 Part 1 Part 2 Genesis a
5、nd development of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM management criteria overview Part 4 Part 5 WCM in FIAT Group today Audit 体系 and WCM Association Fiat Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach_basic 4 Method Focus Objectives Values 成本部署 TQC T
6、IE TPM JIT 人员参与、价值创造、客 户满意 zero waste zero defects zero faults zero stocks Productivity Improvement of 质量 Technical efficiency Level of service Total Industrial Engineering Total 质量 控制 Total Productive 维 护 Just in Time 持续改进 场 质 维护 零浪费 零缺陷 零库存 1 2 3 4 零故障 WCM 框架 Part 1 Part 2 Genesis and development
7、of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM management criteria overview Part 4 Part 5 WCM in FIAT Group today Audit 体系 and WCM Association Fiat Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach_basic 5 WCM 框架 KPI: , 质 , Cost, Delivery Part 1 Part 2 Genesis a
8、nd development of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM management criteria overview Part 4 Part 5 WCM in FIAT Group today Audit 体系 and WCM Association WCM 结构 Fiat Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach_basic 6 WCM 聚焦 全体员工 浪费和损失 标准和方法 Part 1 Par
9、t 2 Genesis and development of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM management criteria overview Part 4 Part 5 WCM in FIAT Group today Audit 体系 and WCM Association Fiat Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach_basic 7 WCM 10 个基本原则 安全第一 没有标准= 没有改进
10、 工厂V.O.C. 目标= 0 WCM 是可视的 WCM是在车间建立起来的 最佳实践 参与度是WCM的助推器 严格应用 能源方面的危机 Part 1 Part 2 Genesis and development of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM management criteria overview Part 4 Part 5 WCM in FIAT Group today Audit 体系 and WCM Association Fiat Sepin all rights reserved
11、 MANUFACTURING TRAINING UNIT WCM_approach_basic 8 Reactive 应 Preventive 预 Proactive 动 Reactive Preventive Proactive WCM - 20 Pillars in 7 Steps Fiat Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach_basic 9 WCM 7 steps approach Problems are addressed at three levels: Reactive Once a
12、 problem has emerged, it is attacked and solved 应 with corrective measures Preventive Analyzing the problem and detecting its root causes, 预 specific countermeasures are taken to avoid future reoccurrence of the same problem (learn from history) Proactive Analyzing potential risks, proper countermea
13、sures are 动 taken to prevent the occurrence of a specific problem Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Reactive Preventive Proactive PROCESS IS STRENGTHEN PROCESS IS NOT CHANGED Part 1 Part 2 Genesis and development of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM mana
14、gement criteria overview Part 4 Part 5 WCM in FIAT Group today Audit System and WCM Association Fiat Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach_basic 10 WCM 支柱实施 渐进的方式 通往卓越的路的特征是复杂性逐步增加：逐步 积累经验，成功案例推广实施，更多的难题得 到解决，工厂的参与度不断扩展。 示范区域 工厂 1 3 更多的示范区域 2 目标是将WCM 扩展到整个体 系和所有流程 05_Yam
15、ashina_2_ModelArea _choice Part 1 Part 2 Genesis and development of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM management criteria overview Part 4 Part 5 WCM in FIAT Group today Audit 体系 and WCM Association Fiat Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach
16、_basic 11 WCM 改进流程 成本 质量 安全 效率 损失&浪费 源于高层 管理层 项目 大型 Kaizen 源于车间 实施 建议 快速 Kaizen Part 1 Part 2 Genesis and development of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM management criteria overview Part 4 Part 5 WCM in FIAT Group today Audit 体系 and WCM Association Fiat Sepin all rig
17、hts reserved MANUFACTURING TRAINING UNIT WCM_approach_basic 12 Measure 4M 分析 5W & 1H Pareto 图 Tools 7 步法 WCM 标准&工具 Part 1 Part 2 Genesis and development of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM management criteria overview Part 4 Part 5 WCM in FIAT Group today Audit 体系 and
18、 WCM Association 改进 知识创造 措施 Fiat Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach_basic 13 WCM implementation follows two directions Step 7 Flusso Controllato Est. 5 Supply Chain Est. 4 Plant Est. 3 100% Processi Est. 2 50% Processi Est. 1 Processo Campione Profondit Estensione Ste
19、p 1 Re-engineering Step 2 Logistica Int. Step 3 Logistica Est. Step 4 Livellamento Step 5 Affinamento Step 6 standardizz. Livello 1 Livello 5 Livello 2 Livello 3 Livello 4 Depth Extension Level 1 Level 2 Level 3 Level 4 Level 5 Ext. 1 Model process Ext. 2 50% proc. Ext. 3 75% proc. Ext. 4 plant Ext.
20、 5 Supply Chain Part 1 Part 2 Genesis and development of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM management criteria overview Part 4 Part 5 WCM in FIAT Group today Audit System and WCM Association Fiat Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach_basic
21、14 WCM 认证体系 生产 体系 KPI s $ 工具 技术标准 （方法） 管理标准 它是评估、指导、支持菲亚特先进生产体系实施并达到WCM 标准的体 系。 WCM Part 1 Part 2 Genesis and development of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM 管理标准 overview Part 4 Part 5 WCM in FIAT Group today Audit 体系 and WCM Association Fiat Sepin all rights reserve
22、d MANUFACTURING TRAINING UNIT WCM_approach_basic 15 WCM 认证体系 自评 外部审计 工厂内部进行，由管理者 跟踪 监控支柱活动的进展 由审计员对于工厂的水 平 进 行 正式认证 内部审计 工厂 3 1 2 0 3 1 2 0 Part 1 Part 2 Genesis and development of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM 管理标准 overview Part 4 Part 5 WCM in FIAT Group today Au
23、dit 体系 and WCM Association Fiat Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach_basic 16 WCM 认证评估等级 对于20 个标准的每一个，评估结果都分为5 个 等级（0-5 ） 每一个级别，都有相应的分数： 等级 1 = 1 分 等级 2 = 2 分 等级 3 = 3 分 等级 4 = 4 分 等级 5 = 5 分 工厂的整体评估有一个指标叫做方法 实施指 标（Methodology Implementation Index ，简称MII ） 得到85 或以上分数为世界
24、级水平。 Part 1 Part 2 Genesis and development of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM 管理标准 overview Part 4 Part 5 WCM in FIAT Group today Audit 体系 and WCM Association Fiat Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach_basic 17 认证标准逻辑 cost deployment cost
25、 deployment safety safety focused improvement focused improvement autonomous activities autonomous activities professional maintenance professional maintenance 1 1 2 2 3 3 4 4 5 5 logistics logistics & & customer customer service service quality control quality control early equipment/ early equipme
26、nt/ product management product management people development people development environment environment 6 6 7 7 8 8 9 9 10 10 (3) 进 FI 评 级别 0.No action There are no projects or programmes based on . All the projects are chosen ad hoc, and no atic approach or a proper method is used. 1. Reactive Site
27、 costs and losses are understood and prioritized. There is a to choose subjects for 进 but no proper cost and benefit analysis is made. There is no to horizontally expand the knowledge gained after each 进. 2. Basic techniques Based on , proper subjects for 进 have been selected. Based on the needs of
28、the 进, a proper cross- functional team is formed. Knowledge to reduce or eliminate 费 损 es is created step by step, by using propoer methods and 7 WCM tools (prioritization, atic, logical and detailed deployment of objectives, problem description with sketches, 5W + 1H with 5G principles, root causes
29、 analysis, phenomena description with sketches and TWTTP). Sketches are used extensively to visualize. Cost/benefits are known for each completed FI project (QK, SK, MK) and are tracked monthly involving the financial service department. Documented lessons/knowledge is used for training. Criteria to
30、 Evaluate Achievement Level Criteria to Evaluate Achievement Level Focused Improvement Focused Improvement 举例 Part 1 Part 2 Genesis and development of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM 管理标准 overview Part 4 Part 5 WCM in FIAT Group today Audit 体系 and WCM Association Fia
31、t Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach_basic 18 认证标准逻辑 cost deployment cost deployment safety safety focused improvement focused improvement autonomous activities autonomous activities professional maintenance professional maintenance 1 1 2 2 3 3 4 4 5 5 logistics logis
32、tics & & customer customer service service quality control quality control early equipment/ early equipment/ product management product management people development people development environment environment 6 6 7 7 8 8 9 9 10 103. Substantial KH, many FI project covering the major areas There is s
33、ubstantial knowledge to eliminate or reduce 费 损 es. Both basic and intermediate FI techniques are used extensively and routinely at all levels of the organization. 4. Advanced level, many FI projects with major Kaizen and PPA The various tools of intermediate and advanced levels such as PPA and DOE
34、are utilized to attack and solve difficult problems which have been left unattended. The lessons learned are horizontally expanded to others. From inductive to deductive approaches. 5. Involvement of everybody in FI with many, many kaizen There is a to continuously increase the in-house knowledge to
35、 reduce or eliminate all possible (and probably hidden ) 费 损 es. Advanced techniques are used, more knowledge is created. Additional losses are attacked. The knowledge is horizontally expanded. Criteria to Evaluate Achievement Level Criteria to Evaluate Achievement Level Focused Improvement Focused
36、Improvement 举例 Part 1 Part 2 Genesis and development of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM 管理标准 overview Part 4 Part 5 WCM in FIAT Group today Audit 体系 and WCM Association 世 界 级 水 平 Fiat Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach_basic 19 WCM 认证评
37、估等级 Last Audit Date Safety/Sicurezza Cost Deployment Focused Improvement Workplace Organization (AA) AM: Manutenzione Autonoma PM: Manutenzione Professionale Early Equipment Management Product Quality Control Sistema logistico di stabilimento Environment/Ambiente Internal Customer Service People dev
38、elopment Management Commitment Clarity of Objectives/Sviluppo del sistema di obiettivi (KPI) Allocation of Highly Qualified People to Model Areas Commitment of the Organization Competence of Organisation Toward Improvement Time and Budget Level of Detail Motivation of Operators IMM stabilimento mar-
39、06 0 3 0 2 1 0 2 2 1 11 Safety/Sicurezza Cost Deployment Focused Improvement Autonomous Activities (AM / WO) Professional Maintenance (PM) Quality Control Customer Service / Logistics Early Product / Equipment Management People development Environment/Ambiente Management Commitment Clarity of Object
40、ives and KPIs Route map to WCM Allocation of Highly Qualified People to Model Areas Commitment of the Organization Competence of Organisation Toward Improvement Time and Budget Level of Expansion Level of Detail Motivation of Operators 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 plant MII Ind
41、ice Implementazione Metodologie - 10 20 30 40 50 60 70 80 90 100 Indice Implementazione Metodologie - 10 20 30 40 50 60 70 80 90 100 WCM score level BRONZE BRONZE SILVER SILVER GOLD GOLD WORLD CLASS WORLD CLASS Part 1 Part 2 Genesis and development of WCM in FIAT Group WCM overview model and Loss &
42、Waste Part 3 WCM 管理标准 overview Part 4 Part 5 WCM in FIAT Group today Audit 体系 and WCM Association Fiat Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach_basic 20 WCM 认证评估等级 Indice Implementazione Metodologie - 10 20 30 40 50 60 70 80 90 100 Indice Implementazione Metodologie - 10 20
43、 30 40 50 60 70 80 90 100 WCM score level Learning & Implementation Learning & Implementation 50 50 Learning & Implementation Learning & Implementation 50 50 WCM methods and results in model areas WCM methods and results in model areas 50 50 - - 59 59 WCM methods and results in model areas WCM metho
44、ds and results in model areas 50 50 - - 59 59 Wide extension & dissemination of best practices Wide extension & dissemination of best practices 60 60 - - 69 69 Wide extension & dissemination of best practices Wide extension & dissemination of best practices 60 60 - - 69 69 Full implementation of WCM
45、 in the plant Full implementation of WCM in the plant 70 70 - - 84 84 Full implementation of WCM in the plant Full implementation of WCM in the plant 70 70 - - 84 84 World Class in KPIs: S, Q, C and D via external benchmarking World Class in KPIs: S, Q, C and D via external benchmarking 85 85 - - 10
46、0 100 World Class in KPIs: S, Q, C and D via external benchmarking World Class in KPIs: S, Q, C and D via external benchmarking 85 85 - - 100 100 BRONZE BRONZE SILVER SILVER GOLD GOLD WORLD CLASS WORLD CLASS Part 1 Part 2 Genesis and development of WCM in FIAT Group WCM overview model and Loss & Was
47、te Part 3 WCM 管理标准 overview Part 4 Part 5 WCM in FIAT Group today Audit 体系 and WCM Association 学习& 实施 广度& 最佳实践 传播 示范区WCM 方法& 结果 WCM 工厂全面推广 KPI 达到世界级 ：外部标杆对比 S/Q/D Fiat Sepin all rights reserved MANUFACTURING TRAINING UNIT WCM_approach_basic 21 授予要求 安全: level 2 AA: level 2 PM: level 1 QC level 1 L &
48、CS level 1 PD level 2 E level 2 安全: level 3 AA: level 3 PM: level 2 QC level 2 L & CS level 2 PD level 3 E level 3 安全: level 4 AA: level 4 PM: level 3 QC level 3 L & CS level 3 PD level 4 E level 4 安全: level =5 AA: level =5 PM: level 4 QC level 4 L & CS level 4 PD level = 5 E level = 5 50 分 60 分 70 分 85 分 Part 1 Part 2 Genesis and development of WCM in FIAT Group WCM overview model and Loss & Waste Part 3 WCM 管理标准 overview Part 4 Part 5 WCM in FIAT Group today Audit 体系 and WCM Association
