施耐德电气公司精益生产体系流程评估标准课件.ppt

1、FLV&IC SPS Deployment Dept. page 1SPS Assessment trainingG&I / Industrial DeploymentSchneider Production SystemSPS Assessment Training (FLV & IC)FLV&IC SPS Deployment Dept. page 2SPS Assessment trainingIcons & meaningsExplanationChecking pointGood exampleBad exampleQuestionFLV&IC SPS Deployment Dept

2、. page 3SPS Assessment training1SIM PRODUCTION4PROCESS ARCHITECTURE / LEAN DESIGN8 PRODUCTION PLANNING & SCHEDULING1AWork Instructions4AManufacturing Time Definition8AMaster Production Scheduling1BShort Interval Production & Quality Tracking4AManufacturing Time Definition (auto workshop /line)8BCDO

3、/ OFO Process1CSIM Production Implementation4BProcess Design / Lean Concept8BQueue Management2SIM SUPPORT FUNCTION4DLate Differentiation / Adaptation8CInventory management2ASIM Support Functions Implementation5ERGONOMICS / ENVIRONMENT - BAT9PULL PRODUCTION2BSIM Support Functions Efficiency5AB Ergono

4、mics / Work station9ASingle Point Scheduling / Pull system2CSuggestion System / Needs Expression Board5CEnvironment - BAT9BSingle Piece Flow Assembly / WIP Management3CONTINUOUS IMPROVEMENT in peoplecommitment5DSafety9CKANBAN Methodology3AOperator Flexibilty6MATERIAL HANDLING9DValue Stream Managemen

5、t3B Versatility & Multi skills Training6AReception / Warehouse Architecture10SUPPLY CHAIN & QUALITY MANAGEMENT3C 5 S6BMPAH Material Providing and Handling Internal10A Supplier Quality Management3DVisual Management / Communicaton Boards6CWater Spider10B Supply Chain (upstream) Management7CONTINUOUS I

6、MPROVEMENT in processengineering10C Down Stream Supply Chain Management7APoka-Yoke10D Shared Quality Management7BChangeover Time Minimization10E Customer Focus7CLean Six SigmaKaizen (See/Do)7DTotal Productive Maintenance7EProcess Control (Part - Product)PEOPLE COMMITMENTPRODUCT / PROCESS ENGINEERING

7、MANAGEMENT OF MANUFACTURING &LOGISTICAL PROCESSESIntroduction: 3 Domains,10 Categories, 38 LinesFLV&IC SPS Deployment Dept. page 4SPS Assessment trainingn1 SPS Notion1. Work instructions exist for: a. Manufacturing. b. Quality.Standard work has been defined for each station2. Work instructions for S

8、afety (based on risk analysis) are posted. (instruction board / workstation). Safety instruction could be combined with other work instructions, it must be posted (for critical machines/stations)Observe whether the operator respects the safety instructionsn2 SPS Basic3. Operators were trained using

9、the work instructionsAsk the trainers how they fulfill the training tasksCheck with the operators4. Operators understand the work instructions: a. Safety b. Quality c. ManufacturingThese 3 kinds of instructions should be posted on the workstationsAsk the operators whether they know the different wor

10、k Instructionsdo they understand the meanings of the work Instructions People Commitment - SIM Production 1a - Work Instructions - P1 - QFLV&IC SPS Deployment Dept. page 5SPS Assessment trainingn3 SPS Standard5. Work instructions are visual Work instructions are easy to be understood, Avoid long sen

11、tence, with favor drawings / chart, colorful picturesAcceptance criterias are clearly defined.6. Workstation instructions also include maintenance information and change over information (if applicable)Two files are concerned: procedure of variant changing & maintenance check list (with the task and

12、 frequency)They should be posted in instruction book in the U-cell7. Work Instructions are respected (followed)Observe the motion of the operator and check with the instructions n4 SPS Advanced8. There is a standard process, known by the operator, to follow when a defect is detected (may include sig

13、nal device, empowerment to stop the line, call the Supervisor)Decision making procedure should be available for operator at cell levelCheck with operatorsPeople Commitment - SIM Production 1a - Work Instructions - P1 - QFLV&IC SPS Deployment Dept. page 6SPS Assessment trainingnFocus on: Work Instruc

14、tions available at workstation / cell / sector nKey points: 5 main Work Instructions (in order of priority)vSafety (for critical machine/stations)vQuality, Process flow chart with Quality check point.vOperations / Line Driving vPreventive Maintenance / Maintenance (for critical machine/stations)vCha

15、nge Over & Management instructions (versatility chart, 5S)Why we need Work Instructions?vTo train operatorsvTo check the operators on the main rules to follow, especially Safety & QualityvTo understand the Global Process (Flow-Chart)Work Instructions must bevKnown & respected vSimple and Visual: can

16、 be seen at the workstation, avoid long sentences, use favor drawing, easy to understand and acceptance criterias are clearly defined. vKeep UpdatedAudit in workshopPeople Commitment - SIM Production 1a - Work Instructions - P1 - Q 1 - SPS Notion 2- SPS Basic 3- SPS Standard 4 - SPS Advanced 5 - SPS

17、 Expert1. Work instructions exist for: a. Manufacturing. b. Quality2. Work instructions for Safety (based on risk analysis) are posted. (instruction board / workstation). 4. Operators understand the work instructions a. Safety b. Quality c. Manufacturing8. There is a standard process, known by the o

18、perator, to follow when a defect is detected (may include signal device, empowerment to stop the line, call the Supervisor)5. Work instructions are visual 9. Operators are routinely participating in determination of new standardized work and definition of work instructions 10. Work instructions are

19、100% visual7. Work Instructions are respected (followed)3. Operators were trained using the work instructions 11. Work instructions are continuously improved 6. Work station instructions also include maintenance information and change over information (if applicable)FLV&IC SPS Deployment Dept. page

20、7SPS Assessment trainingPeople Commitment - SIM Production 1a - Work Instructions - P1 - Qn4 SPS Advanced (continued)9. Operators are routinely participating in determination of new standardized work and definition of work instructions Operators are Involved when re-thinking the system and generatin

21、g ideas for improvementAsk the operators: Do they have suggestions to improve quality, to reduce the waste?How do they submit the suggestions? is there a formal procedure to follow ?visual work instructionsn5 SPS Expert10. Work instructions are 100% visual 11. Work instructions are continuously impr

22、oved FLV&IC SPS Deployment Dept. page 8SPS Assessment trainingPeople Commitment - SIM Production 1b - Short interval production tracking - P3 - Q 1 - SPS Notion 2- SPS Basic 3- SPS Standard 4 - SPS Advanced 5 - SPS ExpertnFocus on: Production trackingnKey points: Quality & efficiency tracked hourly

23、by operatorPareto analysis for defects and wastes is routinely done and updated (daily, weekly, monthly)“5 why” is used to identify the root causeRecurrence of defects are tracked and analyzedActions are efficientnKPIs: MDR - KE - IE - NEEAudit in workshop1. Production Tracking - Good Parts and Defe

24、cts Numbers - is implemented per shift by the operators 3. Production is tracked hourly by the operators (or coherent defined event cycle) 5. Production tracking includes a Red-Green breakdown and the top 3 causes of red.6. Process and component defects are tracked as a key indicator. 7. Quality def

25、ects are analyzed and Countermeasures (containment and/or corrective action) are conducted within the current shift 8. Complex issues are addressed through Six-Sigma or Kaizen9. Pareto analysis of quality issues and waste is routinely done and updated . 10. At least 80% of the difference between red

26、/green is explained down to root causes. 11. Corrective action results lead to a recurrence analysis of defects (defect types are tracked and recorded in a log file)4. At the beginning of each shift, there is a review with operators of issues and objectives related to: a) production; b) quality; and

27、 c) barriers 2 Operators are aware of current and potential process and component quality defects related to each product range FLV&IC SPS Deployment Dept. page 9SPS Assessment trainingn1 SPS Notion1. Production Tracking - Good Parts and Defects Numbers - is implemented per shift by the operators Pr

28、oduction tracking (include quantity and quality) done by operator per shiftCheck at cell level2. Operators are aware of current and potential process and component quality defects related to each product range Operators are aware of quality defects related to each product rangeDefects are listed by

29、QC (ex. Different code means different defects) Check with operators n2 SPS Basic3. Production is tracked hourly by the operators (or coherent defined event cycle)Production tracking (include quantity and quality) done by operator hourlyIf TT0.5H, the interval operator recorded should equal to TT Ch

30、eck the SIM sheet at cell level4. At the beginning of each shift, there is a review with operators of issues and objectives related to: a) production; b) quality; and c) barriers Observe in the workshop to check:Is there a meeting with operators at the beginning of shift? What kind of topics reviewe

31、d in this meeting?People Commitment - SIM Production 1b - Short interval production tracking - P3 - QFLV&IC SPS Deployment Dept. page 10SPS Assessment trainingPeople Commitment - SIM Production 1b - Short interval production tracking - P3 - Qn3 SPS Standard5. Production tracking includes a Red-Green

32、 breakdown and the top 3 causes of red.Red-Green breakdown should done according to SPSTop 3 causes of red should be analyzed daily 6. Process and component defects are tracked as a key indicatorFor the process defects, it tracked as First Pass Ratio, etc.For non quality part, Scrap, its calculated

33、in NQC.Check with line leader and QC engineer.7. Quality defects are analyzed and Countermeasures (containment and/or corrective action)are conducted within the current shiftInformation on the Quality issue includes the following items: what has happened/ what is the root cause/ what is the counterm

34、easure -containment and/or corrective action-/ who is responsible / whenThe analysis must be based on comparison -good part/bad part, operator 1/operator 2, day 1/day2,.- and factsAction effectiveness is verified by the line leader/supervisorCheck with the line leader/supervisor-109,523101,49281,147

35、85,4188,0312,0001,8897,4334,7524,271-20,00040,00060,00080,000100,000120,000UTCyclic / Fre.DTPV ActivityExternal toprocessNon qualityUncertaintiesOTDVC support(NPV)TSRed/Green breakdown according to SPSFLV&IC SPS Deployment Dept. page 11SPS Assessment trainingPeople Commitment - SIM Production 1b - S

36、hort interval production tracking - P3 - Qn4 SPS Advanced 8. Complex issues are addressed through Six-Sigma or KaizenSix-Sigma is focus on reducing variability to reach a performance on a processKaizen is focus on eliminating waste on the whole product flow9. Pareto analysis of quality issues and wa

37、ste is routinely done and updated Pareto analysis of quality issues and waste done and updated at least done weekly10. At least 80% of the difference between red/green is explained down to root causesUse “5 why” to find the root causesFLV&IC SPS Deployment Dept. page 12SPS Assessment trainingPeople

38、Commitment - SIM Production 1b - Short interval production tracking - P3 - Qn5 SPS Expert11. Corrective action results lead to an recurrence analysis of defects (defect types are tracked and recorded in a log file)Defects and non conformities are tracked and recorded by defect type in a log file. Th

39、is is the only way to make sure the have been eradicated by the corrective actions. This log file must be displayed on the information board of the production cell-50050100150200250300JanFebMarAprMayJuneJulyAugSepOctNovDecJanm o n th snumbers of defects/issuesD efect 1D efect 2D efect 3Recurrence of

40、 defect 2!FLV&IC SPS Deployment Dept. page 13SPS Assessment trainingPeople Commitment - SIM Production 1c - SIM Production implementation - P4, P10 1 - SPS Notion 2- SPS Basic 3- SPS Standard 4 - SPS Advanced 5 - SPS ExpertnFocus on: SIM Production implemented and respected the plant event cycle.nKe

41、y points: Operators are involved in SIM Production (beginning / end of shift)vObjectives DefinitionvResults / Barrier Log & Suggestion system managementvSafety & 5S ManagementSupport functions are involved in SIM Production vResults Analysis / Indicators ReviewvBarrier Log Management vAction Plan Ma

42、nagement / Escalation systemAudit in workshopAttend the daily SIM meeting1. SIM Production concepts (SPS Model) are partially implemented2. Plant Event Cycle (frequency, contributors, deliverables) is known by everyone in production 3. SIM Production is led (required by and participated in) by the P

43、lant Manager 4. Cell / Product Sector short interval cycles and frequency are respected according to SPS5. The manager and his team respect the frequency and duration of the event cycle6. Support function s members (Methods , Materials, Logistics , Maintenance , Quality, Engineering ) participate in

44、 SIM Production meetings 7. Internal KPIs particular to the product or process have been established and are tracked.8. The shift supervisor manages the action plans and posts them 9. Evidence of dynamic management of the action plans: a) followed up, b) on time, c) evidence of success.10. Human res

45、ources facilitate and Assess the SIM Production11. Each manufacturing sector consistently reach ones KPIs objectives. 12. Internal KPIs show sustained improvement over a 12 months periodnKPIs: Output : Realized - Forecasted Safety + 5S Quality : Service Level - MDR Efficiency : KE/IE NEE/OEEBarrier

46、Log + Action PlanFLV&IC SPS Deployment Dept. page 14SPS Assessment trainingPeople Commitment - SIM Production 1c - SIM Production implementation - P4, P10 n1 SPS Notion1. SIM Production concepts (SPS Model) are partially implementedThere are regular SIM meetings in productionCheck with operators, li

47、ne leaders, production manager2. Plant Event Cycle (frequency, contributors, deliverables) is known by everyone in production Plant event cycle are established include frequency, contributors, deliverables SPS SIM event CyclesFLV&IC SPS Deployment Dept. page 15SPS Assessment trainingn2 SPS Basic3. S

48、IM Production is led (required by and participated in) by the Plant Manager Ask plant manager whether he know the plant event cycle, does he/she attend the SIM daily meeting (once per week)Check with production manager4. Cell / Product Sector short interval cycles and frequency are respected accordi

49、ng to SPSThere are shiftly, daily, weekly meeting according to SPSCheck with operators, line leaders/supervisors, production manager5. The manager and his team respect the frequency and duration of the event cycle SIM meeting at fixed time with the fixed durationCheck with line leaders / supervisors

50、, and observe the daily meeting.n3 SPS Standard6. Support function s members (Methods , Materials, Logistics , Maintenance , Quality, , Engineering ) participate in SIM Production meetingsObserve the daily meeting and check with the participates.7. Internal KPIs particular to the product or process