1、1 Lean Hand Book 精益生产手册精益生产手册 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 Improv
2、ement 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 好的加倍 Halve the Bad 坏的减半 Double the Speed 改善速度加倍 Kaizen Workshop Goal 改
3、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 标准在线库存定义标准在线库存定义 d) Cycle time defined 周期时间定义 e) No of operators
4、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(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 Elem
5、ents 3项关键要素 4 3 Types of Standard Works 3种标准作业 Takt Time节拍时间Sequence顺序Standard WIP标准在制品1YFew很少YYYNSWCSSMT2Few很少YYYYNWork Load Leveling Chart/SWCSHand Load Assembly手动作业装配Work Standard作业标准3YYNNYYAndon异常报警系统Receiving,Water Spider,HR,Testing收货，水蜘蛛，HR，测试Signal Trigerring信号触发Examples例子Elements 要素Standard
6、Work标准作业Type类型Machine机器Man人Tools工具5 3 Types of Standard Works 3种标准作业种标准作业 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
7、作业方式。 Type 3 : Standard Work (also 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
8、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 calculation shall display all the variable and units to make cl
9、arity 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。 sec 2792,0001,584,000pcs 792,000s 3600 x days 20 x Hours 22 Demand Customer Time AvailableTime Takt?客户需求有效时间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 P
10、rocess 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 per one PCB panel. The Process Takt Time will be ever
11、y 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
12、 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 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 pa
13、nel 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 1.Standard WIP 标准WIP 2.Process WIP 制程WIP 3.Process To Process WIP 制程与制程间WIP 4.Station To Station WIP 工位与工位间WIP 10 What is Standard WIP 什么是标准WIP ? WIP means IN
14、VENTORY. INVENTORY is Basically bad. WIP就是库存。库存从根本上说是“不好”的。 ? Standard 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
15、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
16、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： 1.Separation between machine job and man job 区分机器作业和手动作业 2.Ensures quality requirements 确保质量要求 3.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
17、 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WI
18、P，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)
19、达成，在建立标准作业前，标准WIP是机器和制程强制的WIP。 13 What is Standard WIP 什么是标准WIP Process WIP 制程WIP ?WIP within same process with low variation of cycle time 同一个制程中的 WIP，周期时间CT变化很小 ?It is all that WIP in the same process, not categorized as Standard WIP or PTP WIP. 所有在同一个制程中的 WIP，不是标准 WIP或制程间WIP. ?Example:- 例如 Before
20、 Kaizen, Manual Insert (MI) Line Process WIP =9 pcs. After Kaizen MI Process WIP is 3. Standard WIP for each station is 1pc. 改善前，插件拉的制程WIP=9 pcs。改善后插件拉制程WIP=3pcs。每个工位的标准WIP为1pcs. T.T 60 sec 51 45 58 43 Person Time A B C D T.T 60 sec 60 60 60 12 Person Time A B C D variance After Before Process WIP =
21、 3, Standard WIP = 1 Process WIP = 9, No standard WIP 14 What is Standard WIP 什么是标准WIP Process To Process WIP (PTP WIP) 制程间WIP ? WIP between 2 different processes with big gap cycle time 两个周期时间相差很大的不同制程间的WIP. ? PTP WIP Is needed due to changeover in upstream line. 上游制程需要 转拉，则需设定制程间WIP. ? Not All lin
22、e need PTP WIP . 不是所有产线都需要制程间 WIP. ? If Cycle time of Upstream Process is Less then Down stream process 如果上游制程的周期时间小于下游制程的周期时间 Example 1:- SMT Cycle time (30 sec) Less then Manual Insertion (60 sec) 例1： SMT周期时间(30 sec)小于MI插件周期时间 (60 sec) CT (Upstream process) Need PTP WIP 需要制程间WIP ? If Cycle time Up
23、stream process is Equal or greater then Down stream process, No PTP WIP required. 如果上游制程的周期时间大于或等于下游制程的周期时间，不需要制程间WIP. 节拍时间前工序机器转拉时间制程间Time Takt Machine Previous of Changeov er WIP WIPProcess to Process?15 What is Standard WIP 什么是标准WIP Process To Process WIP 制程间WIP 节拍时间前工序机器转拉时间程间制Time Takt Machine
24、Previous of Changeov er WIP WIPProcess to Process?Example 2:- Process A cycle time 15 sec. It is faster then Process B cycle time 25sec. Process A is running 2 product models as capacity requirement. In order to Keep Process line running, process to process WIP is required between Process A and B. T
25、he calculation as below:- 例2： 制程A周期时间是 15sec，比制程周期时间 25sec快。制程A根据生产能力需求，需要生产 2种产品。为了保证产线正常运作，需要在制程A和制程B之间设定制程间 WIP。计算如下： Takt Time = 30sec Changeover Time = 5 min 30sec Process A Process B pcs 10sec 3060sec x 5min WIPPTP?16 Takt Time 节拍时间 Cycle time Takt time ( 1 Station Process ) C/T than takt for
26、single process (2 same stations needed) C/TTakt (需要2个相同工位) TAKT Time = 20s 10 20 30 40 Machine/Process A : St. #1 Machine/Process A : St. #2 Note注: CT TT : Additional Machine/Man needed 需要额外的机器 /人员 It can be used to calculate 节拍时间可以计算 ? Total Operators needed 员工需求数量 ? Total machines needed 机器需求数量 ?
27、Standard WIP needed & Etc 标准WIP需求数量，等 17 1)Is the Takt time visible (with counter and triggering point)? 节拍时间可以直观地看出来吗？有没有借助工具(计数器和触发机制 ) 。 2) Is the Takt board defined (on the board)? 节拍时间确定了吗？ (把节拍时间写在白板上 ) 3) Are the Standard WIP defined? 标准WIP有定义吗? 4) Do you know how to separate manual (persons)
28、 from auto (the machines) work? 你知道如何区分手动作业和自动作业吗 ? 5) Is the Work load leveling defined for man，machine and C/O? 人工,机器以及换线使用工作负荷均衡表分析了吗？ 6) Is the H/C calculated based on Takt time? 人力的多少是根据节拍时间计算出来的吗 ? 7) Is the Std work (front page) SWCS (back page) posted in front of each operator? 每个工站前都有标准作业 (
29、前页)和标准作业合并表 SWCS(背页)吗? Operations 操作操作 18 Operations ( continue ) 操作(续页) 8) Is the std work being followed by the operator? 操作员有没有按照标准作业流程作业 ? 9) Is the std work defined for water strider? 有没有定义物料员的标准作业 ? 10) Is the operator idle at the station? 在作业过程中 ,操作员是否有等待 ? 11) Does the operator search for co
30、mponents or tools? - Locate all tools and parts within easy access or reach (Doctor & Nurse). 在作业中,操作员有没有寻找物料或工具的动作 ? 工具或物料应该放置在易于获取的位置 ,定点定位.(遵循医生和护士概念： Doctor医生,指直接作业的人员 ,nurse护士,指辅助作业人员 ,如物料员) 12) Do you have std work for inspection station? 检查工站有没有标准作业书 ? 13) Do you have shortest cycle time for
31、inspection? 对于检查工站 ,有没有定义最短周期时间 ? 19 Operations ( continue ) 操作(续页) 14) At the hand load station, do you apply doctor and nurse concept? 在手工作业工站 ,有没有运用医生和护士理念 ? 15) Do you meet the target of 3 sec per component during insertion at hand load? 在手插工站 ,有没有达到每 3 秒一颗零件的插件速度 ? 16) SIC less at hand load sta
32、tion (with template). 手插工站不需要 SIC(用模板来显示需要插件的位置 )? 17)Hand load manual CT Takt time nurse not required. Are there system in place to stop work when abnormal conditions arise? 当手动作业的周期时间小于节拍时间时，不需要”护士”(护士nurse:辅助作业人员 ) 当异常情况出现时，有没有系统来控制停止作业? 18 ) Does the supervisor respond in a quick/crude manner? 当
33、异常发生时，管理人员的反映是快速还是迟钝? 19) Do you have 6S implemented on your line? 线上有实行 6S吗 ?(6S=5S+Safety ) 20 Operations ( continue ) 操作(续页) 20) Is the production qty for the day defined? 日产量有没有定义? 21) Is the Multi skill charts visible and available? 有没有显示和使用多技能培训表？ 22) Do you allow banana peeling on the line? 允
34、许在线拆卸物料包装吗 ? 23) Are you able to detect bottleneck station at a glance? 瓶颈工站能一眼看出来吗 ? 24) The operator must not re-orient the part 操作员不允许重新调整零件方向 ,防止零件极性弄错 .(这里操作员指辅助作业人员 ,即nurse) 25) Change over : 快速换型 a) Internal time 内部时间 d) Adjustment time 调整校准时间 b) External time 外部时间 e) Clean 清洁 c) Trial run 试运
35、行 21 Operations ( continue ) 操作(续页) 26) ETE Operation criteria: 端到端运行标准 a)The line should run based on Takt time 生产线必须按照客户需求节拍合理安排生产 b)The H/C should be loaded based on Takt time 生产线应按客户需求节拍时间合理安排人员 c)Material should be loaded based on Takt time 按客户需求节拍时间备置原材料 d)The line should be configured to zero
36、 defects 配置生产线时需满足零缺陷 e)Supermarket should meet all the 15 criteria 超市必须符合 15个设置准则 27) ETE consists of : 端到端包括 : a) Productivity improvement (MLT,H/C, WIP , Space) 提高生产效率 (生产前置期 ,科学的人员配置 ,适当的在线库存 ,有效的空间利用 ) b) Material replenishment (Water strider, Min- Max, Supermarket) 灵活精益的原材料供给方式 (水蜘蛛补货原则，设置最低最高
37、库存，超市) c) Quality improvement (Zero defects) 提高质量(零缺陷) d) C/O (if the time more than 10 minutes) 换型时间(如果时间超过 10分钟) 22 Operations ( continue ) 操作(续页) 28) 4 functions of Conveyor, Say NO to Conveyor if below criterias not meet “ 传送带”的 4个功能， 如果不符合以下条件 则不能使用“ 传送带” ?Function as a Pace Setter ( Takt Manuf
38、acturing ) 节拍调节器（节拍生产） b)Function as a Value adding work station ( Value being added as it moves) 增值工位（传送带移动时产品可以增值，如在传送带上作业） c)Function as a Jidoka ( Stop every abnormal ) 自働化（异常时停止作业） d)Function as a transportation mode ( 5% of the function ) 传送作用（只占5%的功能） 23 Layout 布局布局 1) Insure the short walkin
39、g distance. 确保产线行走距离短 . 2) Do you have 3 TEI implemented on your line? 产线有没有对物品实施三定原则 ? a) Fix place 定点 b) Fix things 定位/定物 c) Fix qty 定量 3) Is the safety aisle easily accessed by the operator? 安全通道是否易于员工通过 ? 4) Are there trash bins inside the cell? 单元生产线内有没有垃圾箱 ? 5) Do you have cell concept impleme
40、nted on your line? 有没有在生产线上应用单元生产的概念 . 24 Layout ( continue ) 布局(续页) 6) The operator movement in a cell : is it counter clock wise(1) or clockwise(0). Counter clock wise is recommended 操作员在单元内的移动是逆时针还是顺时针(逆时针为佳 ) 7) The gap in a cell : is it wider(0) or narrower(1) (narrower recommended). 单元内工站间的间距合
41、适的吗 ?宽(0) 还是窄(1) (推荐用窄). 8) Is the station made of crefoam material and is it on the wheel for flexible movement? 工作台是由复合管做成的吗 ?是否有滑轮易于移动呢 ? 9) The flow of a layout must be like a single stroke, no zigzag. 产线布局的流向必须是单行程的，而不是弯曲交错的。 10) Do you use 7 ways when designing tools, jigs, fixtures, layout or
42、 process? 在设计工具 ,夹具,治具,工厂布局和流程时有没有采用 7种方法(7 ways)? 11) Do you use Pugh matrix to evaluate 7ways? 有没有使用 Pugh matrix 来评估7种方法? . 25 Layout ( continue ) 布局(续页) 12) Hand load station should meet the below requirements :手动作业工站应该满足以下要求 : a) Part presentation 物料摆放方式 b) Zero defect 物料品质零缺陷 c) Layout /Ergonom
43、ic, 插件的顺序 /根据人机工程学来安排 d) Both hands of operator have to be used during insertion 插件时要双手作业 13) Are the cables, wires and network using the overhead drop point for flexibility? 电线,网线,信号线是否架设在线体上端并连接到产线，易于灵活使用? 14) Do you use the Spaghetti Chart to do the layout, process, movement? 在设计layout，流程,行走路线时有没
44、有使用到 Spaghetti Chart( 意大利面条图 )工具,清晰的画出人流、物流及产品流路线 ? 15) Is the line visibility clear for the supervisor? (boarder post defined for clear visibility) 对于管理者来说，产线可视化吗 ?(定义看板使其清晰可视化 ) 16) Do you use mock-up layout? 有没有模拟 layout实施后的情况吗 ? 17) Tree and Branch connecting sub assembly & main assembly 主干和枝条 主
45、装配线和辅助装配线的合理衔接 26 Layout ( continue ) 布局布局(续页续页) 18) Short Takt time 1minute, multiply takt time by (x) factor and duplicate the backend cell accordingly 客户节拍时间太短小于 1 分钟时，增大节拍时间 X 倍并建立相应数量的相同的单元产线。 19) Do your work stations are in same height ? 工作台都是同一个高度吗？ 20) Do you carry out “rope test” to valida
46、te the continuous value flow ? 有实施“绳子测试”验证连续价值流吗？ 27 Zero Defect 零缺陷零缺陷 1)Can normal and abnormal be visually differentiated? 正常和异常现象易于区分吗 ? 2) Are the escalation paths well defined if abnormality occurs? 针对异常的发生 ,有没有制定出逐级上报的流程 ? 3) Are the defects allowed to escape to down stream? 有没有不良流入下一工站 ? a)
47、Do not pass defect ( Downstream Internal or To End Customer ) 不流出不良品 (内部下游客户或终端客户 ) b) Do not make defect( In Own Process ) 不制造不良品（自己的工位） c) Do not accept defect ( From Upstream) 不接收不良品（从上游工序） d) Do not rework ( Not Build Product Via Rework ) 不允许返工（不通过返工生产产品） 4) Do you have a common area to view the
48、 defect (fish market)? 有没有特定的地点来检讨不良 ?(fish market 鱼市场) 28 Zero Defect ( continue ) 零缺陷零缺陷(续页续页) 5) Do you apply 3 Gens? 有没有做到三 现? a) Genba - Actual place 现场 b) Genbutsu - Actual product 现物 c) Genjitsu - Actual fact 现实 6) Do you use 5 W ( who, what , where, when, why)+1H (how) where rule and regulat
49、ion applied? 规章制度的制定有没有运用 5W+1H的方法? 7) Do you have hand free inspection station? 视检工站,有没有不需要用手的 ? 8) Do you have template with navigation or pointer to guide inspection operators? 有没有模板来辅助视检作业？ 29 Zero Defect ( continue ) 零缺陷(续页) 9) Do you apply SDCA,PDCA? and for defects do you apply PDCA? (Problem
50、,Display,Clear & acknowledge) SDCA ( Standardize, Do, Check & Action ) 工作中有没有运用 SDCA、PDCA方法？针对不良现象，有没有运用 PDCA的方法？ 10) Do you have Kaizen Newspaper displayed? 改善活动的海报有没有展示出来 ? 11) Do you have 1hr, 2hr, 4hr, 8hr tracking system on the floor? (lead to zero defect) 产线有没有跟踪系统，随时了解每 1小时，每2小时，每4小时，每8小时的状况？
