上海通用精益生产PPT课件

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1、精益生产的历史Lean Manufacturing History 1955丰田制造系统TOYOTA PRODUCTION SYSTEM 1979 质量体系 QUALITY SYSTEM 1983 NUMMI,SYCHRONONS MANUFACTURING 1990 LEAN MANUFACTURING,ESENACH 1995 DELPHI MANUFACTURING SYSTEM 1996 GM-GMS 1998 COMPETITIVE MANUFACTURING适应性经济性尊尊重重人人才才，发发挥挥人人的的作作用用不不断断暴暴露露问问题题，不不断断改改善善Edited by 意识改革*

2、5S追求7个极限目标Edited by Edited by GMS简介简介GMS Brief Introduction GMS简介简介GMS Brief Introduction 通用汽车全球制造系统的原则和要素构成了一个完整的系统,只有把它作为一个完整的整体实施才能有效。各原则之间相辅相成，没有一个原则或要素能独立存在。因此我们用一个类似太阳系的图标来表示GMGMS。只有当五个原则共同实施，GMGMS才是一个完整的系统。The principles and elements of GM-GMS comprise a comp-lete system,and to be effective m

3、ust be taken toget-her as a whole.Each principle supports and reinforces the others.No one principle or element can stand alone.For this reas-on,the solar system icon is used to symbolize GM-GMS.GM-GMS is a complete system when all five principles are implemented.GMS简介简介GMS Brief Introduction GMS简介简

4、介GMS Brief Introduction 8个要素8 Elementsv 宗旨、价值观和文化理念 Vision,Values,&Cultural Priorities v 使命 Missionv 健康和安全第一 Health&Safety Priorityv 合格的员工 Qualified Peoplev 人员支持系统/小组原则 People Support System/Team Conceptv 员工参与v People Involvementv 开放式交流 Open Communication Processv 车间现场管理 Shop Floor Management目的：目的：引

5、导员工的个人行为和公司决策，创造一个关注过程和结果的氛围。Purpose:To guide individual behavior and organizational decisions,creating a process and results focused culture.核心要求核心要求 Core Requirements:u 领导层维护和纠偏 Leadership champions the Corporate Vision,Core Values,and Cultural Priorities u 明确清晰The Vision,Values,and Cultural Prior

6、ities are clearly u 公司的政策（包括一、二、三级文件）与其一致Policies,practices,procedures,and systems are consistent with the Vision,Values,and Cultural Prioritiesu 领导层以身作则Leadership leads by example u 评估和改进，确保公司宗旨、价值观和文化理念的一致性Evaluate and improve to ensure consistency with the Vision,Values,and Cultural Priorities1.宗

7、旨、价值观和文化理念Vision,Core Values and Cutrual Priorities 2.使命MISSION定义：定义：传达给具体车间或职能部门的一个目标或者期望 值的陈述Definition:A local statement that conveys a mental image of the goal or desired state for a specific plant or function.目的：目的：激励员工工作并使全体员工知道、理解并趋近理解并趋近公 司的奋斗目标Purpose:To motivate/inspire people to act and h

8、elp the entire workforce visualize,understand,and relate to the organizations competitive goals and objectives.核心要求：核心要求：Core requirements:l是公司领导层制定和牵头，全公司共同参与的Developed and championed by leadership and shared with the entire organization.l支持公司的宗旨、价值观和文化理念，并与其保持一致Aligned with and supports the Corpor

9、ate Vision,Values,and Cultural Priorities.l全公司上下理解和全力支持Understood and committed to by all levels of the organization l审查策略、行动和体系以保证提供支持Strategies,activities,and systems are reviewed to ensure they support peoples efforts to reach the mission.l需支持公司的业务目标Supports the business goals and objectives.l有定期

10、评审使命陈述的流程A process is in place to periodically evaluate the Mission Statement.定义：定义：实施一系列的行为、措施、政策和方法以帮助 员工实现一个健康无伤害的工作环境。Definition:Implementation of behaviors,actions,policies,and practices that help our employees realize a healthy,injury free environment.目的：目的：以安全是最重要的、所有的事故都是可预防的安全是最重要的、所有的事故都是可

11、预防的 理念理念为指导，采取切实的措施保证员工良好的 健康状况和健康无害的环境Purpose:To ensure we protect the well being of our people through actions consistent with the belief that safety is our overriding priority and all accidents are preventable.3.健康和安全优先Health and Safety Priority 核心要求：核心要求：Core Requirements:l 领导层对所有健康和安全核心要素的实施和监控

12、负责 Leadership is responsible for implementation and monitoring of these Health and Safety core requirementsl 工厂安全回顾板 Plant Safety Review Boardl 定期安全巡检 Safety Observation Toursl 安全作业（危险的工作，有健康和安全作业指导书）Safe Operating Practices(Health and Safety standardized work instructions are documented and impleme

13、nted for jobs where risks to employees warrant)l 事故调查（“5个为什么”问题解决流程)Incident Investigation(“5 Why”problem solving process)l 严格遵守安全规章Abide by the safety rules strictly4.合格的员工Qualified People 目的：目的：确保员工的能力与竞争性的生产制造角色 和职责相匹配Purpose:To ensure the best possible fit of peoples abilities with the expectati

14、ons of the competitive manufacturing roles and responsibilities.核心要求核心要求Core Requirements：l 制定行为规范，体现公司核心价值观，书面形式交流 Competencies(Required Behaviors)are defined for each level of the organization l 选择 Selectionl 培训 Trainingl 激励 Inspiritl 发展 Development 5.员工支持系统/班组原则People Support System/Team Concept

15、定义：定义：赋予各班组主人翁和基本工作单位的功能使小组成 员共同承担职责相互支持，通过不断改进达到共同 的目标Definition:Small groups of employees that are empowered to function as the owners and basic work unit who share common tasks,support each other,and achieve common goals through continuous improvement.目的：目的：通过团队合作使员工参与整个工作过程，不断改进 自身表现，产品质量和工作环境，最

16、终树立员工自 豪感和工作成就感并促进员工个人的发展Purpose:To involve employees in the work process to continuously improve performance,product quality,and working conditions through teamwork.To develop employee pride,job satisfaction,and personal growth.核心要求核心要求 Core Requirements：l 制定各级和职能块的职责Roles and responsibilities for

17、each level and function of the organization are defined.l 履行,交流T/M,T/L,G/L职责Team members,team leaders,and group leaders fulfill responsibilities of their position.l 班组原则 Team criteria.l 业务系统和实践操作支持小组原则的实施Business systems and practices support implementation of the team concept.l 班组长的选择 Team leader s

18、election.l 班组长支持小组和班组目标的标准化任务Team Leaders are not assigned standardized work but are assigned standardized tasks that support the team and objectives.l 支持部门对于班组的支持（HR,财务，工程部，质量部等）Support organizations(e.g.HR,Finance,Engineering,Quality,etc.)understand and execute their responsibility to the teams.6.

19、人员参与People Involvement定义：定义：一整套鼓励员工以积极的态度参与公司不断改进活 动的系统、程序、实践和方案Definition:Systems,procedures,practices,and programs that involve all employees as active participants in continuous improvement activities.目的：目的：营造和保持一种培育“自豪感”的氛围。Purpose:Create and maintain an environment which fosters a spirit of pri

20、de”.核心要求：核心要求：实施计划帮助员工作出有依据的决策和改进 Programs and activities are implemented to help people make informed decisions and improvements.实施活动（合理化建议，Go fast(加速），持续改进等）Implement activities(e.g.suggestion program,GoFast Activities,CIP Programs,etc.)建立小团队参与持续改进Small groups are established and participate in im

21、provement activities.给予员工/团队认可Recognition is provided to employees/teams.个人、小组和公司绩效应与福利待遇系统挂钩 Individual,team,and company performance is factored in to the compensation system.7.开放式交流流程Open Communication Process定义：定义：为营造一种所有层次都能畅所欲言和有效 交流的氛围的手段和方法。Definition:Behaviors and practices that create an en

22、vironment that fosters a free and open flow of communication at all levels.目的：目的：交流信息使各级员工作出有依据的决策和 改进部门的表现。Purpose:To exchange information that helps people at all levels make informed decisions and improve organizational performance.核心要求核心要求Core Requirements：会议交流 Conduct regularly scheduled meetin

23、gs to communicate交流媒介（Notes，暗灯板，其它可行的交流工具）Use communication media effectively(e.g.Notes,Andon boards,or any communication tools available).营造公开交流的办公环境（开放式办公室，玻璃分隔，支持部门靠近制造生产部门，小组会议区域，关注操作人员信息的及时获取）Ensure the physical environment fosters open communication(e.g.open offices,glass partitions,support de

24、partments in close proximity to the manufacturing organization,group meeting areas,concern about).领导层以身作则（平易近人，能主动听取意见和深入车间）The leadership style demonstrates behaviors exhibiting open communication(e.g.accessibility,active listening skills,floor presence).信息快速传递的结构程序A structured process is in place

25、to quickly disseminate information(e.g.promotion announcement,cancellation of overtime).8.车间现场管理Shop Floor Management定义：定义：管理和支持小组的行动要在工作现场进行，便于 理解，支持和管理操作Definition:The behavior of management and support groups to go to where the work is performed,to understand,support,and manage the operations.目的：

26、目的：确保所有的决策均在工作现场利用相关、实际、正确的第一手材料作出Purpose:To ensure that decisions are made at the work site by utilizing relevant,factual,accurate,and first-hand information.核心要求：核心要求：定期的管理评审（SPQRC)和流程评审(5S,标准化工作）Regular Management reviews include SPQRC(Safety,People,Quality,Responsiveness,Cost)and process evaluat

27、ions(e.g.Workplace Organization/5S,Standardized Work).每个员工都了解SPQRC的状态SPQRC status indicators are visible so every employee can see and understand current conditions.管理支持人员帮助班组成员通过直接观察相关工艺/工作区域来解决问题 Management and Support Personnel assist Team Members to solve problems by directly observing the proce

28、ss/work area where concerns exist 问题的通报流程（问题升级）Problem escalation processes are developed车间办公室到达所有生产区域，Team Room设置在线旁Shop offices must be accessible to all production areas and team leader workstations are located line side.会议/休息区域能容纳所有员工且在一线主管（工段长/值班长）的控制/责任范围内Meeting/break areas are to be sized to

29、 accommodate all members within the first line supervisors span of control/responsibility(group leader/area leader)where appropriate.定义和消除浪费（七种浪费）Waste is actively identified and eliminated.目视化管理 Visual Management：-偏离标准的情况对每个人可见 make deviations from standards visible to everyone -用显而易见的方式显示操作状态 disp

30、lay the operating status in an easy to see format -提供指示和/或信息给员工 provide instruction and/or information to employees标准化标准化 标准化是不断改进的基石v工作场地有序布置 Workplace Organization v节拍定额时间管理 Management By Takt Time v标准化作业 Standardized Work v目视化管理 Visual Management 9.工作场地有序布置Workplace Organization 核心要求核心要求 Core Req

31、uirements：l5S标准l员工的参与 People involvementl去除多余物品Excess or non-essential things are eliminated.l评估和改进 Audit and adressSort分类Sift筛选Sweep清扫Sustain保持Self-discipline自律物在其位，位有其物物在其位，位有其物目的：目的：通过工作场地的布置和保持，使“不符合标准”的情况显而易见。Purpose:To put order to and maintain the workplace by making out of standard condition

32、s readily visible.定义：定义：用于调节和均衡满足销售需求的生产产量的测量体 系。Definition:A measurement system that regulates and levels the production output to meet sales demand TT=生产时间（秒）/客户需求（件）目的：目的：均衡生产计划且生产所需的产量。Purpose:To level the production schedule and produce what is needed when it is needed.作用：杜绝七种浪费之：“过量生产，等待过量生产，等

33、待”zl:结合开动率，分析一下TT,ATT,CT,JPH之间的关系。10.节拍定额时间管理Management By TAKT Time 核心要求核心要求 Core Requirements：lATT近似满足需求，TT与AT l在某一段时间内（至少一个月）保持节拍定额时间和实际节拍定额时间固定。Takt time and actual takt time remains fixed for a period of time one month minimum.l 应对变化的流程（具体的流程）Procedures must be established to manage takt time a

34、nd actual take time changes(detailed process).l 相关文件的修改 Relevant documents modificationl 辅助设施 Assistant facility11.标准化作业SOS定义：定义：由功能组织同意，制定，遵守和保持的可用于重复 性工序的功能性文件。Definition:The documentation of work functions performed in a repeatable sequence,which are agreed to,developed,followed,and maintained by

35、 the functional organization.目的：目的：为持续改进建立可重复，可预测的基础并使操作者 参与最初和不断的改进过程以便获得最高水平的安 全，质量和生产率。Purpose:To establish a repeatable,predictable baseline for continuous improvement and to involve the operator in both the initial and ongoing improvements to achieve the highest levels of safety,quality,and pro

36、ductivity.核心要求核心要求 Core Requirements:l 记录并且标准化所有重复性工作All repeatable work must be documented and standardizedl 需记录的要素 The following criteria are documented l 所有班次的同意（保证不同班次、不同的人做的一样）All elements and detail of standardized work must be agreed to across all shifts.l 清晰可见 Visually displayedl 评审和改进 Audit

37、 and adressl 生产和支持人员共同参与Manufacturing and support personnel involvementzl:可以在标准化作业单中体现出改版的历史。12.目视化管理Visual Management目的：目的：使工作场地的标准和实际状况一目了然Definition:A process in which standards and actual conditions become quickly visual in the workplace.特点 Specialty：1.作为一种管理手段Work as an measure of management 2.

38、管理差异性Manage the discrepancy 3.是即时的Instantaneous核心要求核心要求 Core Requirements：l目视管理使用和范围 the extent and use of visual management l在标注化作业中，关键或规范的程序应有特别的目视标示Critical or regulated processes receive special visual identifications on the standardized work.l更新并维护目视管理表格和工具Visual management forms and tools are

39、current and maintained l用于相同应用的目视化方法必须标准化The methods to visualize common applications must be standardized l当前和标准的（指标或目标）的状态必须清晰可辨 Both the current and standard(target or goal)conditions must be clearly identifiable.l简单明了 Easily understood l难以立即改正，应记录、张示并交流其相应对策Countermeasures for observed out-of-st

40、andard conditions that cannot be easily rectified must be documented,displayed,and communicated.（与问题解决的链接）应用：工位地址牌，标签，线标识，暗灯板Application:station address brand,label,line indication,Andon board 5 5个要素个要素5 Elementsv 产品质量标准 Product Quality Standards v 制造工艺认证 Manufacturing Process Validation v 工序内控制及验证

41、In-Process Control&Verificationv 质量反馈/前馈 Quality Feedback/Feedforward v 质量系统管理 Quality System Management13.产品质量标准Product Quality Standards定义：定义：产品特性可测的要求，这些要求如能满足，将确保我们的产品达到内/外部客户的要求Definition:Measurable requirements for product characteristics,which when satisfied,ensure our products meet internal/

42、external customer requirements.目的：目的：提供产品评估的标准 Purpose:To provide criteria for product evaluation.核心要求核心要求 Core Requirements:制定,批准,修改的流程(PTQ-1-00-0021.012004.12.30)A documented process is in place to develop,approve,and revise the product quality standards.(PTQ-1-00-0021.012004.12.30)质量标准 quality st

43、andards 满足用户,工程,法规的要求Product quality standards must satisfy customer 用于反馈给工程部的正式的流程A formal process exists to feed back工具tools：KPC,SOS,Visual Aids，边界样品，工序检查记录 表，质量检验规范，冷试规范，热试规范14.制造工艺认证Manufacturing Process Validation 定义：定义：在开始全面生产前进行工艺准备和认证的方法在开始全面生产前进行工艺准备和认证的方法Definition:The method by which proc

44、esses are prepared and validated before starting full volume production.目的：目的：确保每道制造工序在完成生产计划的同时达到既定 的产品质量标准Purpose:To ensure that each manufacturing process is capable of meeting defined product quality standards,while achieving schedule.核心要求核心要求 Core Requirements:符合GPDP工具 Tools：Process Flow Diagra

45、m（Review)Process Control Plan（Review)PFMEA（RPN）PTR Bucket Build PPAP，Pilot，First piece15.在线控制及验证In-Process Control&Verification 定义：定义：通过预防，检测和遏制非正常状况在工位上造入质量的系统Definition:The system of building quality in station through prevention,detection,and containment of abnormalities.目的：目的：减少工序的波动以确保在工位上的所有产品

46、都符合质量要求，并且尽可能快地在制造后的下道工序得到确认以减少缺陷相关的浪费Purpose:To minimize process variation to ensure that all products are OK in station and are confirmed as soon as possible following manufacture and to reduce waste associated with defects.核心要求:预防 Prevention 检测 Detection 遏制 Containmentn下述情况 前馈前馈 缺陷外溢 备用工具/设备 问题解决

47、（经验借鉴）产品/工艺变更下述情况 反馈反馈 缺陷确定 问题解决 为问题解决提供流程 记录跟踪工具：暗灯，问题解决跟踪系统,CARE前馈：对于可能发生的质量问题进行事先的控制反馈：对于已发生的质量问题进行控制16.质量反馈/前馈Quality Feedback/Feedforward 目的：目的：确保质量信息达到需要这些信息的人员手中 Purpose:To ensure that information on quality reaches those who need it.核心要求核心要求 Core Requirements:文件形式确定:v每道工序的客户和供应商v客户和供应商所需的时间表

48、,内容等v工序内测量(FTQ等)17.质量系统管理Quality System Management 目的：目的：定义和规范质量活动的既定操作 Purpose:To define and regulate the intended operation of the quality activities.包括：QS-9000体系，质量阀流程，GPDP（GQS）Including:QS-9000 system,Quality valve process,GPDP(GQS)核心要求核心要求 Core Requirements:质保向工厂领导汇报Head of quality department r

49、eports to Manager/Director of the plant.质保有足够的资源Assure resource allocation for quality activities is sufficient 与质量体系相符compliant with the appropriate quality system standard(s)与质量相关职能的合适的组织结构An appropriate organizational structure is in place for quality related functions BPD来管理和跟踪The BPD process is

50、 used to manage measurements and track progress to goals.17.质量系统管理Quality System Management 产品质量标准u清晰易懂 clearly communicated to the user u融于标准化作业中 incorporated in standardized worku统一的 commonu不能比前道工序应用的标准更苛刻not tighter than those applied in upstream processesu在工艺的每一阶段都有定义和应用defined&applied at each s

51、tage of the processu对于已经建立的标准是可测量,可比较measurable and/or comparable with established criteriaGPDP 结合防错到工艺/产品设计中 在工艺开发过程（至少:关键工艺）中使用FEMA方法 确定和实施工序控制来符合工程要求（KPC工艺控制计划）有人、机、料、法和环的变更时，对工艺进行认证(PTS-0101.012000-4-24工艺验证程序)在生产情况下实施制造认证(PPAP)使用前认证工具、设备、料箱、检具和方法(PTS-0101.012000-4-24工艺验证程序)在系统完成之前实施TPM计划 预防Preve

52、ntionu 标准化作业(生产,维修,检查)SOS(Manufacture,Maintenance,Inspection)u TPMu 遵循零件质量控制计划Follow parts quality control planu 符合标准的部件才能运到生产线旁(来料检查)Only qualified parts can be delivered to the line(material check)u 关键设备的检查 Key equipment checkingu 验证工序改变后的有效性Effectiveness validation for process changingu 在标准化过程中对相

53、似过程进行借鉴。Use similar process for reference during standardizationu 防错计划，防错清单，防错验证error-proofing plan,error-proofing list,error-proofing validation检测Defectionu 把所需的质检纳入标准化作业中（装配）Required quality checks are included in standardized work(assembly).u 质检项目有标准Quality check items are based on defined criter

54、ia u 根据质量计划配备足够的资源Sufficient resources are allocated in accordance with the quality plan u 更新系统 Quality check systems are updated u 制定重要工序的检测频次Inspection frequencies of critical operations are established u 检查站 Inspection stationu 把检查方法（触摸，听，看）纳入标准化作业（装配）Point,touch,listen,and count inspection metho

55、ds are incorporated in standardized work.u 用声光信号 Audio/visual signals are implemented 遏制CONTAINMENTu采用暗灯 An Andon system is implemented u本工位控制缺陷A process is stopped when discrepancies that impact downstream activities must be controlled in station.u问题解决流程确定有效的长期措施A problem solving process is initiat

56、ed to identify permanent corrective action that is verified as being effective.缩短制造周期缩短制造周期 整体制造周期(从得到订单到收到货款）产品发展周期（从概念到投产）过程制造周期（从原材料到最终装配）9个要素9 Elementsv简易的工艺流程 Simple Process Flow v少量包装 Small Lot Packaging v固定周期定货系统/定购零部件vFixed Period Ordering System/Order Parts v受控的外部运输 Controlled External Tran

57、sportation v有计划的交运/收货 Scheduled Shipping/Receiving v临时物料储存-CMA（中心物料区域）vTemporary Material Storage(CMA Central Material Area)v拉动式系统 Pull Systems v均衡已定购车辆的生产计划 Level Vehicle Order Schedules v供应链管理 Supply Chain Management 18.简易的工艺流程 Simple Process Flow定义定义:以获得一个简易的物料与信息流为目的的流程Definition:Definition:A pr

58、ocess that incorporates a constant drive to attain a simple sequential process flow of material and information.目的目的:设计和实行流程，来维护“先进先出”，可追溯，可视，缩短制造周期，检查降低成本时的问题，降低库存和按流程工作。(简易的物料和信息流）Purpose:Purpose:To design and implement processes that maintain FIFO,allow traceability,are visual,reduce lead time,ea

59、sily detects problems while optimizing cost,and reduces inventory and work in process.核心要求核心要求 Core RequirementsCore Requirements：所有操作中体现“先进先出先进先出”FIFOFIFO present in all operations.工序和缓冲区（车辆，零件）是受控，优化和目视的Work-in-process and buffers(vehicles,parts)are controlled,optimized,and visualized.需要批量或少量生产时，尽

60、量减少规模。When batch or small lot production is economically necessary,batch or lotsize must always be challenged for reduction.布局和工艺要有助于形成直接，持续和简易的物料流Layouts and processes facilitate a direct,continuous,and simple materialflow.操作工的工作区域设置必须考虑安全有效的零部件摆放Operator envelopes are set to allow safe,efficient p

61、arts presentation.生产目视化辅助（载货单，屏幕，拉动式系统，等等）以简洁的格式显示在车间现场Production visual aids(manifest,screens,pull systems,etc.)are present on the shop floor in a simple format.移动设备和生产设备要有助于形成简易的流程 Mobile equipment and production equipment facilitate simple flow.19.少量包装Small Lot Packaging定义定义:确定，分配或设计合适的标准数量和料箱Def

62、inition:Determining,assigning or designing the appropriate standard quantity and container.目的：目的：以在运输，储存和运送中不易损坏，容易控 制的“用户喜欢”的包装方式为操作工提供零 件。Purpose:To provide parts to the operator in a user-friendly package that facilitates damage-free and economical handling during shipment,storage and delivery.核心

63、要求核心要求 Core Requirements：料箱设计 Container Design标准包装数量应能满足多次重复运输的需要Standard pack quantity provides for frequent delivery.a.手工处理的料箱，使用点库存：2小时 Point of use inventory target is 2 hours for manually handled container.b.大件料箱，使用点库存：少于4小时 Point of use inventory for bulk containers targeted for 4 hours or les

64、s.将料箱装满（没有多余空间）Container contents should fill the container(no air).核心要求核心要求 Core Requirements：尽可能使用通用的可回用料箱 Use of the common returnable containers is maximized.人工搬运的料箱和部件间衬垫应满足人机工程提升准则（把手孔，重量等）Manually handled containers and dunnage meet ergonomic lifting guidelines(e.g.hand holes,weight,etc.).物料在

65、生产性料箱中运输 Material should be shipped in production containers最小化/消除重新包装 Repacking is minimized/eliminated.核心要求核心要求 Core Requirements：空箱返回区域 Empty container return areas n指定的收集，分类和分级运输区 nAre designated for collecting,sorting and staging n地址和目视化识别（“分类”，“分级”区域，供应商，箱盖说明等）Are clearly identified with appro

66、priate addresses and visual controls(e.g.type of area Sort,Stage,supplier,return schedule,capping instructions,etc.)n能容纳计划数量的料架、托板和料箱Accommodate planned quantities of racks,pallets and containers n每个供应商（和/或供应商组）的料箱有指定区域Are designated for every supplier and/or container combination n减少运输距离和标准化作业流程 Are located to minimize travel distance and standardize the work flow核心要求核心要求 Core Requirements：空箱处理准则n确保操作工把空箱放置在合适的返回装置中nAssure operator places empty container on appropriate return devicen遵循书面形式的内部衬垫