精益生產(chǎn)基本概念介紹精益生產(chǎn)基本概念介紹1SPS的四個(gè)主要組成部分4KeyElementsOfTheSolectronProductionSystem精益之屋HouseofSPSSixSigma檢查缺陷ErrorProof零缺陷ZeroDefects利用數(shù)據(jù)分析來解決系統(tǒng)的問題SystematicProblemSolvingVia

DataAnalysis拉動生產(chǎn)PullProduction一個(gè)流SinglePieceFlow平衡化生產(chǎn)TaktTimeProductionJidokaJIT基礎(chǔ)Foundation客戶之聲VoiceOfCustomer;質(zhì)量體系QualitySystem;5S;平整化生產(chǎn)Heijunka不斷地改善和提高GembaKaizen(ShopFloorContinuousImprovement)集中在效率上EfficiencyFocus自動化Stop@Abnormality集中在質(zhì)量上QualityFocus精益之屋SixSigma檢查缺陷ErrorProof零缺2質(zhì)量靈活性競爭力精益給客戶帶來什么?LEANSolectronProductionSystemTM(SPS)LEANImplementation(2004)…1Of3ElementsForCustomerValueProposition質(zhì)量靈活性競爭力精益給客戶帶來什么?LEANLEANImp3消除缺陷的二個(gè)途徑6Sigma消除缺陷SMTSolderPT/HHPtestFQACustomerTestPrinter立刻有效!用眼鏡看,采取行動TestTest25%缺陷Test現(xiàn)場改善消除缺陷75%缺陷用測量系統(tǒng)和數(shù)據(jù)分析,再采取行動? 6Sigma

項(xiàng)目? GageR&R? DOE? 防呆? 擴(kuò)展好的改善方法基礎(chǔ):現(xiàn)場改善可消除75%的缺陷消除缺陷的二個(gè)途徑6SigmaSMTSolderPT/HH4為什么要六西格碼精益生產(chǎn)？/

Why6-SigmaLean?滿足客戶需求Tomeetcustomerdemands.客戶只會為有價(jià)值的行為買單Customeriswillingtopayforonlyvalue-addedactivities.沒有價(jià)值的行為會增加生產(chǎn)的成本Non-valueaddedactivitiesaddcosttomanufacturing.要想在競爭激烈的商業(yè)環(huán)境下生存，就必須最充分地利用資源Tosurviveinthiscompetitivebusinessenvironment,thereisaneedtomaximiseutilisationofresources.保持公司的收益Sustainedprofitabilityofthecompany.對于公司FortheCompany對于個(gè)人ForYou為了在旭電的安全工作JobsecurityforSolectron集中你的時(shí)間成就有價(jià)值的分派任務(wù)Focusyourtimeandeffortonvaluabletasks.停止步行/檢查/查找/重做和其他一些無價(jià)值的行為Stopwalking,checking,searching,reworkingandothernon-valueactivities.加入到工廠的成功當(dāng)中InvolvedinthesuccessofthePlant.你的技能和領(lǐng)導(dǎo)能力的提高從而得到認(rèn)可Yourskillsandleadershipdevelopmentandtheopportunitytoberecognized.

為什么要六西格碼精益生產(chǎn)？/Why6-SigmaLea5客戶愿意付錢,并使產(chǎn)品發(fā)生轉(zhuǎn)變或給產(chǎn)品增加價(jià)值的行為才是有價(jià)值的生產(chǎn)活動Activitiesthattransformtheproducts,oraddvaluetotheproductswhichthecustomeriswillingtopayfor.例如/Examples：貼裝元件Mountingcomponentsontheboard;集成電路程序燒制ProgrammeIC印刷電路板放入盒子SecurePCBtothechassis;手工插裝元件Handloadthecomponents;波峰焊操作等WavesolderthePCBetc

什么是有附加值的活動？/WhatareValue-Added(VA)activities?客戶愿意付錢,并使產(chǎn)品發(fā)生轉(zhuǎn)變或給產(chǎn)品增加價(jià)值的行為才是有6什么是可增加附加值的行為？/WhatareValue–Enabled(VE)activities?不增加附加值但是必須要做的事情Activitieswhicharenon-valueaddedbutnecessary…today例如/Examples: -

視覺檢查與測試 -Visualinspectionandtesting -為了組裝操作在小范圍拿取工具和原料 -Smallmovementstoreachfortoolsormaterialsforassemblyetc;

什么是可增加附加值的行為？/不增加附加值但是必須要做的事情7什么是浪費(fèi)？/Whatiswaste?做不增加產(chǎn)品附加值的工作Workwhichdoesnotincreasethevalueoftheproducts例如/Examples

-錯(cuò)料返修

-Reworkduetotheuseofwrongparts; -補(bǔ)焊 -Touch-up; -當(dāng)機(jī)器運(yùn)轉(zhuǎn)時(shí)，操作工等待的時(shí)間 -Operatorwaiting-timewhilemachineisrunning; -找料，計(jì)算 -ARF,lookingforparts,counting; -走動 -Walkingetc.什么是浪費(fèi)？/Whatiswaste?做不增加產(chǎn)品附8什么是七大浪費(fèi)？/Whatis“7+1Waste”?Overproduction 過量生產(chǎn)Overprocessing 多余的工作程序Inventory 庫存Motion 多余動作Transportation 運(yùn)輸

Rework 返修Waiting 等待Intellectwaste

人才浪費(fèi)什么是七大浪費(fèi)？/Whatis“7+1Waste9消除7大浪費(fèi)過量生產(chǎn)多余搬運(yùn)等待多余的工作程序庫存多余動作不良品消除7大浪費(fèi)過量生產(chǎn)多余搬運(yùn)等待多余的工作程序庫存多余動作不10生產(chǎn)過剩/Overproduction客戶何時(shí)需要，需要什么是我們的生產(chǎn)目的Ourgoalistoproduceonlywhatthecustomerswant,whentheywantit.過量生產(chǎn)是一種最大的浪費(fèi)，它能夠?qū)е赂嗟睦速M(fèi)，諸如多余動作，等待，運(yùn)輸，返修;Overproductionistheworsttypeofwasteasitleadstofurtherwaste,suchasmotion,waiting,transportation,rework.例如/Examples: -為了周末的野餐,而帶了一周的食物 -Bringoneweeksworthoffoodforaweekendpicnic;

-存貨的返修

-ECreworkforinventory;

-提前36小時(shí)備好料

-Kit36hoursbeforepartsareneeded;

-后道工序運(yùn)作得比前道工序快

-Runbottomsidefasterthantopsideetc生產(chǎn)過剩/Overproduction客戶何時(shí)需要，需要11等待材料和機(jī)器操作時(shí)不做任何事Doingnothingwhilewaitingformaterialsormachinetocompleteaprocess.機(jī)器和人力利用率低下Underutilisemachineormanpower實(shí)質(zhì)浪費(fèi)時(shí)間會降低生產(chǎn)運(yùn)作Essentialwastetimecanbefilledwithproductiveactivities重新平衡生產(chǎn)線會減少等待時(shí)間Rebalanceactivitiestoremovewaitingtime.例子/Examples -提早到達(dá),等待開會

-Arrivinganhourearlyforameeting; -開會遲到,所以其他與會人員等待

-Cominglateforameetingwhiletherestarewaitingforyou; -板子等待壓配合

-Boardsawaitingpress-fit; -手工組裝的操作員等待板子

-Handloadoperatorswaitingforboardsetc.等待/Waiting等待材料和機(jī)器操作時(shí)不做任何事等待/Waiting12運(yùn)輸/Transportation工藝過程中不必要的物料和人力移動Unnecessarymovementofpartsorpeoplebetweenprocesses.差勁的物流安排導(dǎo)致不必要的材料運(yùn)輸Poorlogisticslayoutthatcauseunnecessarytransportationofmaterials.能造成運(yùn)輸損壞或是產(chǎn)品質(zhì)量問題等Cancreatehandlingdamageandcauseproductionrejectssuchasknock-off,droppedboardsetc例如/Examples: -傳送帶太長或工藝間隙太遠(yuǎn)

-Conveyoristoolongorgapbetweenprocessistoofarapart;

-在兩站之間不必要的存貨,板子送去清洗和5DX等

-Unnecessaryinventorybetweenstations,boardssenttowashand5DXetc運(yùn)輸/Transportation工藝過程中不必要的物料13庫存/Inventory原料放置不動不能增加附加值Materialsthataresittingidledonotaddvalue.庫存與現(xiàn)金緊密相聯(lián)Inventorytiesupcash(million/billionUSD)庫存可能是倉庫里的原料或是生產(chǎn)線上的在制品Inventorycanberawmaterialsinwarehouse/storeorWIPontheline.大量庫存會增加成本，并提高損壞，丟失，被盜等的可能性Highinventoryincreasesthepotentialforhigheroperationcosts,scrap,loss,theftetc差的生產(chǎn)線5SPoor5Sontheline例如/Example:

-Stockupamonth’ssupplyofMaggieMeewhenthesupermarketisnearby; -Absenteeismthatcausesinventorytopileupatcertainoperations; -Comboboardstrafficjam; -Overflowofinventoryatparkinglotsetc庫存/Inventory原料放置不動不能增加附加值14多余的工作程序/OverProcessing客戶不需求的工藝作業(yè)是一種浪費(fèi)Processingbeyondwhatthecustomerrequiresisawaste.可能是由于缺乏標(biāo)準(zhǔn),或不了解客戶的需求,或知識不知道規(guī)范Maybeduetoalackofstandardsorlackofknowledgeofcustomersrequirementsorsimplydonotknowthespecifications.多余的工作程序不能增加附加值,因?yàn)榭蛻舨⒉淮蛩銥橹跺XOverprocessingdoesnotaddvalueascustomerisnotgoingtopayforit.例如/Example：咖啡里加太多的糖Puttoomuchsugarforcoffee焊料過多Extendedstirringofsolderpaste將已經(jīng)清洗干凈的鏡子再清洗一次Cleaningthemirroroverandoveragaineventhoughthemirrorisalreadyclean.多余的工作程序/OverProcessing客戶不需求15多余動作/Motion在一個(gè)工序中不必要的物品或人員移動Unnecessarymovementofpartsorpeoplewithinaprocess差的工作站規(guī)劃,差的5S.Poorworkstationlayout,poor5S.安排人員或物品圍繞工作站,改善5S,并消除動作浪費(fèi)Arrangepeopleorpartsaroundstation,improve5Sandeliminatemotionwaste.例如/Example:手工組裝的元件遠(yuǎn)離操作員Handloadcomponentsareplacedfarfromtheoperator;常用的工具遠(yuǎn)離工作站等Frequentlyusedtoolsarefarawayfromworkstationetc.多余動作/Motion在一個(gè)工序中不必要的物品或人員移動16返修/Rework每個(gè)人盡力第一次就做好Everyonedoitrightthefirsttime.返修可能是由原料，機(jī)器或人為引起的Canbecausedbymaterials,machineorpeople.返修需要額外的資源并且增加生產(chǎn)成本Requiresadditionalresourcetorework,addcosttoproduct.廢料，高成本(數(shù)百萬美元)-50%的板子需要去返修Scrap,highcost(millionsUSD)–50%ofboardsgototheHospital!使客戶不安Upsetscustomers

例如/Examples：集成元件極性錯(cuò)誤ICinstalledwithwrongorientation;用錯(cuò)機(jī)器程序等Usingwrongmachineprogrametc返修/Rework每個(gè)人盡力第一次就做好17才能、智力/Talent&Intellect未采用人們的意見和行為Untappedpeople’sideasandaction優(yōu)秀的返修工去做手工插件組裝

Welltrainedreworkoperatorputtohandloadoperation操作員浪費(fèi)時(shí)間找料，點(diǎn)料Operatorswastingtimesearchingforcomponents,countingparts好主意未被采納執(zhí)行Goodideanotcommunicatedforimplementation才能、智力/Talent&Intellect未采用人18我該怎樣排除浪費(fèi)？/HowcanIcontributetoeliminatewaste?了解不同類型的浪費(fèi)Understandthedifferenttypesofwaste了解以下的行為,將有助于消除浪費(fèi)UnderstandingthefollowingLeanconceptscanhelpyoutoeliminatewaste.識別它們Identifythem根據(jù)流程工作Carryoutyourprocessaccordingtoprocedure正確的處理印刷電路板和原材料ProperhandlingofPCBandmaterials根據(jù)目標(biāo)時(shí)間工作Followthetakttime,worktocycletimeoftheprocess發(fā)現(xiàn)浪費(fèi)時(shí),向主管匯報(bào)Reporttosupervisorifyouspotanyofthe“waste”,like…“Iamwaiting”我該怎樣排除浪費(fèi)？/了解不同類型的浪費(fèi)19Jidoka(Autonomation)Autonomation是任何時(shí)候異常狀況發(fā)生時(shí)停止生產(chǎn)的原則Autonomationistheprincipleofstoppingmanufacturingprocesswheneveranabnormalityoccurs.異常狀況是背離標(biāo)準(zhǔn)的Anabnormalityisanyformofdeviationfromthestandard例如/Examples：

質(zhì)量問題，低合格率，元件丟失等Qualityproblems,lowyield,missingcomponentetc機(jī)器參數(shù)：溫度太高等Machineparameters–temperaturetoohighetc氣管漏氣Airleakingfromairpipes不依照計(jì)劃生產(chǎn)Productionnotaccordingtoplan當(dāng)發(fā)現(xiàn)異常問題停止生產(chǎn)并通知管理員，管理員會找到原因和知道解決方案并解決異常事件Whenanabnormaleventisobserved,stopandcallthesupervisor.TheSupervisorwillfindthecauseandprovidethesolutiontosolvetheabnormality.出現(xiàn)異常Abnormalityoccurs發(fā)現(xiàn)異常Abnormalitydetected停止生產(chǎn)并通知Processofstopandcall決定問題Problemresolution解決問題Problemsolved正規(guī)操作NormalOperationJidoka(Autonomation)Autonomat20什么是5S?/Whatis“5S”?Aplaceforeverythingandeverythingisinitsplace.排除工作場所不需要的工具材料Eliminateallnon-essentialtools,materialsfromworkplace整理Seri(Sort)整頓Seiton(Setinorder)清掃Seiso(Shine)清潔Seiketsu(Standard)紀(jì)律Shitsuke(Sustain)組織好需要的工具材料Organiseallnecessarytools,materials

分配到最佳的工作場所Assignanoptimalareaintheworkplace有規(guī)則的打掃工作場所和設(shè)備Regularlycleantheworkplaceandequipment發(fā)展標(biāo)準(zhǔn)流程和檢查表,以維持有序/整潔/實(shí)用的工作場所Developstandardproceduresandcheckliststomaintainanorderly,clean&functionalworkarea貫徹5S體系,確保工作場所良好，5S將成為公司文化的一部分Implementsystemstoensuretheworkplaceisimprovedand5Sbecomespartoftheculture EliminateWaste!!什么是5S?/Whatis“5S”?Aplac215S不是一次的事情，它是一條紀(jì)律5Sisnotaonetimeevent,itisadiscipline.紀(jì)律給你帶來所有好的習(xí)慣，做正確的事Disciplineishavingthehabitofdoingtherightthingright.習(xí)慣是知識，技能和愿望的交叉點(diǎn)Habitistheintersectionofknowledge,skillsanddesire.“追求優(yōu)秀不是一件行為而是一種習(xí)慣”-亞里斯多德“Wearewhatwerepeatedlydo.Excellenceisnotanactbutahabit.”-Aristotle知識Knowledge怎樣取做Whattodo為何去做Whydoit目標(biāo)條件Atargetcondition技能Skills怎樣去做Howtodoit愿望Desire將去做Willtodoit什么是5S?/Whatis“5S”?5S不是一次的事情，它是一條紀(jì)律“追求優(yōu)秀不是一件行為而是一22設(shè)備效率/OEE(OverallEquipmentEffectiveness)OEE衡量設(shè)備效率損失,例如：OEEmeasuresmachinelosses,suchas:速度的降低Reducedspeed停頓Breakdowns換線/產(chǎn)品切換Changeover等待Idlingandminorstops報(bào)損和返工ScrapandreworkStartuplosses設(shè)備效率/OEE衡量設(shè)備效率損失,例如：23我能為改善OEE做什么?/HowcanIhelptoimproveOEE?理解指標(biāo),了解操作Understandtheindicatorsandknowtheperformancelevel參加并遵守?fù)Q線程序,以減少換線時(shí)間

Participateandfollowchangeoverprocedurestoreducechange-overtime交叉培訓(xùn)以勝任不同操作,以減少等待和停止Youarecross-trainedtosupportmultipleoperationstoreduceidlingandminorstops遵循標(biāo)準(zhǔn)的工作流程,以減少導(dǎo)致返工和報(bào)損的錯(cuò)誤

Followstandardworkprocedurestoeliminateerrorsthatleadtoreworkandscrap根據(jù)目標(biāo)時(shí)間操作,以減少等待和停止Performaccordingtotakttimetoreduceidlingandminorstops發(fā)生異常時(shí)通知主管,以減少設(shè)備停止時(shí)間

Informsupervisorswhenabnormalityisobservedtoreducemachinebreakdowns計(jì)劃好工作,以減少等待/搬運(yùn)/停工的浪費(fèi)Planyourworktoeliminatewaiting,transportation,downtimewasteduringtheconversion預(yù)測導(dǎo)致設(shè)備停止的原因Anticipatetheconditionthatcausedthemachinetostop我能為改善OEE做什么?/理解指標(biāo),了解操作24你知道一輛賽車在大獎(jiǎng)賽中換4個(gè)輪胎需要多少時(shí)間嗎?DoyouknowhowmuchtimeistakenforaracingcarintheGrandPrixtohaveall4tyreschanged?你認(rèn)為你將要花多少時(shí)間去換4個(gè)輪胎?Howlongdoyouthinkyouwillneedtochange4tyres?你知道需要多少時(shí)間換一個(gè)生產(chǎn)線嗎?Doyouknowhowmuchtimeistakentoconvertoneline?我們能進(jìn)一步改善我們現(xiàn)在的換線時(shí)間嗎?Canwefurtherimproveourcurrentconversiontime?你知道哪些因素會造成換線過程中的浪費(fèi)嗎?Doyouknowwhataretheelementsandwasteinthechange-overprocess?我們能改善它嗎?Canweimproveit?快速換線/SMED(SingleMinuteExchangeofDie)你知道一輛賽車在大獎(jiǎng)賽中換4個(gè)輪胎需要多少時(shí)間嗎?快速換線25為什么快速換線對我們重要？/WhySMEDisimportanttous?在客戶不斷變化的需求下,我們不得不小批量生產(chǎn),在指定時(shí)間內(nèi)交給客戶。迅速的change-over讓我們有靈活性去實(shí)現(xiàn)這個(gè)目標(biāo)Withthechangingdemandsofourcustomers,wehavetobuildproductsinsmallerquantities,delivertocustomersthequantitywithinthetimetheywanttheproducts.Fastchange-overgivesustheflexibilitytomeetthisobjective.最少的change-over時(shí)間能讓我們的設(shè)備有更多的時(shí)間去生產(chǎn)好的產(chǎn)品Minimisingchange-overtimewillgiveourequipmentmoretimetoproducegoodpartsintheshift/day.有競爭力，能夠滿足客戶需求，從而保持公司的利潤.Becompetitiveandsatisfycustomersrequirementtosustainprofitability.為什么快速換線對我們重要？/在客戶不斷變化的需求下,我們不26ChangeOver的重要元素/Importantelementsinchange-over內(nèi)部時(shí)間/Internaltime在change-over執(zhí)行時(shí)，機(jī)器必須要停止.Machinemustbestoppedforthechange-overtobecarriedout.例如/Example:從印刷機(jī)里取出stencil，機(jī)器必須停止Toremovestencilfromtheprinter,youneedtostopthemachine.外部時(shí)間/ExternaltimeChange-over在機(jī)器運(yùn)轉(zhuǎn)時(shí)仍然可以做.Change-overactivitiescanbedonewhilethemachineisstillrunning.例如/Example:可以在目前的程式運(yùn)行時(shí)，將新產(chǎn)品需要的FEEDER裝載于機(jī)器的另一個(gè)TABLEYoucanloadthefeedersofthenewmodelstoanotherSMTtablewhilethemachineisstillrunningcurrentmodel.ChangeOver的重要元素/內(nèi)部時(shí)間/Inte27我可以如何減少換線時(shí)間？/HowcanIhelptoreduceconversion(changeover)time?盡可能利用外部時(shí)間執(zhí)行換線操作

Youcanperformtheconversionactivitiesinexternaltimeasmuchaspossible盡可能地把內(nèi)部時(shí)間轉(zhuǎn)為外部時(shí)間.LookforopportunitytopushtheconversionactivitiesfromInternaltoExternaltimeifpossible準(zhǔn)備好材料，工具，模版，剪刀，PCBs等，以減少在移動/運(yùn)輸/等待上的時(shí)間浪費(fèi)Getconversionkits,tools,fixture,gauges,cutters,PCBsetcreadyandminimisewasteonmotion,transportationandwaitingtime5S好的工作區(qū)域，將減少找料和找工具的時(shí)間Good5Sinyourworkareatominimisesearchingfor

parts,toolsetc多任務(wù)的安排，以幫助換線Multitaskingtohelpintheconversion我可以如何減少換線時(shí)間？/盡可能利用外部時(shí)間執(zhí)行換線操作286-SIGMALEAN問題和回答Q&A/Feedback6-SIGMALEAN問題和回答296-SIGMALEANThankYou6-SIGMALEANThankYou30精益生產(chǎn)基本概念介紹精益生產(chǎn)基本概念介紹31SPS的四個(gè)主要組成部分4KeyElementsOfTheSolectronProductionSystem精益之屋HouseofSPSSixSigma檢查缺陷ErrorProof零缺陷ZeroDefects利用數(shù)據(jù)分析來解決系統(tǒng)的問題SystematicProblemSolvingVia

DataAnalysis拉動生產(chǎn)PullProduction一個(gè)流SinglePieceFlow平衡化生產(chǎn)TaktTimeProductionJidokaJIT基礎(chǔ)Foundation客戶之聲VoiceOfCustomer;質(zhì)量體系QualitySystem;5S;平整化生產(chǎn)Heijunka不斷地改善和提高GembaKaizen(ShopFloorContinuousImprovement)集中在效率上EfficiencyFocus自動化Stop@Abnormality集中在質(zhì)量上QualityFocus精益之屋SixSigma檢查缺陷ErrorProof零缺32質(zhì)量靈活性競爭力精益給客戶帶來什么?LEANSolectronProductionSystemTM(SPS)LEANImplementation(2004)…1Of3ElementsForCustomerValueProposition質(zhì)量靈活性競爭力精益給客戶帶來什么?LEANLEANImp33消除缺陷的二個(gè)途徑6Sigma消除缺陷SMTSolderPT/HHPtestFQACustomerTestPrinter立刻有效!用眼鏡看,采取行動TestTest25%缺陷Test現(xiàn)場改善消除缺陷75%缺陷用測量系統(tǒng)和數(shù)據(jù)分析,再采取行動? 6Sigma

項(xiàng)目? GageR&R? DOE? 防呆? 擴(kuò)展好的改善方法基礎(chǔ):現(xiàn)場改善可消除75%的缺陷消除缺陷的二個(gè)途徑6SigmaSMTSolderPT/HH34為什么要六西格碼精益生產(chǎn)？/

Why6-SigmaLean?滿足客戶需求Tomeetcustomerdemands.客戶只會為有價(jià)值的行為買單Customeriswillingtopayforonlyvalue-addedactivities.沒有價(jià)值的行為會增加生產(chǎn)的成本Non-valueaddedactivitiesaddcosttomanufacturing.要想在競爭激烈的商業(yè)環(huán)境下生存，就必須最充分地利用資源Tosurviveinthiscompetitivebusinessenvironment,thereisaneedtomaximiseutilisationofresources.保持公司的收益Sustainedprofitabilityofthecompany.對于公司FortheCompany對于個(gè)人ForYou為了在旭電的安全工作JobsecurityforSolectron集中你的時(shí)間成就有價(jià)值的分派任務(wù)Focusyourtimeandeffortonvaluabletasks.停止步行/檢查/查找/重做和其他一些無價(jià)值的行為Stopwalking,checking,searching,reworkingandothernon-valueactivities.加入到工廠的成功當(dāng)中InvolvedinthesuccessofthePlant.你的技能和領(lǐng)導(dǎo)能力的提高從而得到認(rèn)可Yourskillsandleadershipdevelopmentandtheopportunitytoberecognized.

為什么要六西格碼精益生產(chǎn)？/Why6-SigmaLea35客戶愿意付錢,并使產(chǎn)品發(fā)生轉(zhuǎn)變或給產(chǎn)品增加價(jià)值的行為才是有價(jià)值的生產(chǎn)活動Activitiesthattransformtheproducts,oraddvaluetotheproductswhichthecustomeriswillingtopayfor.例如/Examples：貼裝元件Mountingcomponentsontheboard;集成電路程序燒制ProgrammeIC印刷電路板放入盒子SecurePCBtothechassis;手工插裝元件Handloadthecomponents;波峰焊操作等WavesolderthePCBetc

什么是有附加值的活動？/WhatareValue-Added(VA)activities?客戶愿意付錢,并使產(chǎn)品發(fā)生轉(zhuǎn)變或給產(chǎn)品增加價(jià)值的行為才是有36什么是可增加附加值的行為？/WhatareValue–Enabled(VE)activities?不增加附加值但是必須要做的事情Activitieswhicharenon-valueaddedbutnecessary…today例如/Examples: -

視覺檢查與測試 -Visualinspectionandtesting -為了組裝操作在小范圍拿取工具和原料 -Smallmovementstoreachfortoolsormaterialsforassemblyetc;

什么是可增加附加值的行為？/不增加附加值但是必須要做的事情37什么是浪費(fèi)？/Whatiswaste?做不增加產(chǎn)品附加值的工作Workwhichdoesnotincreasethevalueoftheproducts例如/Examples

-錯(cuò)料返修

-Reworkduetotheuseofwrongparts; -補(bǔ)焊 -Touch-up; -當(dāng)機(jī)器運(yùn)轉(zhuǎn)時(shí)，操作工等待的時(shí)間 -Operatorwaiting-timewhilemachineisrunning; -找料，計(jì)算 -ARF,lookingforparts,counting; -走動 -Walkingetc.什么是浪費(fèi)？/Whatiswaste?做不增加產(chǎn)品附38什么是七大浪費(fèi)？/Whatis“7+1Waste”?Overproduction 過量生產(chǎn)Overprocessing 多余的工作程序Inventory 庫存Motion 多余動作Transportation 運(yùn)輸

Rework 返修Waiting 等待Intellectwaste

人才浪費(fèi)什么是七大浪費(fèi)？/Whatis“7+1Waste39消除7大浪費(fèi)過量生產(chǎn)多余搬運(yùn)等待多余的工作程序庫存多余動作不良品消除7大浪費(fèi)過量生產(chǎn)多余搬運(yùn)等待多余的工作程序庫存多余動作不40生產(chǎn)過剩/Overproduction客戶何時(shí)需要，需要什么是我們的生產(chǎn)目的Ourgoalistoproduceonlywhatthecustomerswant,whentheywantit.過量生產(chǎn)是一種最大的浪費(fèi)，它能夠?qū)е赂嗟睦速M(fèi)，諸如多余動作，等待，運(yùn)輸，返修;Overproductionistheworsttypeofwasteasitleadstofurtherwaste,suchasmotion,waiting,transportation,rework.例如/Examples: -為了周末的野餐,而帶了一周的食物 -Bringoneweeksworthoffoodforaweekendpicnic;

-存貨的返修

-ECreworkforinventory;

-提前36小時(shí)備好料

-Kit36hoursbeforepartsareneeded;

-后道工序運(yùn)作得比前道工序快

-Runbottomsidefasterthantopsideetc生產(chǎn)過剩/Overproduction客戶何時(shí)需要，需要41等待材料和機(jī)器操作時(shí)不做任何事Doingnothingwhilewaitingformaterialsormachinetocompleteaprocess.機(jī)器和人力利用率低下Underutilisemachineormanpower實(shí)質(zhì)浪費(fèi)時(shí)間會降低生產(chǎn)運(yùn)作Essentialwastetimecanbefilledwithproductiveactivities重新平衡生產(chǎn)線會減少等待時(shí)間Rebalanceactivitiestoremovewaitingtime.例子/Examples -提早到達(dá),等待開會

-Arrivinganhourearlyforameeting; -開會遲到,所以其他與會人員等待

-Cominglateforameetingwhiletherestarewaitingforyou; -板子等待壓配合

-Boardsawaitingpress-fit; -手工組裝的操作員等待板子

-Handloadoperatorswaitingforboardsetc.等待/Waiting等待材料和機(jī)器操作時(shí)不做任何事等待/Waiting42運(yùn)輸/Transportation工藝過程中不必要的物料和人力移動Unnecessarymovementofpartsorpeoplebetweenprocesses.差勁的物流安排導(dǎo)致不必要的材料運(yùn)輸Poorlogisticslayoutthatcauseunnecessarytransportationofmaterials.能造成運(yùn)輸損壞或是產(chǎn)品質(zhì)量問題等Cancreatehandlingdamageandcauseproductionrejectssuchasknock-off,droppedboardsetc例如/Examples: -傳送帶太長或工藝間隙太遠(yuǎn)

-Conveyoristoolongorgapbetweenprocessistoofarapart;

-在兩站之間不必要的存貨,板子送去清洗和5DX等

-Unnecessaryinventorybetweenstations,boardssenttowashand5DXetc運(yùn)輸/Transportation工藝過程中不必要的物料43庫存/Inventory原料放置不動不能增加附加值Materialsthataresittingidledonotaddvalue.庫存與現(xiàn)金緊密相聯(lián)Inventorytiesupcash(million/billionUSD)庫存可能是倉庫里的原料或是生產(chǎn)線上的在制品Inventorycanberawmaterialsinwarehouse/storeorWIPontheline.大量庫存會增加成本，并提高損壞，丟失，被盜等的可能性Highinventoryincreasesthepotentialforhigheroperationcosts,scrap,loss,theftetc差的生產(chǎn)線5SPoor5Sontheline例如/Example:

-Stockupamonth’ssupplyofMaggieMeewhenthesupermarketisnearby; -Absenteeismthatcausesinventorytopileupatcertainoperations; -Comboboardstrafficjam; -Overflowofinventoryatparkinglotsetc庫存/Inventory原料放置不動不能增加附加值44多余的工作程序/OverProcessing客戶不需求的工藝作業(yè)是一種浪費(fèi)Processingbeyondwhatthecustomerrequiresisawaste.可能是由于缺乏標(biāo)準(zhǔn),或不了解客戶的需求,或知識不知道規(guī)范Maybeduetoalackofstandardsorlackofknowledgeofcustomersrequirementsorsimplydonotknowthespecifications.多余的工作程序不能增加附加值,因?yàn)榭蛻舨⒉淮蛩銥橹跺XOverprocessingdoesnotaddvalueascustomerisnotgoingtopayforit.例如/Example：咖啡里加太多的糖Puttoomuchsugarforcoffee焊料過多Extendedstirringofsolderpaste將已經(jīng)清洗干凈的鏡子再清洗一次Cleaningthemirroroverandoveragaineventhoughthemirrorisalreadyclean.多余的工作程序/OverProcessing客戶不需求45多余動作/Motion在一個(gè)工序中不必要的物品或人員移動Unnecessarymovementofpartsorpeoplewithinaprocess差的工作站規(guī)劃,差的5S.Poorworkstationlayout,poor5S.安排人員或物品圍繞工作站,改善5S,并消除動作浪費(fèi)Arrangepeopleorpartsaroundstation,improve5Sandeliminatemotionwaste.例如/Example:手工組裝的元件遠(yuǎn)離操作員Handloadcomponentsareplacedfarfromtheoperator;常用的工具遠(yuǎn)離工作站等Frequentlyusedtoolsarefarawayfromworkstationetc.多余動作/Motion在一個(gè)工序中不必要的物品或人員移動46返修/Rework每個(gè)人盡力第一次就做好Everyonedoitrightthefirsttime.返修可能是由原料，機(jī)器或人為引起的Canbecausedbymaterials,machineorpeople.返修需要額外的資源并且增加生產(chǎn)成本Requiresadditionalresourcetorework,addcosttoproduct.廢料，高成本(數(shù)百萬美元)-50%的板子需要去返修Scrap,highcost(millionsUSD)–50%ofboardsgototheHospital!使客戶不安Upsetscustomers

例如/Examples：集成元件極性錯(cuò)誤ICinstalledwithwrongorientation;用錯(cuò)機(jī)器程序等Usingwrongmachineprogrametc返修/Rework每個(gè)人盡力第一次就做好47才能、智力/Talent&Intellect未采用人們的意見和行為Untappedpeople’sideasandaction優(yōu)秀的返修工去做手工插件組裝

Welltrainedreworkoperatorputtohandloadoperation操作員浪費(fèi)時(shí)間找料，點(diǎn)料Operatorswastingtimesearchingforcomponents,countingparts好主意未被采納執(zhí)行Goodideanotcommunicatedforimplementation才能、智力/Talent&Intellect未采用人48我該怎樣排除浪費(fèi)？/HowcanIcontributetoeliminatewaste?了解不同類型的浪費(fèi)Understandthedifferenttypesofwaste了解以下的行為,將有助于消除浪費(fèi)UnderstandingthefollowingLeanconceptscanhelpyoutoeliminatewaste.識別它們Identifythem根據(jù)流程工作Carryoutyourprocessaccordingtoprocedure正確的處理印刷電路板和原材料ProperhandlingofPCBandmaterials根據(jù)目標(biāo)時(shí)間工作Followthetakttime,worktocycletimeoftheprocess發(fā)現(xiàn)浪費(fèi)時(shí),向主管匯報(bào)Reporttosupervisorifyouspotanyofthe“waste”,like…“Iamwaiting”我該怎樣排除浪費(fèi)？/了解不同類型的浪費(fèi)49Jidoka(Autonomation)Autonomation是任何時(shí)候異常狀況發(fā)生時(shí)停止生產(chǎn)的原則Autonomationistheprincipleofstoppingmanufacturingprocesswheneveranabnormalityoccurs.異常狀況是背離標(biāo)準(zhǔn)的Anabnormalityisanyformofdeviationfromthestandard例如/Examples：

質(zhì)量問題，低合格率，元件丟失等Qualityproblems,lowyield,missingcomponentetc機(jī)器參數(shù)：溫度太高等Machineparameters–temperaturetoohighetc氣管漏氣Airleakingfromairpipes不依照計(jì)劃生產(chǎn)Productionnotaccordingtoplan當(dāng)發(fā)現(xiàn)異常問題停止生產(chǎn)并通知管理員，管理員會找到原因和知道解決方案并解決異常事件Whenanabnormaleventisobserved,stopandcallthesupervisor.TheSupervisorwillfindthecauseandprovidethesolutiontosolvetheabnormality.出現(xiàn)異常Abnormalityoccurs發(fā)現(xiàn)異常Abnormalitydetected停止生產(chǎn)并通知Processofstopandcall決定問題Problemresolution解決問題Problemsolved正規(guī)操作NormalOperationJidoka(Autonomation)Autonomat50什么是5S?/Whatis“5S”?Aplaceforeverythingandeverythingisinitsplace.排除工作場所不需要的工具材料Eliminateallnon-essentialtools,materialsfromworkplace整理Seri(Sort)整頓Seiton(Setinorder)清掃Seiso(Shine)清潔Seiketsu(Standard)紀(jì)律Shitsuke(Sustain)組織好需要的工具材料Organiseallnecessarytools,materials

分配到最佳的工作場所Assignanoptimalareaintheworkplace有規(guī)則的打掃工作場所和設(shè)備Regularlycleantheworkplaceandequipment發(fā)展標(biāo)準(zhǔn)流程和檢查表,以維持有序/整潔/實(shí)用的工作場所Developstandardproceduresandcheckliststomaintainanorderly,clean&functionalworkarea貫徹5S體系,確保工作場所良好，5S將成為公司文化的一部分Implementsystemstoensuretheworkplaceisimprovedand5Sbecomespartoftheculture EliminateWaste!!什么是5S?/Whatis“5S”?Aplac515S不是一次的事情，它是一條紀(jì)律5Sisnotaonetimeevent,itisadiscipline.紀(jì)律給你帶來所有好的習(xí)慣，做正確的事Disciplineishavingthehabitofdoingtherightthingright.習(xí)慣是知識，技能和愿望的交叉點(diǎn)Habitistheintersectionofknowledge,skillsanddesire.“追求優(yōu)秀不是一件行為而是一種習(xí)慣”-亞里斯多德“Wearewhatwerepeatedlydo.Excellenceisnotanactbutahabit.”-Aristotle知識Knowledge怎樣取做Whattodo為何去做Whydoit目標(biāo)條件Atargetcondition技能Skills怎樣去做Howtodoit愿望Desire將去做Willtodoit什么是5S?/Whatis“5S”?5S不是一次的事情，它是一條紀(jì)律“追求優(yōu)秀不是一件行為而是一52設(shè)備效率/OEE(OverallEquipmentEffectiveness)OEE衡量設(shè)備效率損失,例如：OEEmeasuresmachinelosses,suchas:速度的降低Reducedspeed停頓Breakdowns換線/產(chǎn)品切換Changeover等待Idlingandminorstops報(bào)損和返工ScrapandreworkStartuplosses設(shè)備效率/OEE衡量設(shè)備效率損失,例如：53我能為改善OEE做什么?/HowcanIhelptoimproveOEE?理解指標(biāo),了解操作Understandtheindicatorsandknowtheperformancelevel參加并遵守?fù)Q線程序,以減少換線時(shí)間

Participateandfollowchangeoverprocedurestoreducechange-overtime交叉培訓(xùn)以勝任不同操作,以減少等待和停止Youarecross-trainedtosupportmultipleoperationstoreduceidlingandminorstops遵循標(biāo)準(zhǔn)的工作流程,以減少導(dǎo)致返工和報(bào)損的錯(cuò)誤

Followstandardworkprocedurestoeliminateerrorsthatleadtoreworkandscrap根據(jù)目標(biāo)時(shí)間操作,以減少等待和停止Performaccordingtotakttimetoreduceidlingandminorstops發(fā)生異常時(shí)通知主管,以減少設(shè)備停止時(shí)間

Informsupervisorswhenabnormalityisobservedtoreducemachinebreakdowns計(jì)劃好工作,以減少等待/搬運(yùn)/停工的浪費(fèi)Planyou