福特生產(chǎn)系統(tǒng)的使命我們將教導(dǎo),吸引,以及激發(fā)福特汽車公司的所有組織和每一個人來了解以及應(yīng)用精實(shí)的行為原理和方法 -以促使連續(xù)不斷的改進(jìn)安全,品質(zhì),速 度,和總成本 -更而帶給顧客更多的價值一個不斷學(xué)習(xí)的組織Ateachingorganization….從大量生產(chǎn)到精實(shí)生產(chǎn)的轉(zhuǎn)變...

TransformationfromMasstoLean…附加價值與非附加價值附加價值是顧客願意出錢購買一些事物而這些事物帶給他外觀舒適功能

非附加價值=浪費(fèi)何謂附加價值?範(fàn)例:鑽孔裝設(shè)凸緣驅(qū)動螺絲

有附加價值2%浪費(fèi)60%無附加價值,但是必要的38%時間12639範(fàn)例:

走去取零件等待時間儲存零件運(yùn)輸範(fàn)例:拿取鑽孔機(jī)放下扳手挾住或鬆綁工具它是一個能改變產(chǎn)品之型式、裝配、及功能以合乎消費(fèi)者之規(guī)格的程序。Processesthatchangetheproductform,fit,orfunctiontomeetcustomerspecifications.消費(fèi)者願意付費(fèi)的工作

Workthecustomeriswillingtopayfor.何謂附加價值?只增加成本及工時未增加附加價值之部份消費(fèi)者不願意付費(fèi)的工作問題之癥兆而非問題之根源瞭解與認(rèn)知才是找出浪費(fèi)的根源

Therecognitionandunderstandingofwasteiskeyindefiningtherootcause必須認(rèn)識浪費(fèi)才能減少浪費(fèi)Toeliminatewaste,youhavetobeabletorecognizewaste何謂浪費(fèi)?MOVEITOVERTHEREUNTILWENEEDIT___________________________________________________________________________________________________七大浪費(fèi)SUPPLEMENTD1MOVEITOVERTHEREUNTILWENEEDIT等待過度加工庫存移動搬運(yùn)矯正生產(chǎn)過剩SUPPLEMENTD2七大浪費(fèi)Makingmorethanthenextprocessneeds生產(chǎn)過剩什麼是生產(chǎn)過剩?生產(chǎn)的數(shù)量量比下一工工程所需用用的還多以比下一站站還快的速速度生產(chǎn)以比下一工工程所需的的速度還快快的生產(chǎn)InventoryInventoryInventoryInventoryMotionInventoryExtraProcessingDefectsTimeWaitingInventory生產(chǎn)過剩InventoryInventoryInventory生產(chǎn)過剩為什麼這一一類的浪費(fèi)費(fèi)會發(fā)生?勞動成本及及間接成本本的指標(biāo)可可驅(qū)使人員員和設(shè)備的的使用率LaborandOverheadMeasurabledrivingutilizationofpeopleandequipment庫存而引起起的損失Lossesfromoutofstockconditions堵塞及斷線線而引起的的損失Lossesfromblockedandstarvedconditions特殊材料的的需求MaterialproducedtospeculativedemandRejects,rework,reruns改善Correction改善Correction為什麼這一一類的浪費(fèi)費(fèi)會發(fā)生?品質(zhì)回饋太太慢Poor,slowqualityfeedback增加生產(chǎn)線線外之撿察察工作Incrementalinspectiondoneoutsideprocessstation認(rèn)可檢修工工作Repairoperationsareviewedasacceptable缺乏有效之之錯誤防止止措施FeweffectiveErrorProofingdevicesinuse未推行標(biāo)準(zhǔn)準(zhǔn)作業(yè)Standardizedworknotinplace產(chǎn)品與製程程不相容Product/processincompatibility產(chǎn)品過度複複雜Productover-complexity沒必要的步步驟或程序序Unnecessarystepsorprocesses過度加工OverProcessing過度加工Overprocessing為什麼這一一類的浪費(fèi)費(fèi)會發(fā)生?作業(yè)標(biāo)準(zhǔn)不不明確Standardsunknown/uncleartooperators顧客之規(guī)格格不明確或或常變動Customerspecificationsarevagueorfluctuate產(chǎn)品試驗(yàn)過過多Producttestingandre-testingoccurs部門間目標(biāo)標(biāo)不一致且且溝通不良良Functionaldepartmentshavemisalignedgoalsandpoorcommunication多多益善的的想法Conceptthatmoreisbetter動作Motion多餘的移動動作業(yè)員的的走動Excessmovement;operatorwalking動作Motion為什麼這一一類的浪費(fèi)費(fèi)會發(fā)生?外觀及組織織不良之工工作站Poorworkstationconfigurationandorganization工作量不平平衡Workimbalance未實(shí)施目視視化工廠VisualFactorynotimplemented未實(shí)施標(biāo)準(zhǔn)準(zhǔn)化StandardizedWorknotimplemented長距離或重重複搬運(yùn)材材料Longdistanceordoublehandlingofmaterial“運(yùn)輸工具”Conveyance將它移到這裡等到我們需要時再動運(yùn)輸工具Conveyance為什麼這一一類的浪費(fèi)費(fèi)會發(fā)生?工作間距離離過長Longdistancesfromoperationtooperation物料輸送未未按排訂路路線MaterialHandlersnotonscheduledroutes倉庫在工廠廠內(nèi)部或外外部Warehouseonoroffsite收料點(diǎn)與工工作站間距距離太遠(yuǎn)Distancebetweenreceivingandpointofuse庫存過量Handlingexcessinventory缺乏部品作作業(yè)或看顧顧機(jī)臺Lackofpartsorwatchingmachine等候Waiting等候Waiting為什麼這一一類的浪費(fèi)費(fèi)會發(fā)生?等候支援訊訊息及物料料Waitingforsupport,information,and/ormaterials總和設(shè)備效效率過低，，機(jī)器停擺擺過高LowOverallEquipmentEffectivenessandhighmachinedowntime作業(yè)業(yè)線線不不平平衡衡Unbalancedoperations長且且不不一一致致的的等等候候時時間間Longandinconsistentleadtimes生產(chǎn)產(chǎn)時時程程經(jīng)經(jīng)常常變變動動Continualproductionschedulefluctuations看守守自自動動機(jī)機(jī)臺臺Watchingautomatedmachines未事事先先安安排排的的會會議議Undisciplinedmeetings過剩剩的的原原材材料料半半成成品品或或成成品品庫庫存存Excessrawmaterials,WIP,orfinishedgoods庫存存Inventory過度度庫庫存存Inventory(Excess)為什什麼麼這這一一類類的的浪浪費(fèi)費(fèi)會會發(fā)發(fā)生生?堅(jiān)持持大大量量生生產(chǎn)產(chǎn)的的想想法法MassProductionmindset,batchandqueue產(chǎn)能能無無法法預(yù)預(yù)估估Unpredictableproductivity內(nèi)外外部部材材料料供供應(yīng)應(yīng)不不順順I(yè)nfrequentdelivery/shipmentofmaterialsinternallyandexternally排程程與與製製程程間間不不相相連連結(jié)結(jié)Schedulesnotlinkedbetweenprocesses未啟啟用用目目視視化化工工廠廠管管理理VisualFactorynotinusetocontrol大料料架架或或大大批批量量Largecontainers/batchsizes改善善的的機(jī)機(jī)會會躲躲藏藏於於超超額額庫庫存存之之間間Excessinventoryhidesopportunitiesforimprovement如汪汪洋洋大大海海之之庫庫存存SeaofInventory過多之庫存EXCESSINVENTORY認(rèn)知知過度度庫庫存存成成本本之之知知多多少少TheTRUECOSTofExcessInventory額外外的的運(yùn)運(yùn)送送成成本本ExtraCarryingCost額外外的的庫庫存存成成本本ExtraStorage額外外的的料料架架ExtraContainers額外的管管理ExtraHandling額外時間間浪費(fèi)ExtraTime額外損害害ExtraDamage不安全UnsafeConditions過度庫存存隱藏品品質(zhì)問題題Excessinventoryhidesqualityproblems...無止盡的的改善Nocontinuousimprovement!其它浪費(fèi)費(fèi)OtherWastes人員People心態(tài)Minds想法Ideas能力Abilities科技Technologies有關(guān)安全全之浪費(fèi)費(fèi)Allwastesrelatetosafety精實(shí)製造造LeanManufacturing以消除浪浪費(fèi)來說說縮短顧顧客之等等候時間間Amanufacturingphilosophywhichshortensthetimelinebetweenthecustomerorderandtheshipmentbyeliminatingwaste貨品送達(dá)達(dá)PRODUCTSHIPMENT顧客訂單單CUSTOMERORDER時間TimeBusinessasUsualLeanManufacturing貨品送達(dá)達(dá)PRODUCTSHIPMENT顧客訂單單CUSTOMERORDER時間〈縮縮短〉Time(Shorter)WasteWaste福特生產(chǎn)產(chǎn)系統(tǒng)FordProductionSystem福特生產(chǎn)產(chǎn)系統(tǒng)是是以減少少浪費(fèi)來來穫致持持續(xù)的改改善TheFordProductionSystem(FPS)isdefinedasasystemofcommonprocessesandtoolsthatsupportcontinuousimprovementthroughtheeliminationofwaste.FTPMTrainingISPCMEEnvironmentalIMSHARPSMFWorkGroups福特生產(chǎn)產(chǎn)系統(tǒng)之之要素FPSElementsFTPMTrainingISPCMEEnvironmentalIMSHARPSMFWorkGroups福特生產(chǎn)產(chǎn)系統(tǒng)之之要素FPSElements精實(shí)之家家HouseofLeanHighestQuality,LowestCost,ShortestLeadTime作業(yè)穩(wěn)定STABLEPROCESSES平準(zhǔn)化生產(chǎn)LeveledProduction標(biāo)準(zhǔn)化作業(yè)StandardizedWork改善KaizenJITJidoka往未來圖圖五個階階段的目目的PurposeofFivePhasestoFutureStateContinuous連續(xù)的流動Flow後拉式系統(tǒng)PullSystem平準(zhǔn)化生產(chǎn)LevelProduction同步生產(chǎn)SynchronousProduction穩(wěn)定性Stability福特原始始的生產(chǎn)產(chǎn)哲學(xué)Ford’sOriginalManufacturingPhilosophy(1926)標(biāo)準(zhǔn)化及及持續(xù)改改善StandardizationandContinuousImprovement減少浪費(fèi)費(fèi)EliminateWaste採用連續(xù)續(xù)生產(chǎn)模模式UseContinuousFlowManufacturing物料在來來源處即即採品質(zhì)質(zhì)管理PracticeQualityattheSource摘錄自亨亨利福特特的著作作今日與明明日FromTodayandTomorrowbyHenryFord人員互動動ThePeoplePinionGear以小組作作業(yè)為基基礎(chǔ)減少少浪費(fèi)，，以求持持續(xù)改善善AWorkGroup-basedorganizationalignedanddriventocontinuallyimprovebusinessresultsbyeliminatingwaste.FlexibleCapable,HighlyMotivated&EmpoweredPeopleExceedCustomerExpectationsQualityCostTime信賴度&產(chǎn)能維護(hù)護(hù)TheReliabilityMaintainabilityPinionGear使用世界界級之設(shè)設(shè)備設(shè)計(jì)計(jì)、維護(hù)護(hù)與製程程，以確確保安全全、穩(wěn)定定、彈性性及品質(zhì)質(zhì)，以期期達(dá)成並並或超越越內(nèi)部及及顧客之之須要Processesandequipmentdesignedandmaintainedataworldclassleveltoensuresafety,stability,flexibility,andin-stationqualitythatconsistentlymeetorexceedinternalandexternalcustomerrequirementsExceedCustomerExpectationsQualityCostTimeWorldClassReliability&Maintainability運(yùn)轉(zhuǎn)不息息的轉(zhuǎn)輪輪TheContinuouslyFlowingPinionGear運(yùn)用精實(shí)實(shí)生產(chǎn)與與即時供供料觀念念，以維維持持續(xù)續(xù)且有順順序的供供料，以以附合顧顧客要求求ApplicationofleanmanufacturingandJust-In-TimeprinciplestoprovideacontinuousflowofmaterialsandproductsinsequenceattherateofcustomerdemandExceedCustomerExpectationsQualityCostTimeContinuouslyFlowingMaterial&Products福特生產(chǎn)產(chǎn)系統(tǒng)模模式TheFordProductionSystemModel絕竅Key:連結(jié)內(nèi)3小齒輪輪才能帶帶動中央央齒輪Thethreepiniongearsarelinkedtodrivethecentralgear.所有3齒齒輪必須須有效運(yùn)運(yùn)轉(zhuǎn)才能能達(dá)到目目標(biāo)Allthreemustperformeffectivelytodeliverthegoal.FlexibleCapable,HighlyMotivated&EmpoweredPeopleExceedCustomerExpectationsQualityCostTimeWorldClassReliability&MaintainabilityContinuouslyFlowingMaterial&ProductsFord生生產(chǎn)系系統(tǒng)模模式品質(zhì)成本時效超越顧顧客期期望具彈性性,有能力力,高度被被激勵勵&授權(quán)權(quán)的員員工世界級級的信信賴性性&維護(hù)保保全連貫性性的物物料&產(chǎn)品品流動動如同合合作夥夥伴關(guān)關(guān)係的的協(xié)力力廠強(qiáng)健的的產(chǎn)品品及作作業(yè)制制度(Ford產(chǎn)品品發(fā)展展系統(tǒng)統(tǒng)<24個個月車車輛推推出)產(chǎn)能規(guī)規(guī)劃訂購到到交貨貨<15天Ford顧顧客服服務(wù)2000價值流流圖的的循環(huán)環(huán)周期期ValueStreamMappingCycle...願景VISIONPROCESSDATAgatheredCurrentStateMapdrawnFutureStateMapdrawnProcessandFlowKaizensidentifiedValueLoopsIdentifiedActionstakenFutureStateMapbecomestheCurrentStateMap減少浪費(fèi)重重點(diǎn)FocusedeliminationofWASTEDate:2/16

newslidesafterthispage…福特現(xiàn)況HarbouronFord...目前重點(diǎn)RecentHighlights:Atlanta裝配線AssemblyValencia裝配線AssemblyChicago沖壓線StampingKTP沖壓線StampingLima引擎裝配線線EngineCleveland引擎裝配第第2線Engine#2Bridgend引擎裝配線線EngineLivonia變速箱裝配配線TransmissionBordeaux變速箱裝配配線Transmission福特現(xiàn)況HarbouronFord...檢查重點(diǎn)PlantTourChecklist標(biāo)準(zhǔn)作業(yè)StandardizedWork防止錯誤ErrorProofing目視管理Visualcontrols預(yù)防性維護(hù)護(hù)Preventivemaintenance工作地點(diǎn)的的組織Workplaceorganization貨櫃化Containerization拉式生產(chǎn)Pullsystems小批量生產(chǎn)產(chǎn)Smalllotproduction低庫存Lowinventory團(tuán)隊(duì)精神Workteams現(xiàn)場佈置流流程Layout/flow快速換模換換線Quicktoolchangeover產(chǎn)出時間ThroughputtimeRichardChenVicePresidentPurchasing,FordLioHoMotorCompany,Ltd.AndExecutivePurchasingDirector,FordChinaOperationsChungLi,Taiwan方針展開是是一個可見見的,已已架構(gòu)的計(jì)計(jì)畫程序,用以做做為組織因因策略的優(yōu)優(yōu)先次序所所做的調(diào)整整及目標(biāo)PolicyDeploymentisavisible,structuredplanningprocessthatfocusesandalignstheorganizationonthestrategicpriorities.定義Definition為什麼要方針展開?WhyPolicyDeployment?尋找,集集中以及調(diào)調(diào)整組織以以突破目標(biāo)標(biāo)Identifies,focuses,andalignstheprioritiestoenablebreakthroughperformance.經(jīng)由合作發(fā)發(fā)展的目標(biāo)標(biāo)提供真真正員工放放權(quán)授能的的環(huán)境Providesframeworkfortrue““EmployeeEmpowerment”throughcollaborativedevelopmentofobjectives.以主要目標(biāo)標(biāo)為決策及及解決問題題的準(zhǔn)則Usesmajorobjectivesascriteriafordecisionmakingandproblemsolving.讓經(jīng)營計(jì)劃劃及其細(xì)則則目視化Visualizestheplansandassociateddetails利用系統(tǒng)驅(qū)驅(qū)使持續(xù)不不斷的改善善Utilizesthesystemsapproachforcontinuousimprovement.使它和管理理考績系統(tǒng)統(tǒng)相連接IntegratedwiththePerformanceManagementSystem.POM’sPlantMgrs.PolicyDeploymentObjectivePlantMgr.AreaMgrsPolicyDeploymentObjectivePlantMgr.AreaMgrsPolicyDeploymentObjectiveAreaMgr.Supt.PolicyDeploymentObjectiveAreaMgr.PolicyDeploymentObjectiveAreaMgr.Supt.PolicyDeploymentObjectiveAreaMgr.PolicyDeploymentObjectiveAreaMgr.Supt.PolicyDeploymentObjectiveAreaMgr.Supt.PolicyDeploymentObjectiveSupt.Supt.調(diào)整目標(biāo)的方方針展開AlignmentofObjectivesPolicyDeployment方針展開在A階段的需求求如下:廠內(nèi)正在進(jìn)行行方針展開的的程序目的是是:使全公司不論論垂直的及水水平的跨部門門根據(jù)方針展展開調(diào)整部門門目標(biāo)使方針展開傳傳遞到現(xiàn)場主主任及他的部部屬FPS的目的的包括於方針針展開的程序序之內(nèi)每日的營運(yùn)數(shù)數(shù)據(jù),展現(xiàn)現(xiàn)出來的營運(yùn)運(yùn)績效和調(diào)整整後的目標(biāo)做做比較並且傳傳遞管理的第第一層管理的第一層層於一固定時時間和他的下下屬討論績效效和目標(biāo)的差差距方針展開A階段的需求求PolicyDeploymentCheckpointARequirements企業(yè)經(jīng)營計(jì)劃劃的傳承BUSINESSPLANCASCADE營運(yùn)計(jì)劃的傳傳承主要是要要顯示出製造造部門(代表表相當(dāng)比例的的固定及變動動成本)如如何根據(jù)營運(yùn)運(yùn)計(jì)劃作調(diào)整整TheBusinessPlanCascadeisintendedtoshowhowmanufacturingoperations(whichrepresentasubstantialpercentageoffixedandvariableoverhead)canbealignedwithBusinessPlanobjectives.根據(jù)營運(yùn)計(jì)劃劃調(diào)整生產(chǎn)型型態(tài)ALIGNMENTOFOPERATIONSWITHTHEBUSINESSPLAN每一直接或間間接生產(chǎn)部門門,都必需需根據(jù)營運(yùn)計(jì)計(jì)劃設(shè)定目標(biāo)標(biāo)以及衡量基基準(zhǔn),並且且持續(xù)的朝目目標(biāo)改善TobealignedwiththeBusinessPlaneachdepartmentwhichoperatesorsupportsproductionequipment/facilitiesneedtosetanappropriateobjectiveandmeasureperformanceusingkeymeasurables.Continuousimprovementtowardtheseobjectiveswill:根據(jù)營運(yùn)計(jì)劃劃調(diào)整生產(chǎn)型型態(tài)ALIGNMENTOFOPERATIONSWITHTHEBUSINESSPLAN根據(jù)營運(yùn)計(jì)劃劃調(diào)整生產(chǎn)型型態(tài)ALIGNMENTOFOPERATIONSWITHTHEBUSINESSPLAN排除價值鏈上上的浪費(fèi)Eliminatewasteintheentirevaluechain,includingoverhead降低生產(chǎn)的基基本成本Reducetheanufacturer’scostbase增加目前產(chǎn)品品的獲利率Improveitsprofitabilityonexistingbusiness.以更低的成本本來吸引顧客客,以及在在銷售的增加加情況下獲利利率也同時增增加Makethemanufacturermoreattractivetocustomers(viaalowercostbase)andprovideforincreasedsaleswithacommensurateincreaseinprofits.9、靜靜夜夜四四無無鄰鄰，，荒荒居居舊舊業(yè)業(yè)貧貧。。。。12月月-2212月月-22Thursday,December29,202210、雨中黃黃葉樹，，燈下白白頭人。。。14:34:5614:34:5614:3412/29/20222:34:56PM11、以我獨(dú)沈沈久，愧君君相見頻。。。12月-2214:34:5614:34Dec-2229-Dec-2212、故故人人江江海海別別，，幾幾度度隔隔山山川川。。。。14:34:5614:34:5614:34Thursday,December29,202213、乍見翻疑疑夢，相悲悲各問年。。。12月-2212月-2214:34:5614:34:56December29,202214、他鄉(xiāng)生生白發(fā)，，舊國見見青山。。。29十十二月20222:34:56下午午14:34:5612月-2215、比比不不了了得得就就不不比比，，得得不不到到的的就就不不要要。。。。。十二二月月222:34下下午午12月月-2214:34December29,202216、行動動出成成果，，工作作出財(cái)財(cái)富。。。2022/12/2914:34:5614:34:5629December202217、做前，，能夠環(huán)環(huán)視四周周；做時時，你只只能或者者最好沿沿著以腳腳為起點(diǎn)點(diǎn)的射線線向前。。。2:34:56下午午2:34下午午14:34:5612月-229、沒有失敗敗，只有暫暫時停止成成功！。12月-2212月-22Thursday,December29,202210、很多事情情努力了未未必有結(jié)果果，但是不不努力卻什什么改變也也沒有。。。14:34:5614:34:5614:3412/29/20222:34:56PM11、成功就是是日復(fù)一日日那一點(diǎn)點(diǎn)點(diǎn)小小努力力的積累。。。12月-2214:34:5614:34Dec-2229-Dec-2212、世間成事，，不求其絕對對圓滿，留一一份不足，可可得無限完美美。。14:34:5614:34:5614:34Thursday,December29,202213、不不知知香香積積寺寺，，數(shù)數(shù)