1、,xxxxxxxxxx有限公司,LEAN MANUFACTURING TRAINING 精益生產(chǎn)培訓(xùn),銷售,未預(yù)計(jì)的訂單變化,訂單下達(dá)到工廠,YES,NO,超時(shí)加班,額外費(fèi)用,我們每天坐班的工廠？,停工待料 積壓庫(kù)存 設(shè)備故障 質(zhì)量問(wèn)題 人員調(diào)配 .,快！119,轟隆?。∞Z隆??！,What Shall We Talk?內(nèi)容安排,精益生產(chǎn)系統(tǒng)簡(jiǎn)介 現(xiàn)場(chǎng)管理及班組建設(shè) 質(zhì)量、成本和交貨周期 運(yùn)行效率 價(jià)值流分析 柔性生產(chǎn)單元 看板拉動(dòng)和精益供應(yīng)鏈 精益指標(biāo)和推行策略 模擬演練 討論,Lean Manufacturing System Briefing精益生產(chǎn)系統(tǒng)簡(jiǎn)介,1,制造系統(tǒng)的要點(diǎn) 市場(chǎng)競(jìng)爭(zhēng)及

2、全球化 精益生產(chǎn)五項(xiàng)原則 最好的工廠？,Starting with Toyota in the late 50s and catching on in the mid 80s in the reminder of the industrial world, Lean Manufacturing has become a key strategy for manufacturers 起源于20世紀(jì)50年代豐田汽車公司，而在80年代中期被歐美企業(yè)紛紛采用。隨著微利時(shí)代的來(lái)臨，精益生產(chǎn)模式成為企業(yè)競(jìng)爭(zhēng)的有力武器,Lean Thinking and Lean Manufacturing System

3、精益思維和精益生產(chǎn)系統(tǒng),Manufacturing Evolution 制造系統(tǒng)演化史,Henry Ford Assembly line mass production Produce in high volume with low variety Single skill 福特首創(chuàng)的裝配線是大規(guī)模低品種生產(chǎn)方式的代表，工人被當(dāng)成工作的機(jī)器,Toyota Production System (TPS) Just-In-Time Production (produce only what is needed) Pull System High variety to meet customers

4、wants 豐田系統(tǒng)是建立在準(zhǔn)時(shí)化觀念上的拉動(dòng) 式生產(chǎn)模式，以應(yīng)付小訂單多品種的挑戰(zhàn),Key Points for Manufacturing System 制造系統(tǒng)要點(diǎn),Craft 手工生產(chǎn),Mass 大規(guī)模生產(chǎn),Synchronous 同步生產(chǎn),Agile 敏捷生產(chǎn)組織,Lean 精益生產(chǎn)組織,Low volume Customized 低產(chǎn)量 個(gè)性化,Large batches of similar products Inflexible machinery Manufacture of goods by process 大批量少品種 工序式生產(chǎn) 設(shè)備大難組合,Focused on to

5、tal elimination of waste Ongoing efforts to improve Quality, Productivity, and Responsiveness Recognition of employee abilities 消除浪費(fèi) 不斷改進(jìn) 員工參與,Builds on synchronous manufacturing Emphasize on lead time reduction Improve asset utilization Built to customer demand 在同步生產(chǎn)的基礎(chǔ)上，強(qiáng)調(diào)縮短生產(chǎn)周期 提高資源利用率 需求驅(qū)動(dòng),Remov

6、e constraints to respond to customer demand through the entire supply pipeline (supplier-customer) Capable plants linked to lean concepts 改善整個(gè)價(jià)值鏈 節(jié)點(diǎn)上連著精益工廠,Marketing Competition and Globalization 市場(chǎng)競(jìng)爭(zhēng)及全球化,Shorter lead time and on time delivery 快速并準(zhǔn)時(shí)交貨 Grow the mix，special configurations 需求品種增加，特殊定制

7、Maintain / improve quality and reduce price 不斷改進(jìn)質(zhì)量及降低銷售價(jià)格 Total life cycle of product becoming shorter and shorter 產(chǎn)品的生命周期越來(lái)越短 No boundary，business globalize village 無(wú)國(guó)界，業(yè)務(wù)“地球村”,Marketing Competition and Globalization 市場(chǎng)競(jìng)爭(zhēng)及全球化,Life Cycle Cost In Different System不同系統(tǒng)中的成本,精益生產(chǎn)系統(tǒng)之產(chǎn)品 生命周期成本,大規(guī)模生產(chǎn)模式下的 產(chǎn)品

8、生命周期成本,產(chǎn)量,$/ piece,V,銷售價(jià)格,The Cost / Lean Relationship 精益生產(chǎn)與成本的關(guān)系,靈巧的雙手,投資,直接員工,自動(dòng)化程度,產(chǎn)品生命周期成本,全自動(dòng),What Is Lean?,lean adj. 1a: lacking or deficient in flesh b: containing little or no fat 2: lacking richness 3: deficient in an essential or important quality or ingredient 4: characterized by economy

9、of style or expression syn. thin, skinny, lanky, scrawny, gaunt, bony, emaciated, svelte, lank ant. fat, fleshy, overweight, flabby, obese, plump, chunky, corpulent, soft,Lean -“精益”釋義,精益：形容詞 1： a：無(wú)肉或少肉， b：少脂肪或無(wú)脂肪 2： 不富裕 3： 在必要性，重要性，質(zhì)量或成分方面稀缺 4： 文體或措詞簡(jiǎn)練 同義詞：薄，極瘦，過(guò)分瘦長(zhǎng)，骨瘦如柴，瘦削的， 似 骨的，消瘦的，細(xì)長(zhǎng)的，瘦長(zhǎng)的 反義詞： 肥

10、胖的，多肉的，過(guò)重的，不結(jié)實(shí)的，過(guò)分 肥胖的，豐滿的，粗短的，肥大的，軟的,What is Lean Manufacturing 什么是精益生產(chǎn)-五個(gè)原則,Value 價(jià)值,站在客戶 的立場(chǎng)上,Value Stream 價(jià)值流,從接單到發(fā)貨 過(guò)程的一切活動(dòng),Flow 流動(dòng),象開發(fā)的河流 一樣通暢流動(dòng),Demand Pull 需求拉動(dòng),BTR-按需求生產(chǎn),Perfect 完美,沒(méi)有任何事物 是完美的 不斷改進(jìn),With Lean Manufacturing You Can Get 通過(guò)精益生產(chǎn)可以實(shí)現(xiàn),生產(chǎn)時(shí)間減少 90% 庫(kù)存減少 90% 到達(dá)客戶手中的缺陷減少 50% 廢品率降低 50% 與

11、工作有關(guān)的傷害降低 50% The amount of human effort, time, space, tools, and inventories can typically be cut in half very quickly, and steady progress can be maintained from this point onward to cut inputs in half again within a few years. -精益思維, Womack perhaps faster than normal projects 建議訂立進(jìn)取性的進(jìn)度安排；也許要比正常的項(xiàng)目要快 Depends on pace of culture change 依賴于“企業(yè)文化”的改變步調(diào) Typical “典型的” Pilot area - 12 weeks First wall-to-Wall line half to one year Plant 3-5 years 生產(chǎn)試驗(yàn)區(qū) 3個(gè)月 第一個(gè)“全方位”的生產(chǎn)車間 半年到一年 工廠：4 - 5 年,Lean Implementation-The Path精益實(shí)施之進(jìn)程,設(shè)計(jì)目標(biāo)流程 和目標(biāo)測(cè)定,行動(dòng)計(jì)劃,全員參與的文化 5S - 整理工作場(chǎng)地 系