精益生产工具介绍

Process
Building Quality into the Process 2 ways to perform SPF
Hale Waihona Puke Transportation is integrated into the production process via human conveyance e.g., Chaku-Chaku
Supermarket
Material Information Empty container Full container 1 Sequence / Timing
3
4
Cell or Chaku-Chaku line
2
1
Assembly Line
JIT Jidoka
e
GPS for GPC
Heijunka
Check, Do, Verify
One Piece Flow
Your customer is the next step in the process. Give to your customer, exactly what they need ( 1 item),
exactly when they need it, done perfect every time.
Production Line Cell 6
Part Number All Parts
Part Name
All Tubes
Operator
Orbital Weld
Flex
Weld
End Finish
Weld
End Finish
Torch Braze
Mech. Clean
Mech. Clean
Mark
The next process is the customer … never send defects !
Check, Do, Verify
Check - The previous operators work. Do - Your work. Verify - That you did your work correctly.
lowering the peaks among the daily production volumes
HEIJUNKA
as much as possible and making the production flow smooth and unflucuating.
Average by total volume
Level Loading
taken from memory Jogger
•Finding a balance between the volume of work
that your organization needs to do and your
capacity
•Adjusting a production schedule to meet unexpected changes in customer demand
Pull Production Methodology & Sequence
Definition
System of manufacturing in which the final process withdraws the parts it needs from the preceding process at exact timing intervals, in the exact standardized amount needed.
GEMS Global Production System
g ACTION WORKOUT
New / Rev Organization
Tubing
Area
CFM Cell
Page 1 of 1
Supervisor
Fern Bissonnette
Date 2nd Qtr. ‘01
Standard Work Sheet
Check, Do, Verify
Every Customer in a Process has:
- a right to expect perfect material - an obligation to inspect the material before use. - an obligation to inform the previous step in the
Average by
model
In general, the more fluctuations you in the production flow, the more muda you
end up having. That is because the capacity and capability of a line tends to be set
at a level that meets the peak production demand rather than the average demand.
If the production line produces only a single product, you may be able to reduce
# Lots of
Total Manual & Travel Time
Standard Work-in-Process
Operator
Man/Travel Time
27 - avg lot = 6
Turns
Takt/Rate Time
100/Day
DPU's
The next process is the customer … never send defects !
Single Piece Flow catches Defects immediately • When you find a Defect
• You only have one • You know where it occurred • You Can find/Resolve the Root Cause immediately
Sample Inspect catches Defect too Late • When you Finally Find a Defect
• How many more do you have? • Where are they in the process? • What is the root Cause?
Hydro Test
Outside Cell FPI X-Ray EDM
Weld
End Finish
Scope of Operations
From: Raw material To: Finished Goods
Quality Check
Safety Precaution
Standard Work-in-Process
1. Takt time 2. Std work
Flow: work (process) that is done in conjunction with or simultaneous to transportation
One Piece Flow
• The production is organized into a synchronous chain where each person has a balanced amount of work relative to his/her supplier and customer in the chain.
process of any problem. - an obligation to stop the process until any
problem has been resolved.
Single piece or one piece flow is a means to primarily build Quality into the process. This is achieved by establishing a takt Time, developing std work, and swip. The premise is that an Operator can only work on one piece at a time, and performs a Quick quality check on the CTQs of the process before moving The part to the following process. If a defect is detected, Jidoka Is enacted…the line is stopped, and immediate action is taken To remediate the situation and take countermeasures to prevent reoccurence
Sequencing
•Ordering the production in such a fashion to achieve the desired TAKT for all items
Leveled Production
Leveled production means
Amount of products that can be sold
The next process is the customer … never send defects !
Check, Do, Verify
Gets you into Parts Per Million qualityWhen you verify your work, you catch 1