（精）精益生产方式的概念.ppt

WIP---work in process/overproduction(在制品过多) Inventory(库存) Transportation---Moving materials/handling(搬运) Waiting---people and product (人/产品的等待) Reject---defect/rework(返工) Excess motion---improve work place layout and organization,6s(多余的运输-改善工作区布局和组织) Extra process steps(多余的工序步骤 ) Inspection(检查工序) Loading parts into trays(将产品装入料盘) Paperwork(记录产品数量等文件工作) Only value adding activities(做对产品有价值的动作) Zero inventory and WIP(零库存/在制品) Prevent defects(预防缺陷产生) Reduce space(减少空间) More communication(更多的沟通) Balance work flow(平衡流程) Value-Adding Activities增值活动 ….changes the raw material or information so it meets the customers requirements. 改变产品的物理状态，使其更接近于客户所需要的形式 ….are valued by the end customer ( customer is willing to pay for the activity) Non-Value-Adding Activities – Waste非增值活动 ….consume resources and take time, but does not directly transform the raw material or information .消耗资源，占用空间，但不直接转换到产品中。 Traditional MFG(传统生产) Build parts in batches(批量生产) Work to make processes efficient(行为活动高效率) Arrange products in process area(流程组化安排工厂) Develop methods to catch errors/defects(事后寻求改正错误或缺陷的方法) carry large inventories so they can meet delivery requirements 堆积大批量存货以满足交货所需 Example:airplane simulation(举例:模拟飞机生产) Traditional factory VS Lean factory(传统工厂VS精益工厂) Customer demand:20 planes/day(客户需求:20架飞机/天) $2000,000/plane---sale $1000,000/plane---cost value(including labor/materials) 1 days=10 minutes,every station30 seconds. 制程1：仓库---送料---做机身---做机翼（左/右）---QC---喷漆 制程2：做机身---做机翼（左/右）---喷漆--- QC Metrics Delivery---OTD（On time delivery)? Productivity---PPH（Part/Person/Hour）? Quality---40% yield? Profits---$30 millions? WIP---30? Improvements:(改善) Operators training on criteria(own inspection)(自检) Remove bottle neck(消除瓶颈) Reduce batch size(减小批量) Reduce distance(减小距离) Re-layout line(重新设计产线) Tools to simplify the work(夹具简化工作) Response to incoming materials(每个工序检查上工序来料) Measure cycle time(测量周期时间)---time to complete a process step(完成一个工序的时间) Example(举例): To write a nam