manufactory excellence 1

1、 what is manufacturing excellence ? 什么是卓越制造什么是卓越制造 business and manufacturing strategy 經(jīng)營與制造戰(zhàn)略經(jīng)營與制造戰(zhàn)略 manufacturing process vs supply chain 制造與供應(yīng)鏈制造與供應(yīng)鏈 manufacturing process vs pdca wk15-16 fty changed plastic parts supplier; wk23 slide switch shortage clip ppm level (ave. defects) company 26 motor

2、ola 10 texas instruments 100 hewlett packard (hp) (source: ge 6) world class benchmark process capability defects per million opportunities s sppm 2308,537 3 66,807 46,210 5 233 6 3.4 process quality jan. - aug., 2000 381 245 49 0 4473 605 176 0 391 237 122 333 341 274 614 223 00 163 000 158 0 200 4

3、00 600 800 1000 ppm hq 200/30027134282206266397154109 hq 20/3038124549044736051760 hp000278006100 moulding391237122333341274614 pcb22300163000158 jan.feb.mar.apr.mayjun.jul.aug. targets: hq 20/30/200/300 & hp/pcb - 400 ppm moulding - 500 ppm process quality dap zhuhai 199419951996199719981999 years

4、0% 5% 10% 15% 20% 25% inventories in % of sales dell philips inventories/sales dell - philips benchmark dap zhuhai inventory total days 0 10 20 30 40 50 60 70 80 90 97.1 97.3 97.5 97.7 97.9 97.1 98.1 98.3 98.5 98.7 98.9 98.1 99.1 99.3 99.5 99.7 99.9 99.1 00-1 00-3 00-5 00-7 00-9 working days dap zhu

5、hai total quality 全面質(zhì)量全面質(zhì)量 jit manufacturing 即時制造即時制造 people involvement 全員參與全員參與 source:robert w. hall, attaining manufacturing excellence, the irwin professional publishing for a factory, the utmost manufacturing objective is to make the material flow and information flow through the supply chain

6、as fast as possible. a goal 一個目標(biāo)一個目標(biāo) to be one of the best companies in the world: the best to trade with, work for and invest in. 成為世界最好的公司 a mindset 一種思維一種思維 we can always improve the way we improve 我們總能改進(jìn)自己的工作方法 we can always increase our speed of learning 我們總能加快學(xué)習(xí)的速度 an approach for managing imp

7、rovement 一套改進(jìn)的方法一套改進(jìn)的方法 plan-do-check-act-plan-do-check-act-plan. pdca不斷循環(huán) a set of tools 一系列工具一系列工具 bbs, survey tools, pqa/pbe, mini co., glasswall, tpm, jit, 5s etc.業(yè)務(wù)平衡卡, 調(diào)查工具, pqa/pbe, 小公司, 展 示板, 全員預(yù)防性生產(chǎn)維護(hù), 即時生產(chǎn), 五常法等等 design review設(shè)計評估, fmea, field test, call rate md, skill matrix 技能矩陣 伙伴供應(yīng)商，pi

8、tstop/sprint(jit)，看板管理 建議機(jī)制，小公司，qit，qcc pdca，六步工作法，質(zhì)量七工具，doe，pst iso 9002 pqa - 90 pbeiso 14001 ppm 檢驗，iqc免檢，過程能力，非質(zhì)量成本 glasswall 白板管理，5s，tpm，flowline 流水線 people involvement 全 員 參 與 jit ?jit ? qcdsm 展示板 建議的數(shù)量 出勤、投訴、委屈情況 housekeeping與組織 現(xiàn)場圖表、照片的應(yīng)用 通過可視材料、報紙等共 享信息 現(xiàn)場會議：日會、周會、月 會等 高層領(lǐng)導(dǎo)共同參與改進(jìn)活動 高層管理在現(xiàn)場的

9、可視程度 教育與培訓(xùn)的效果 管理過程的清晰度 暴露問題的機(jī)制 i make the staff 做東西做東西 ii copy competition 模仿對手模仿對手 iii manufacturing tuned to other functions 制造隨著其他工作轉(zhuǎn)制造隨著其他工作轉(zhuǎn) iv world class manufacturing plays key role 世界級水平的制造發(fā)揮關(guān)鍵作用世界級水平的制造發(fā)揮關(guān)鍵作用 v innovative, rigid flexibility 創(chuàng)新、執(zhí)著靈活創(chuàng)新、執(zhí)著靈活 degree of integration and pro-acti

10、ve acting 整合與預(yù)先行動整合與預(yù)先行動 source: philips cft 15th mmp, block 1 lower level 低水平低水平 you belong in stage i or ii if these characteristics apply to your organization 如具備以下特點那么你們單位屬于第如具備以下特點那么你們單位屬于第i或第或第ii階段階段 “command and control mentality 命令、控制的思維方式 organization is considered a collection of specialis

11、ts who operate within fairlynarrow job description 工廠由專業(yè)人員在狹隘的工作描述范圍內(nèi)各自做自己的事 senior mgrs makes major resource allocation decisions with help of staff andexternal experts 主 要由高層經(jīng)理對資源分配決策（職員和外面的專家協(xié)助） role of line mgrs is simply to operate the resulting configuration of facilities etc.部門經(jīng)理的作用只 是按既定方針執(zhí)行

12、 values specialists,missing capabilities are bought outside有價值的專業(yè)人員及知識、能力要從外 面買入 mgts primary task is orderly assimilation, exploitation and coordination ofseparate source of expertise 經(jīng)理們主要是將現(xiàn)成的資源、知識進(jìn)行吸收、剝削 organization is hierarchical, primary relationships between people are vertical分層、垂直式機(jī)構(gòu)， 人員之

13、間的關(guān)系是縱向關(guān)系 higher level 高水平高水平 source: philips cft 15th mmp, block 1 you belong in stage iv if these characteristics apply to your organization 如具備以下特點那么你們單位屬于第如具備以下特點那么你們單位屬于第iii或更高階段或更高階段 employee are so skilled & effective that other cos are continually to attract 員工技能好、效率高，其他公司都想不斷地挖走他們，但他們卻不愿意離開

14、 equipment suppliers are continually seeking ones advice 設(shè)備供應(yīng)商不斷地來向你咨詢 more nimble than competitors in responding to market shifts or price change, and in getting new products to the market faster 在市場及價格變化方面比對手更靈活，新 產(chǎn)品投入市場比對手快 interwinning the design of a new product with the design of its manufactu

15、ring process 緊密結(jié)合制造過程的設(shè)計開展新產(chǎn)品“內(nèi)部雙贏”設(shè)計 continually improving facilities, support systems, and skills that are considered to be optimal or state of art when first introduced, to surpass their initial capabilities 不斷改進(jìn)設(shè)施、支持系統(tǒng)及技能達(dá)到最優(yōu)，并不斷超越從前的能力 horizontal relationships throughout the company 橫向合作遍布全公司 - - - - - - - the best