DMSOverviewDelphi的制造體系

1、delphi confidentialdmsdmsfebruary 20031delphi 制造系統(tǒng)（dms）lean精益精益dmsdelphi 制造系統(tǒng)提供所有l(wèi)ean活動(dòng)的基礎(chǔ)provides the foundation for all leanactivities in delphi.delphi confidentialdmsdmsfebruary 20032delphi 制造系統(tǒng)（dms）dms是流動(dòng)的基礎(chǔ)制造系統(tǒng)用以轉(zhuǎn)換和持續(xù)改進(jìn)操作以支持顧客的要求 delphi confidentialdmsdmsfebruary 20033f提供一套指導(dǎo)方針使delphi能夠計(jì)劃:從傳統(tǒng)的“

2、大量生產(chǎn)”轉(zhuǎn)向緊系顧客要求的流動(dòng)基礎(chǔ)系統(tǒng)從制造和商務(wù)活動(dòng)中消除浪費(fèi)。建立標(biāo)準(zhǔn)的過(guò)程和方法。f是一個(gè)整體的應(yīng)用于車間或部門(mén)的商務(wù)系統(tǒng)。delphi 制造系統(tǒng)（dms）delphi confidentialdmsdmsfebruary 20034流程制造流程制造 (msd)材料運(yùn)送材料運(yùn)送質(zhì)量質(zhì)量操作可用性操作可用性車間組織車間組織&目視控制目視控制員工環(huán)境員工環(huán)境相互依賴的元素fdelphi 有6個(gè)相互依賴的元素：車間組織、目視控制和員工環(huán)境提供在基礎(chǔ)之上的過(guò)程制造構(gòu)造。質(zhì)量、材料運(yùn)送和操作可用性能使流程運(yùn)作。delphi confidentialdmsdmsfebruary 20035

3、f為了促進(jìn)整個(gè)系統(tǒng),你的制造系統(tǒng)的所有元素必須是相互依賴的 ；必須基于并能夠彼此在構(gòu)造之上。相互依賴的元素整個(gè)系統(tǒng)策略通過(guò)領(lǐng)導(dǎo)層、知識(shí)和有效的計(jì)劃過(guò)程來(lái)促進(jìn)。 通常不建議只理解一個(gè)或兩個(gè)相互聯(lián)系的元素并試圖孤立執(zhí)行策略。 該方法能在犧牲其余元素系統(tǒng)和總成本的情況下解決一種元素的程序問(wèn)題。delphi confidentialdmsdmsfebruary 20036fdms 觀念建立在觀察和標(biāo)準(zhǔn)化的基礎(chǔ)上。f有效的改善依靠能力觀測(cè)和理解我們的過(guò)程。要求標(biāo)準(zhǔn)化、能力和可重復(fù)性的出臺(tái)。o s k k k關(guān)鍵觀念觀測(cè)和標(biāo)準(zhǔn)化必須先于任何改進(jìn)活動(dòng)標(biāo)準(zhǔn)化delphi confidentialdmsdmsf

4、ebruary 20037delphi confidentialdmsdmsfebruary 200385 kaizen steps to a lean, agile enterprise5改善步驟創(chuàng)建精益敏捷型企業(yè) kaizen fundamentals1. 觀測(cè)2. 標(biāo)準(zhǔn)化3. 改善 流程 &過(guò)程4.改善 設(shè)備5.改善 布置圖這里開(kāi)始這里開(kāi)始delphi confidentialdmsdmsfebruary 20039delphi confidentialdmsdmsfebruary 200310cowboy theory牧童理論 delphi confidentialdmsdms

5、february 200311the leader sets boundaries and, if a cow strays from the herd, a cowboy is sent to steer the cow back within the boundary領(lǐng)導(dǎo)領(lǐng)導(dǎo)者者設(shè)設(shè)置界限，如果母牛偏離牧群，牧童在界限內(nèi)將母牛引置界限，如果母牛偏離牧群，牧童在界限內(nèi)將母牛引導(dǎo)導(dǎo)回來(lái)?；貋?lái)。30? possibly可能地 . 3000? - no! u technique utilized in quality arena (process control charts).質(zhì)質(zhì)量利用技量利用

6、技術(shù)術(shù)（ （過(guò)過(guò)程控程控制表）制表）u metaphor for the concept of delegation of responsibility within a boundary. 界限界限內(nèi)內(nèi)職責(zé)職責(zé)委托的委托的觀觀念念u a management tool.管理工具管理工具u managers focus on exceptions, not every “cow”: this is our goal as we develop systems; managers are required for exceptions only.管理者聚焦例外：管理者聚焦例外：這這是我是我們們的

7、的目目標(biāo)發(fā)標(biāo)發(fā)展系展系統(tǒng)統(tǒng)；管理者；管理者僅對(duì)僅對(duì)例外要求。例外要求。delphi confidentialdmsdmsfebruary 200312how is dms structured?dms怎樣構(gòu)造的？http:/ is structured in six “interdependent elements”and an implementation guidedms由六個(gè)相互依賴的元素和一個(gè)執(zhí)行機(jī)構(gòu)組成。delphi confidentialdmsdmsfebruary 200313 dms的怎樣構(gòu)成的？dms 相互依賴的元素make what we need, when we ne

8、ed it.pull systemmaterial movement (mm)planimplementimplementation guide (ig)start hereemployee environment and involvement (ee)opopopoptlaempowered teamsflow manufacturingsystem design (msd) kaizen-layout kaizen-equipment kaizen-flow & process standardizationobservationquality (q)definedefineme

9、asuremeasureanalyzeanalyzeimproveimprovecontrolcontrolorganizational accountabilityorganizational accountabilitywhy? why? why? why? why?i&cimoperational availability (oa)visual controlsfor quick responsecleaninginspectionand properlubricationimproves availabilityworkplace organization (wo)a plac

10、e for everything and everything in its place.delphi confidentialdmsdmsfebruary 200314關(guān)鍵觀念fwe measure plant performance, dms implementation and flow improvement in a number of different ways:我們以不同的方式測(cè)量工廠能力，dms執(zhí)行和流程改進(jìn)： schedule attainment進(jìn)度表達(dá)到 inventory turns存貨轉(zhuǎn)向 operational effectiveness操作效力 customer

11、 returns (r/rppm)顧客回饋fwe must balance the application of these metrics. overemphasis of a single metric will compromise system improvement.我們必須平衡這些矩陣的應(yīng)用，單個(gè)矩陣的過(guò)分強(qiáng)調(diào)危及系統(tǒng)的改進(jìn)。平衡記分卡scrap dollars廢品價(jià)overtime加班per unit cost每件成本first time quality一次下線不合格率delphi confidentialdmsdmsfebruary 200315價(jià)值流圖關(guān)鍵觀念delphi c

12、onfidentialdmsdmsfebruary 200316kaizen改善on-goingobservationsto identifywaste andcontinuousimprovementopportunities.problem solvingand standardizationobserve觀測(cè) poor work distribution employees not engaged unorganized and/or dirtywork areas poor first time quality long changeovers poor machine reliabi

13、lity high inventoriesstandardize標(biāo)準(zhǔn)interdependent elements flow manufacturingsystem design employee environment &involvement workplace organization quality operational availability material movement觀測(cè)關(guān)鍵觀念four observations will help to pinpoint which dms interdependent can provide guidance for the

14、 standardization step. 觀測(cè)將幫助我們精確哪個(gè)dms相互依賴的可以提供對(duì)標(biāo)準(zhǔn)化步驟的導(dǎo)向。delphi confidentialdmsdmsfebruary 200317underlying concept:潛在觀念：潛在觀念：implement the best possible combination of the 3ms:執(zhí)行最好的可能的3ms聯(lián)合 through the identification and elimination of: 始終貫穿辨認(rèn)和消除 focusing on the 3ss: 集中在3ss 通過(guò)無(wú)休止的5改善步驟 創(chuàng)建精益敏捷型企業(yè)wast

15、e 浪費(fèi) - - fluctuation起伏 - - unreasonable practices不合理的實(shí)踐 改善改善-布置圖布置圖 改善改善-設(shè)備設(shè)備 改善改善-流程流程 & 過(guò)程過(guò)程 標(biāo)準(zhǔn)化標(biāo)準(zhǔn)化觀測(cè)觀測(cè)改善基礎(chǔ)關(guān)鍵觀念delphi confidentialdmsdmsfebruary 200318精益車間natural workgroupsaarea manageradvisorpmdmsplant manager(value stream manager)industrial engineer (dms manager)supportfunctionsteam leaders

16、value stream manageramteam membervsmpc&lqualitymaintenanceengineeringthe natural work group is integral toestablishing a lean shop floor structure.自然工作組是確立精益車間結(jié)構(gòu)的完整所需要的。關(guān)鍵觀念f精益車間結(jié)構(gòu)描述的是由操作價(jià)值流管理者擬訂，通過(guò)工廠領(lǐng)導(dǎo)者和職能人員的支持獲得的平面的組織結(jié)構(gòu)。delphi confidentialdmsdmsfebruary 200319解決問(wèn)題develop “eyes for waste”發(fā)展“尋找浪

17、費(fèi)hiding problems will undermine the system隱瞞問(wèn)題將破壞系統(tǒng)“沒(méi)有問(wèn)題”就是問(wèn)題 關(guān)鍵觀念fproblem solving is a key ingredient of a successful companys culture and must:解決問(wèn)題是成功的公司文化的關(guān)鍵元素并且必須：become part of every employees daily routine.成為每個(gè)雇員的日常事務(wù)focus on root causes.聚焦根源問(wèn)題be supported by continuous follow-up.追蹤調(diào)查支持delphi

18、confidentialdmsdmsfebruary 200320目視控制tools關(guān)鍵觀念fvisual controls communicate instructions in the workplace. characteristics of effective visual controls include:目視控制在車間溝通說(shuō)明，有效的目視控制特性包括： the ability to quickly distinguish between normal and abnormal conditions.快速區(qū)分普通和反常情況的能力 the ability to communicate

19、simple instructions at-a-glance. 對(duì)簡(jiǎn)單說(shuō)明溝通的能力 a method for viewing production status and performance.評(píng)審產(chǎn)品狀態(tài)和性能的方法the idea is to make improvement opportunities visible!delphi confidentialdmsdmsfebruary 200321計(jì)劃維護(hù)關(guān)鍵觀念f planned maintenance is the total system of activities to ensure the proper operation

20、of equipment. a good planned maintenance system is characterized by:計(jì)劃維護(hù)是活動(dòng)的總系統(tǒng)以保證合適的設(shè)備操作。好的計(jì)劃維護(hù)系統(tǒng)可以通過(guò)以下表現(xiàn)： appropriate data analysis to predict and prevent unplanned failure.合適的數(shù)據(jù)分析以預(yù)言和防止未計(jì)劃的失誤。 equipment capable of producing a consistent, quality product at desired rate.在目標(biāo)率下，設(shè)備能夠產(chǎn)生一致質(zhì)量的產(chǎn)品 operato

21、rs involved in the monitoring and care of equipment and the workplace.操作工監(jiān)控并注意相關(guān)的設(shè)備和工件。quick response systems that supportimmediate repair of equipment.快速響應(yīng)系統(tǒng)以支持對(duì)設(shè)備的即刻修復(fù)。delphi confidentialdmsdmsfebruary 200322關(guān)鍵觀念f production maintenance partnership (pmp) is the practice of involving the production

22、 operator in the maintenance and improvement of their own equipment.生產(chǎn)維護(hù)伙伴關(guān)系是指在本身的設(shè)備維護(hù)和改進(jìn)里包括生產(chǎn)操作的實(shí)踐fobjectives of pmp 目標(biāo) improve the overall availability of the equipment by eliminating the six major forms of production loss通過(guò)消除六個(gè)主要生產(chǎn)損失的樣式來(lái)改進(jìn)全部設(shè)備的可用性x breakdown loss明細(xì)分類損失x setup and adjustment losse

23、s設(shè)置和調(diào)整損失x minor stoppage losses較小的中斷損失x speed losses加速損失x defects and rework過(guò)失與修復(fù)x startup/yield losses啟動(dòng)/收益損失生產(chǎn)維護(hù)伙伴關(guān)系cleaning, inspection and proper lubrication improves availability.delphi confidentialdmsdmsfebruary 200323關(guān)鍵觀念fquick response is a production response system that facilitates the imm

24、ediate resolution to lost time and downtime issues by alerting the appropriate support group快速響應(yīng)是通過(guò)合適的支持小組對(duì)損失時(shí)間和停工事宜做出即刻解決的生產(chǎn)響應(yīng)系統(tǒng)fandon systems production management visual and audio control tool that monitors and displays production status andon系統(tǒng)生產(chǎn)維護(hù)目視的和聲頻的控制對(duì)工具監(jiān)控和顯示生產(chǎn)狀態(tài)assembly equipment - dept.

25、45built shipped goal1 9 5 180 51 9 7 0assmsta.1assmsta.2assmsta.3assmsta.4assmsta.5dialtabledrillmach.teststanddownshortfullovertaktcoordgagemainttoolchangestock快速響應(yīng)delphi confidentialdmsdmsfebruary 200324轉(zhuǎn)變pit stop mentality關(guān)鍵觀念fquick setup or changeover is the ability to minimize production losses

26、 when changing from one part type to the next.快速設(shè)置或轉(zhuǎn)變是在轉(zhuǎn)變一種產(chǎn)品為下一種時(shí)將生產(chǎn)損失最小化的能力。the improvement process follows a standardized approach and enables the plant to implement a small lot strategy.改進(jìn)過(guò)程隨著標(biāo)準(zhǔn)的方法并能夠?qū)S執(zhí)行許多小策略的改進(jìn)。delphi confidentialdmsdmsfebruary 200325生產(chǎn)級(jí)別成品緩沖成品緩沖供應(yīng)商供應(yīng)商 fab 次極裝配次極裝配 裝配裝配 成品成品

27、顧客顧客 without levelingwith leveling顧客要求顧客要求顧客要求顧客要求關(guān)鍵觀念fproduction leveling is used to buffer customer demand variation and allow manufacturing to build to a stable quantity.生產(chǎn)級(jí)別被用于緩沖客戶的要求變差和允許制造建立穩(wěn)定生產(chǎn)數(shù)量。delphi confidentialdmsdmsfebruary 200326pull systemskey conceptsfpull systems provide a method to

28、 control the flow of material and information by replacing only what has been consumed.drive the level schedule back through the operation.develop a repetitive daily cadencethat is reviewed weekly.process 1finalprocess process 3process 2level load backwardsfinished goods pull looppull looppull loopp

29、c & lcustomer planlevel scheduledelphi confidentialdmsdmsfebruary 2003271) specify value in the eyes of the customer在顧客的心中確定價(jià)值 2) identify value stream and eliminate waste確定價(jià)值流和消除浪費(fèi) 3) make value flow at pull of the customer顧客對(duì)價(jià)值流的推動(dòng) 4) involve & empower employees包括 &授權(quán)雇員 5) continuously

30、 improve in pursuit of perfection持續(xù)改進(jìn)追求完美精益企業(yè)1. what are you doing to ensure that your function supports the value streams?你將做什么以保證功能支持價(jià)值流？2. what are you doing to make your own function lean?你將做什么使得功能變的精益？questions for lean leaders精益領(lǐng)導(dǎo)的問(wèn)題關(guān)鍵觀念delphi confidentialdmsdmsfebruary 200328精益企業(yè)執(zhí)行change cult

31、ure first(conventional way)change system first(tps way)首先改變首先改變系統(tǒng)系統(tǒng)where do you start從哪開(kāi)始 - from the top or the bottom?頂部還是底部？關(guān)鍵觀念culture文化values價(jià)值&attitudes態(tài)度whatwe do我們做什么delphi confidentialdmsdmsfebruary 200329back-up slidesdelphi confidentialdmsdmsfebruary 200330new business sustainable prof

32、its新商新商務(wù)可從中獲利務(wù)可從中獲利decreasedcost減少成減少成本本the linkage between variation, flow and cost:變差變差，流程流程和和成本成本間的聯(lián)接間的聯(lián)接waste elimination消消除浪費(fèi)除浪費(fèi)improved product and information flow改進(jìn)產(chǎn)品和信息流改進(jìn)產(chǎn)品和信息流成本鑒定鏈improved product and information flow改進(jìn)產(chǎn)品和信息流改進(jìn)產(chǎn)品和信息流process variation reduction過(guò)程變差過(guò)程變差降低降低waste elimination

33、消消除浪費(fèi)除浪費(fèi)decreasedcost減少成減少成本本關(guān)鍵觀念delphi confidentialdmsdmsfebruary 200331six sigma attacks variation, creating predictable products and processes that enable dms concepts to be effective. 6影響變差，創(chuàng)建可預(yù)知的產(chǎn)品和過(guò)程使dms觀念能有效的接受。f dms is based on the elimination of waste using concepts of :基于對(duì)浪費(fèi)的消除 product/pro

34、cess flow產(chǎn)品/過(guò)程流 standard work標(biāo)準(zhǔn)工作 quick set-up快速設(shè)置 pull systems推系統(tǒng) machine reliability機(jī)器可靠性f six sigma is based on understanding and reducing process variation through a detailed, structured problem solving methodology基于通過(guò)詳細(xì)的結(jié)構(gòu)問(wèn)題解決方法論來(lái)理解和降低過(guò)程變差wastethe focus of six sigma聚焦聚焦6define定義定義measure測(cè)量測(cè)量ana

35、lyze分析分析improve改進(jìn)改進(jìn)control控制控制精益生產(chǎn) & dms與6的關(guān)系knowledgeleadershipflowwastewasteperformanceknowledgeleadershipflowwastewasteperformanceworkplaceorganizationworkplaceorganizationqualityflowmanufacturingsystemdesignflowmanufacturingsystemdesignemployeeenvironment& involvementemployeeenvironment&

36、amp; involvementmaterialmovementmaterialmovementoperationalavailabilityoperationalavailabilitydelphi confidentialdmsdmsfebruary 200332執(zhí)行導(dǎo)向dms的結(jié)構(gòu)value stream map - future statesite planmetricsschedulecurrent statefuture statedms gap assessment1234site planning value streammapping ig-1ig-2implementati

37、on guide執(zhí)行導(dǎo)向執(zhí)行導(dǎo)向12345678production reportknowledgeleadershipflowwastewasteperformanceworkplaceorganizationqualityflowmanufacturingsystemdesignemployeeenvironment& involvementmaterialmovementoperationalavailability.對(duì)總系統(tǒng)應(yīng)用相互依賴的元素的方法論下一個(gè)812個(gè)月的標(biāo)準(zhǔn)計(jì)劃價(jià)值流和信息流的圖象表示方法對(duì)每一個(gè)生產(chǎn)單元或設(shè)備的日常操作記錄.標(biāo)準(zhǔn)清單用來(lái)評(píng)估dms執(zhí)行的當(dāng)前狀態(tài)和

38、確定改進(jìn)機(jī)會(huì)delphi confidentialdmsdmsfebruary 200333site plandivision:plant:inclusive dates:revision date:current state layoutfuture state layoutmetricstiming planmeasurementfunction currentfutureinitativesj f m a m j j a s o n drecordables1lost work days2parts per million3spills4customer complaints5first

39、 time quality6schedule attainment %7% on time shipments8manufacturing expense9mfg. exp. as a % of sales10overtime %11scrap expense %12premium freight %13inventory turns14operational effectiveness %15tpc/t improvement %16dms gap assessment17labor hours per piece18number of people per vs19per unit cos

40、t20this section maybe included asan attachment.this section maybe included asan attachment.布局規(guī)劃過(guò)程關(guān)鍵觀念fthe site planning process is used to identify, organize and prioritize activities into an implementation plan that supports the value streams and business goals.布局規(guī)劃過(guò)程用于定義、組織和使活動(dòng)優(yōu)先為執(zhí)行計(jì)劃以支持價(jià)值流和商務(wù)目標(biāo)。d

41、elphi confidentialdmsdmsfebruary 200334布局規(guī)劃過(guò)程關(guān)鍵觀念f the site plan is created from many data layers down to individual value stream segments.從許多數(shù)據(jù)層下至單個(gè)的價(jià)值流片段創(chuàng)建布局規(guī)劃site plan布局規(guī)劃布局規(guī)劃gap assessment間隙評(píng)估間隙評(píng)估value stream mapping:價(jià)值流圖價(jià)值流圖value stream 1價(jià)值流圖價(jià)值流圖1value stream mapping:value stream 2 production r

42、eportingproduction reporting collects segment data.生產(chǎn)報(bào)告收集片段數(shù)據(jù)。 value stream mapsvalue stream maps identify opportunities for improvement.價(jià)值流圖定義改進(jìn)的機(jī)會(huì) the gap assessmentgap assessment measures implementation attainment for the site.對(duì)場(chǎng)所的間隙評(píng)估測(cè)量執(zhí)行production reporting:segment 生產(chǎn)報(bào)告：生產(chǎn)報(bào)告：片段片段1aproduction re

43、porting:segment 1bproduction reporting:segment 1cproduction reporting:segment 2aproduction reporting:segment 2bproduction reporting:segment 2cdelphi confidentialdmsdmsfebruary 200335間隙評(píng)估（摘要）關(guān)鍵觀念 gap assessment overall summarylocation: bloomfield date: mar-02level of attainmentimplementation guide2.5

44、site planning2continuous improvement3i. employee environment and involvement2.0beliefs & values2health and safety3education & training/operator certification2people and team recognition2suggestion program2natural work groups1standards of manufacturing leadership2ii. workplace organization2.7

45、workplace organization standards - the production area2visual controls3address system3area information center4plant communication center2workplace organization standards - the office2iii. quality2.3quality leadership2protect the customer3inspection and test; error proofing2measurement and feedback 2

46、iv. operational availability1.8planned maintenance system2quick response system2production maintenance partnership1quick set-up2v. material movement2.1shipping to schedule3building to plan (production leveling)2plan for every part (pfep)1designated storage2container right sizing and supporting the o

47、perator2pull systems2internal delivery routes3external material delivery2vi. flow manufacturing system design2.0flow improvement and msd workshop activity2natural process cycle time 1incremental investment2operator balance and labor linearity2parts presentation and material handling3plant summary2.2

48、iii. qualityvi. flow manufacturingi. employee environmentand involvementii. workplace organizationv. material movementiv. operational availabilityimplementation guidei. employee environment & involvement beliefs & valueshealth & safetyeducation & trainingpeople & team recognition

49、suggestion programnatural work groupsstandards of manufacturing leadershipstandards of manufacturing leadershipdelphi confidentialdmsdmsfebruary 200336manufacturing leadership does not follow standard practices. supervisor responsibilities vary within the plant. focus is on fire fighting rather than continuous improvement.間隙評(píng)估（詳細(xì)）關(guān)鍵觀念interdependent element:location: _date: _employee environ