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活動的基礎provides the foundation for all leanactivities in delphi.delphi confidentialdmsdmsfebruary 20032delphi 制造系統(tǒng)（dms）dms是流動的基礎制造系統(tǒng)用以轉換和持續(xù)改進操作以支持顧客的要求 delphi confidentialdmsdmsfebruary 20033f提供一套指導方針使delphi能夠計劃:從傳統(tǒng)的“

2、大量生產”轉向緊系顧客要求的流動基礎系統(tǒng)從制造和商務活動中消除浪費。建立標準的過程和方法。f是一個整體的應用于車間或部門的商務系統(tǒng)。delphi 制造系統(tǒng)（dms）delphi confidentialdmsdmsfebruary 20034流程制造流程制造 (msd)材料運送材料運送質量質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)境提供在基礎之上的過程制造構造。質量、材料運送和操作可用性能使流程運作。delphi confidentialdmsdmsfebruary 20035

3、f為了促進整個系統(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造之上。相互依賴的元素整個系統(tǒng)策略通過領導層、知識和有效的計劃過程來促進。 通常不建議只理解一個或兩個相互聯(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題。delphi confidentialdmsdmsfebruary 20036fdms 觀念建立在觀察和標準化的基礎上。f有效的改善依靠能力觀測和理解我們的過程。要求標準化、能力和可重復性的出臺。o s k k k關鍵觀念觀測和標準化必須先于任何改進活動標準化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2. 標準化3. 改善 流程 &過程4.改善 設備5.改善 布置圖這里開始這里開始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領導領導者者設設置界限，如果母牛偏離牧群，牧童在界限內將母牛引置界限，如果母牛偏離牧群，牧童在界限內將母牛引導導回來?；貋?。30? possibly可能地 . 3000? - no! u technique utilized in quality arena (process control charts).質質量利用技量利用

6、技術術（ （過過程控程控制表）制表）u metaphor for the concept of delegation of responsibility within a boundary. 界限界限內內職責職責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、的目目標發(fā)標發(fā)展系展系統(tǒng)統(tǒng)；管理者；管理者僅對僅對例外要求。例外要求。delphi confidentialdmsdmsfebruary 200312how is dms structured?dms怎樣構造的？http:/ is structured in six “interdependent elements”and an implementation guidedms由六個相互依賴的元素和一個執(zhí)行機構組成。delphi confidentialdmsdmsfebruary 200313 dms的怎樣構成的？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量工廠能力，dms執(zhí)行和流程改進： schedule attainment進度表達到 inventory turns存貨轉向 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用，單個矩陣的過分強調危及系統(tǒng)的改進。平衡記分卡scrap dollars廢品價overtime加班per unit cost每件成本first time quality一次下線不合格率delphi confidentialdmsdmsfebruary 200315價值流圖關鍵觀念delphi c

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

13、lity high inventoriesstandardize標準interdependent elements flow manufacturingsystem design employee environment &involvement workplace organization quality operational availability material movement觀測關鍵觀念four observations will help to pinpoint which dms interdependent can provide guidance for the

14、 standardization step. 觀測將幫助我們精確哪個dms相互依賴的可以提供對標準化步驟的導向。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: 始終貫穿辨認和消除 focusing on the 3ss: 集中在3ss 通過無休止的5改善步驟 創(chuàng)建精益敏捷型企業(yè)wast

15、e 浪費 - - fluctuation起伏 - - unreasonable practices不合理的實踐 改善改善-布置圖布置圖 改善改善-設備設備 改善改善-流程流程 & 過程過程 標準化標準化觀測觀測改善基礎關鍵觀念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構的完整所需要的。關鍵觀念f精益車間結構描述的是由操作價值流管理者擬訂，通過工廠領導者和職能人員的支持獲得的平面的組織結構。delphi confidentialdmsdmsfebruary 200319解決問題develop “eyes for waste”發(fā)展“尋找浪

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

18、confidentialdmsdmsfebruary 200320目視控制tools關鍵觀念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. 對簡單說明溝通的能力 a method for viewing production status and performance.評審產品狀態(tài)和性能的方法the idea is to make improvement opportunities visible!delphi confidentialdmsdmsfebruary 200321計劃維護關鍵觀念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:計劃維護是活動的總系統(tǒng)以保證合適的設備操作。好的計劃維護系統(tǒng)可以通過以下表現(xiàn)： appropriate data analysis to predict and prevent unplanned failure.合適的數據分析以預言和防止未計劃的失誤。 equipment capable of producing a consistent, quality product at desired rate.在目標率下，設備能夠產生一致質量的產品 operato

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

22、 operator in the maintenance and improvement of their own equipment.生產維護伙伴關系是指在本身的設備維護和改進里包括生產操作的實踐fobjectives of pmp 目標 improve the overall availability of the equipment by eliminating the six major forms of production loss通過消除六個主要生產損失的樣式來改進全部設備的可用性x breakdown loss明細分類損失x setup and adjustment losse

23、s設置和調整損失x minor stoppage losses較小的中斷損失x speed losses加速損失x defects and rework過失與修復x startup/yield losses啟動/收益損失生產維護伙伴關系cleaning, inspection and proper lubrication improves availability.delphi confidentialdmsdmsfebruary 200323關鍵觀念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快速響應是通過合適的支持小組對損失時間和停工事宜做出即刻解決的生產響應系統(tǒng)fandon systems production management visual and audio control tool that monitors and displays production status andon系統(tǒng)生產維護目視的和聲頻的控制對工具監(jiān)控和顯示生產狀態(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delphi confidentialdmsdmsfebruary 200324轉變pit stop mentality關鍵觀念fquick setup or changeover is the ability to minimize production losses

26、 when changing from one part type to the next.快速設置或轉變是在轉變一種產品為下一種時將生產損失最小化的能力。the improvement process follows a standardized approach and enables the plant to implement a small lot strategy.改進過程隨著標準的方法并能夠對工廠執(zhí)行許多小策略的改進。delphi confidentialdmsdmsfebruary 200325生產級別成品緩沖成品緩沖供應商供應商 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鍵觀念fproduction leveling is used to buffer customer demand variation and allow manufacturing to build to a stable quantity.生產級別被用于緩沖客戶的要求變差和允許制造建立穩(wěn)定生產數量。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值 2) identify value stream and eliminate waste確定價值流和消除浪費 3) make value flow at pull of the customer顧客對價值流的推動 4) involve & empower employees包括 &授權雇員 5) continuously

30、 improve in pursuit of perfection持續(xù)改進追求完美精益企業(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精益領導的問題關鍵觀念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從哪開始 - from the top or the bottom?頂部還是底部？關鍵觀念culture文化values價值&attitudes態(tài)度whatwe do我們做什么delphi confidentialdmsdmsfebruary 200329back-up slidesdelphi confidentialdmsdmsfebruary 200330new business sustainable prof

32、its新商新商務可從中獲利務可從中獲利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消消除浪費除浪費improved product and information flow改進產品和信息流改進產品和信息流成本鑒定鏈improved product and information flow改進產品和信息流改進產品和信息流process variation reduction過程變差過程變差降低降低waste elimination

33、消消除浪費除浪費decreasedcost減少成減少成本本關鍵觀念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)建可預知的產品和過程使dms觀念能有效的接受。f dms is based on the elimination of waste using concepts of :基于對浪費的消除 product/pro

34、cess flow產品/過程流 standard work標準工作 quick set-up快速設置 pull systems推系統(tǒng) machine reliability機器可靠性f six sigma is based on understanding and reducing process variation through a detailed, structured problem solving methodology基于通過詳細的結構問題解決方法論來理解和降低過程變差wastethe focus of six sigma聚焦聚焦6define定義定義measure測量測量ana

35、lyze分析分析improve改進改進control控制控制精益生產 & dms與6的關系knowledgeleadershipflowwastewasteperformanceknowledgeleadershipflowwastewasteperformanceworkplaceorganizationworkplaceorganizationqualityflowmanufacturingsystemdesignflowmanufacturingsystemdesignemployeeenvironment& involvementemployeeenvironment&

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

37、on guide執(zhí)行導向執(zhí)行導向12345678production reportknowledgeleadershipflowwastewasteperformanceworkplaceorganizationqualityflowmanufacturingsystemdesignemployeeenvironment& involvementmaterialmovementoperationalavailability.對總系統(tǒng)應用相互依賴的元素的方法論下一個812個月的標準計劃價值流和信息流的圖象表示方法對每一個生產單元或設備的日常操作記錄.標準清單用來評估dms執(zhí)行的當前狀態(tài)和

38、確定改進機會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)劃過程關鍵觀念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)劃過程用于定義、組織和使活動優(yōu)先為執(zhí)行計劃以支持價值流和商務目標。d

41、elphi confidentialdmsdmsfebruary 200334布局規(guī)劃過程關鍵觀念f the site plan is created from many data layers down to individual value stream segments.從許多數據層下至單個的價值流片段創(chuàng)建布局規(guī)劃site plan布局規(guī)劃布局規(guī)劃gap assessment間隙評估間隙評估value stream mapping:價值流圖價值流圖value stream 1價值流圖價值流圖1value stream mapping:value stream 2 production r

42、eportingproduction reporting collects segment data.生產報告收集片段數據。 value stream mapsvalue stream maps identify opportunities for improvement.價值流圖定義改進的機會 the gap assessmentgap assessment measures implementation attainment for the site.對場所的間隙評估測量執(zhí)行production reporting:segment 生產報告：生產報告：片段片段1aproduction re

43、porting:segment 1bproduction reporting:segment 1cproduction reporting:segment 2aproduction reporting:segment 2bproduction reporting:segment 2cdelphi confidentialdmsdmsfebruary 200335間隙評估（摘要）關鍵觀念 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.間隙評估（詳細）關鍵觀念interdependent element:location: _date: _employee environ