Yamazumi 山積圖培訓(xùn)

1、YamazumiLes HopeKen Richardson山積圖Les HopeKen RichardsonWhat Are They For?Planning for changeHelp to create safe, smooth and efficient processes TAKT change, new model introductionAssist in problem solvingSupport effective process design ergo concerns, quality concern issuesImprove to current conditi

2、onMake True Condition Visual, highlight waste, show waiting times作用作用變更規(guī)劃變更規(guī)劃幫助創(chuàng)造安全、暢通且高效的過(guò)程生產(chǎn)節(jié)拍變更、新車(chē)型上市協(xié)助問(wèn)題的解決協(xié)助問(wèn)題的解決支持有效的過(guò)程設(shè)計(jì)人體工程學(xué)相關(guān)問(wèn)題、質(zhì)量相關(guān)問(wèn)題改善目前的狀態(tài)改善目前的狀態(tài)使真實(shí)現(xiàn)狀一目了然，突顯浪費(fèi)并顯示等待時(shí)間How Do They Work?Yamazumi is a visual representation of standardised work as documented within your QPS and WES. To be eff

3、ective, they must: Show the true work being carried out, in sufficient detail to identify opportunities for improvement Be based on accurate timings Show the standardised work as it is being followed across all shifts工作原理工作原理山積圖是標(biāo)準(zhǔn)化作業(yè)的可視化表征，記錄在QPS和WES中。為了有效工作，山積圖必須： 顯示正在開(kāi)展的工作，盡量詳細(xì)以識(shí)別改顯示正在開(kāi)展的工作，盡量詳細(xì)以

4、識(shí)別改進(jìn)機(jī)會(huì)進(jìn)機(jī)會(huì) 基于精確時(shí)間基于精確時(shí)間 顯示所有班組遵照的標(biāo)準(zhǔn)化作業(yè)顯示所有班組遵照的標(biāo)準(zhǔn)化作業(yè)What does the board look like? The process content is visualised in a series of coloured magnetic strips, stacked onto of one another in the correct working sequence.The work type is analysed at the same time as the element times are studied, to det

5、ermine which of the following categories it falls into:Value Added Work (VA)Work which changes/ alters the form/ properties/ value of the productEssential Non-Value Added Work (ENVA)Non-Value Added work carried out which is required to achieve the change to the form/ properties/ value of the product

6、Non-Value Added Work (NVA)Work which does not change/ alter the form/ properties/ value of the productOption WorkWork which is not carried out on every vehicle and is dependent of the specification1.Variable WorkWork which is carried out on every vehicle, but varies in length depending on the spec.

7、E.g. A low spec harness loom has 3 connections but the high spec one has 7By classifying work in this way we can easily identify areas on which we should focus our efforts to improve efficiency.山積圖形式過(guò)程內(nèi)容顯示在一系列彩色磁條中，按照正確的工序彼此層疊。研究時(shí)間要素的同時(shí)分析工作類(lèi)型，以確定屬于以下哪一類(lèi)：增值工作（增值工作（VA）改變/修改產(chǎn)品形式/屬性/價(jià)值的工作必要非增值工作必要非增值工作

8、(ENVA)為實(shí)現(xiàn)產(chǎn)品形式/屬性/價(jià)值而需要實(shí)施的非增值工作。非增值工作（非增值工作（NVA）不改變/修改產(chǎn)品形式/屬性/價(jià)值的工作選擇性工作選擇性工作并非每輛車(chē)上都要進(jìn)行的、取決于車(chē)輛規(guī)格的工作1.可變量工作可變量工作在每輛車(chē)上進(jìn)行的、但基于車(chē)輛規(guī)格工作時(shí)間有所不同的工作，比如低規(guī)格線束織機(jī)在每輛車(chē)上進(jìn)行的、但基于車(chē)輛規(guī)格工作時(shí)間有所不同的工作，比如低規(guī)格線束織機(jī)有有3個(gè)接頭，但高規(guī)格的有個(gè)接頭，但高規(guī)格的有7個(gè)個(gè)通過(guò)該方法對(duì)工作進(jìn)行分類(lèi)，我們能輕易確定我們應(yīng)該努力改進(jìn)效率的區(qū)域通過(guò)該方法對(duì)工作進(jìn)行分類(lèi)，我們能輕易確定我們應(yīng)該努力改進(jìn)效率的區(qū)域Compiling the boardEach

9、of the coloured blocks, should be labelled with the Unique WES number, the work content being carried out and the time taken to complete the step (in whole seconds), all of which can be found on every WES.If there is limited space on your tile to write all of the above information, it is imperative

10、that you write in: The time taken to complete the WES. The WES number編制山積圖每個(gè)色塊應(yīng)標(biāo)明獨(dú)特的WES編號(hào)、正在開(kāi)展的工作內(nèi)容和完成步驟所花費(fèi)的時(shí)間（以整秒），所有這一切都可以在每個(gè)WES中找到。如果你的展開(kāi)圖上的空間有限，不足以寫(xiě)下所有上述如果你的展開(kāi)圖上的空間有限，不足以寫(xiě)下所有上述信息，則必須寫(xiě)下以下信息：信息，則必須寫(xiě)下以下信息：完成WES所花費(fèi)的時(shí)間WES編號(hào)過(guò)程質(zhì)量檢查表過(guò)程質(zhì)量檢查表節(jié)拍時(shí)間循環(huán)時(shí)間最大標(biāo)準(zhǔn)過(guò)在制品庫(kù)存在制品庫(kù)存質(zhì)量檢查過(guò)程名稱(chēng)右側(cè)發(fā)動(dòng)機(jī)罩鉸鏈固定（3門(mén)）表格第2張，共2張工作區(qū)域/位置發(fā)布日

11、期發(fā)布日期2011年年1月月2日日1級(jí)工作要素描述編號(hào)規(guī)范所有所有所有所有關(guān)鍵點(diǎn)符號(hào)WES編號(hào)時(shí)間自動(dòng)行走將發(fā)動(dòng)機(jī)罩固定件安裝在車(chē)體上獲取2個(gè)鉸鏈螺栓和手動(dòng)啟動(dòng)工具手動(dòng)啟動(dòng)發(fā)動(dòng)機(jī)罩鉸鏈螺栓1和2緊固2個(gè)發(fā)動(dòng)機(jī)罩螺栓 Yamazumi example 山積圖示例工作平衡圖工作平衡圖車(chē)身底部團(tuán)隊(duì)車(chē)身底部團(tuán)隊(duì)5工段工段2012年年6月月14日日OPTION WORKIs defined as “work which is not carried out on every vehicle and is dependent of the specification”. The OPTION work b

12、lock is coloured and has circular inserts to show the different duration/s and type/s of work contained within the element, in this case it is 3 seconds of Essential Non-value Add work.選擇性工作定義為“并非每輛車(chē)上都要進(jìn)行的、取決于車(chē)輛規(guī)格的工作”。The OPTION work block is coloured and has circular inserts to show the different d

13、uration/s and type/s of work contained within the element, in this case it is 3 seconds of Essential Non-value Add work.選擇性工作框標(biāo)注并帶圓形插件，以顯示要素內(nèi)包含的工作的不同持續(xù)時(shí)間和類(lèi)型，在這種情況下，其為3秒必要非增值工作。過(guò)程質(zhì)量檢查表過(guò)程質(zhì)量檢查表節(jié)拍時(shí)間循環(huán)時(shí)間最大標(biāo)準(zhǔn)在制品庫(kù)存工作區(qū)域/位置過(guò)程名稱(chēng)發(fā)布日期2005年7月5日12級(jí)表格第1張，共1張編號(hào)工作要素描述規(guī)范關(guān)鍵點(diǎn)符號(hào)WES編號(hào)從對(duì)置操作臺(tái)上取下左右地板側(cè)內(nèi)部組件將左右地板側(cè)內(nèi)部組件安裝在架子#34上

14、，按下啟動(dòng)按鈕檢查可變量燈將一個(gè)零件安裝在架子#30將四個(gè)墊片安裝在架子#30上，按下啟動(dòng)按鈕檢查變量并將兩個(gè)零件安裝在架子#10上獲得并安裝2個(gè)零件在架子#10將“Longit”安裝在架子#10上將一個(gè)零件安裝在架子#10上，按下啟動(dòng)按鈕將兩個(gè)圓形帶安裝在地板側(cè)加強(qiáng)板上所有所有所有所有所有所有所有所有所有VARIABLE WORKWork which is carried out on every vehicle, but varies in duration depending on the specification of each vehicle.VARIANT work blocks

15、 are coloured and have circular inserts to show the different duration/s and type/s of work contained within each element in this case both VALUE ADDED & ESSENTIAL NON-VALUE ADDED work are present可變量工作在每輛車(chē)上進(jìn)行的、但基于車(chē)輛規(guī)格工作時(shí)間有所不同的工作VARIANT work blocks are coloured and have circular inserts to show the d

16、ifferent duration/s and type/s of work contained within each element in this case both VALUE ADDED & ESSENTIAL NON-VALUE ADDED work are present可變量工作框標(biāo)注為并具有圓形插件，以顯示要素內(nèi)的工作的不同持續(xù)時(shí)間和類(lèi)型，在這種情況下，存在增值工作和必要非增值工作。過(guò)程質(zhì)量檢查表過(guò)程質(zhì)量檢查表過(guò)程名稱(chēng)左側(cè)車(chē)頂溝螺栓節(jié)拍時(shí)間循環(huán)時(shí)間最大標(biāo)準(zhǔn)過(guò)程內(nèi)庫(kù)存表格第1頁(yè)，共1頁(yè)工作區(qū)域/位置發(fā)布日期2010年10月8日規(guī)范關(guān)鍵點(diǎn)符號(hào)WES編號(hào)所有所有完全獲得2個(gè)車(chē)頂溝螺

17、栓編號(hào)手啟動(dòng)螺栓#1手啟動(dòng)螺栓#2緊固螺栓#1緊固螺栓#2獲得3個(gè)車(chē)頂溝螺栓手啟動(dòng)3個(gè)FREELANDER車(chē)頂溝螺栓手啟動(dòng)3個(gè)標(biāo)準(zhǔn)車(chē)頂溝螺栓手啟動(dòng)3個(gè)天窗頂溝螺栓擰緊FREELANDER螺栓3，4和5擰緊標(biāo)準(zhǔn)螺栓3，4和5擰緊天窗螺栓3，4和5手啟動(dòng)螺栓6手啟動(dòng)螺栓7安裝后車(chē)頂螺栓工裝擰緊螺栓7#擰緊螺栓6#拆除后車(chē)頂工裝完全所有所有所有所有Showing Kaizen activityYour Yamazumi visually shows which of your processes are above or below the TAKT time and can help you to

18、 balance these processes more equally.If any processes are considerably over TAKT time you must ensure that the timings are actually correct and that you havent made any errors transferring the information from the QPS sheet on to your Yamazumi.If you are sure that everything is correct, take action

19、.Firstly look at the walk times, as these are usually the easiest parts of a process to address. These can be reduced by making a change as simple as moving a part rack closer, but could also mean a major re-organisation of the area layout. You should involve ALL relevant personnel in the decision-m

20、aking process, from the Work group members on the processes to the area supervisor and, if required, Process & Lay-out engineers and maintenance personnel too. When you have found a viable proposal raise it onto a Kaizen bulletin. Having raised the bulletin, attach a RED sticker, with the bulletin n

21、umber on it, to the block of time which will be effected by the proposal (for electronic Yamazumis, draw in a circle on the relevant block of time).顯示持續(xù)改進(jìn)活動(dòng)你的山積圖可直觀顯示哪些過(guò)程耗時(shí)高于或低于節(jié)拍時(shí)間，可幫助你更好地平衡這些過(guò)程。如果任何過(guò)程大大超過(guò)節(jié)拍時(shí)間，你必須確保確保時(shí)間設(shè)置實(shí)際合理實(shí)際合理，并且在將QPS表中的信息傳輸至山積圖的過(guò)程中沒(méi)有沒(méi)有犯錯(cuò)。如果你確定正確無(wú)誤，則采取行動(dòng)采取行動(dòng)。首先查看行走時(shí)間，這些通常是過(guò)程中最容易

22、解決的部分?？赏ㄟ^(guò)簡(jiǎn)單移近零件機(jī)架縮短這些時(shí)間，但也可能意味著重大的區(qū)域布局整改。在決策過(guò)程中，應(yīng)要求所有相關(guān)人員參與，包括操作工段工人、區(qū)域主管（如果需要）、過(guò)程和布局工程師和維護(hù)人員。當(dāng)你發(fā)現(xiàn)一個(gè)可行的建議時(shí)，將其發(fā)布到持續(xù)改進(jìn)公告中。發(fā)布公告后，在受此建議影響的時(shí)間框中粘貼一個(gè)標(biāo)有公告編號(hào)的紅色貼紙（對(duì)于電子版山積圖，在相關(guān)時(shí)間框中劃一個(gè)圈）。Halewood Group Process Improvement PlanPurpose: To explain the application of the Work Group Process Improvement Plan which

23、aims to track the status of opportunities for improvement identified by the Yamazumi boardsSept 2002BackgroundThis sheet will be completed by the WGL to show:the quantity of ideas generated by the workgroup based on Yamazumi analysis The status of each concernThe sheet is to be displayed with the Ya

24、mazumi boardFill in the teams proposed countermeasure following a brainstorming session and the date this was raised. The confirmed countermeasure column is to facilitate differences in countermeasure implementation from the original group ideasTick the box to show the reason why the concern has bee

25、n raised.NVA Work = As QPS definition of NVAWalking = Walks between elements identified on the QPSOverburden = Over taktOption deletion = by combining elements we can reduce the number of optional elements on a process, thus reducing the process variationChain of operation = fully completing the fit

26、 of 1 part on the same process where practically possibleSame function same process = where the same part type is fitted independent of vehicle spec, e.g. brake pedalsSafety = balancing the process to improve MFA (Sue Rodgers) scores or as a countermeasure to an accident or near miss report.Input th

27、e planned date for the countermeasure to be implemented and the actual date this occurred. Add the name of the person responsible for implementing the countermeasure to the Resp column to show accountabilityEnsure all WGL and Sv sign off the planned countermeasure prior to implementation to demonstr

28、ate cross shift communication and agreement.The Checksheet at the end of the form is to demonstrate that all updates have been completed and that the training has taken place. This information will also need to be tracked on versatility and competence sheets.Basic process data is tracked here along with affected elements. This will demonstrate which areas of concern identified on the Yamazumi have been addressed or are currently being processed哈利伍德工廠車(chē)間工段流程