精益生產(chǎn)的歷史概述

精益生產(chǎn)的歷史

LeanManufacturingHistory1955豐田制造系統(tǒng)TOYOTAPRODUCTIONSYSTEM1979質(zhì)量體系QUALITYSYSTEM1983NUMMI,SYCHRONONSMANUFACTURING1990LEANMANUFACTURING,ESENACH1995DELPHIMANUFACTURINGSYSTEM1996GM-GMS1998COMPETITIVEMANUFACTURING豐田準(zhǔn)時(shí)化生產(chǎn)方式的技術(shù)構(gòu)造體系企業(yè)教育，開(kāi)發(fā)人力資源全員參加的改善和合理化活動(dòng)自動(dòng)化全面質(zhì)量管理設(shè)備快速準(zhǔn)備設(shè)備合理布置多技能作業(yè)員標(biāo)準(zhǔn)化作業(yè)質(zhì)量保證小批量生產(chǎn)同步化生產(chǎn)均衡化生產(chǎn)良好的外部協(xié)作看板管理準(zhǔn)時(shí)化生產(chǎn)消除浪費(fèi)、降低成本全公司整體性利潤(rùn)增加柔性生產(chǎn)、提高競(jìng)爭(zhēng)力適應(yīng)性經(jīng)濟(jì)性尊重人才，發(fā)揮人的作用不斷暴露問(wèn)題，不斷改善意識(shí)改革*5S精益生產(chǎn)方式體系架構(gòu)生產(chǎn)的快速與維護(hù)精益品質(zhì)保證與自動(dòng)化柔性生產(chǎn)系統(tǒng)均衡化同步化現(xiàn)場(chǎng)IE作業(yè)研究生產(chǎn)設(shè)計(jì)與物流系統(tǒng)產(chǎn)品開(kāi)發(fā)設(shè)計(jì)系統(tǒng)精益工廠(chǎng)追求7個(gè)“零”極限目標(biāo)精益工廠(chǎng)追求7個(gè)“零”極限目標(biāo)“零”“零”切換浪費(fèi)“零”庫(kù)存“零”浪費(fèi)“零”不良“零”故障“零”停滯“零”災(zāi)害GMS簡(jiǎn)介GMSBriefIntroduction

GMS簡(jiǎn)介GMSBriefIntroduction

通用汽車(chē)全球制造系統(tǒng)的原則和要素構(gòu)成了一個(gè)完整的系統(tǒng),只有把它作為一個(gè)完整的整體實(shí)施才能有效。各原則之間相輔相成，沒(méi)有一個(gè)原則或要素能獨(dú)立存在。因此我們用一個(gè)類(lèi)似太陽(yáng)系的圖標(biāo)來(lái)表示GM－GMS。只有當(dāng)五個(gè)原則共同實(shí)施，GM－GMS才是一個(gè)完整的系統(tǒng)。TheprinciplesandelementsofGM-GMScompriseacomp-letesystem,andtobeeffectivemustbetakentoget-herasawhole.Eachprinciplesupportsandreinforcestheothers.Nooneprincipleorelementcanstandalone.Forthisreas-on,thesolarsystemiconisusedtosymbolizeGM-GMS.GM-GMSisacompletesystemwhenallfiveprinciplesareimplemented.

GMS簡(jiǎn)介GMSBriefIntroduction

GMS簡(jiǎn)介GMSBriefIntroduction

8個(gè)要素

8Elements 宗旨、價(jià)值觀和文化理念

Vision,Values,&CulturalPriorities 使命

Mission 健康和安全第一

Health&SafetyPriority 合格的員工

QualifiedPeople 人員支持系統(tǒng)/小組原則 PeopleSupportSystem/TeamConcept 員工參與 PeopleInvolvement 開(kāi)放式交流 OpenCommunicationProcess 車(chē)間現(xiàn)場(chǎng)管理

ShopFloorManagement目的的：：引導(dǎo)導(dǎo)員員工工的的個(gè)個(gè)人人行行為為和和公公司司決決策策，，創(chuàng)創(chuàng)造造一一個(gè)個(gè)關(guān)關(guān)注注過(guò)過(guò)程程和和結(jié)結(jié)果果的的氛氛圍圍。。Purpose:Toguideindividualbehaviorandorganizationaldecisions,creatingaprocessandresultsfocusedculture.核心心要要求求CoreRequirements:領(lǐng)導(dǎo)導(dǎo)層層維維護(hù)護(hù)和和糾糾偏偏LeadershipchampionstheCorporateVision,CoreValues,andCulturalPriorities明確清清晰TheVision,Values,andCulturalPrioritiesareclearly公司的的政策策（包包括一一、二二、三三級(jí)文文件））與其其一致致Policies,practices,procedures,andsystemsareconsistentwiththeVision,Values,andCulturalPriorities領(lǐng)導(dǎo)層層以身身作則則Leadershipleadsbyexample評(píng)估和和改進(jìn)進(jìn)，確確保公公司宗宗旨、、價(jià)值值觀和和文化化理念念的一一致性性EvaluateandimprovetoensureconsistencywiththeVision,Values,andCulturalPriorities1.宗旨、、價(jià)值值觀和和文化化理念念Vision,CoreValuesandCutrualPriorities2.使命MISSION定義：：傳達(dá)給給具體車(chē)車(chē)間或或職能能部門(mén)門(mén)的一個(gè)個(gè)目標(biāo)標(biāo)或者者期望望值值的陳陳述Definition:Alocalstatementthatconveysamentalimageofthegoalordesiredstateforaspecificplantorfunction.目的：：激勵(lì)員員工工工作并并使全全體員員工知知道、、理解并并趨近近公司司的奮奮斗目目標(biāo)Purpose:Tomotivate/inspirepeopletoactandhelptheentireworkforcevisualize,understand,andrelatetotheorganization’scompetitivegoalsandobjectives.核心要求求：Corerequirements:是公司領(lǐng)領(lǐng)導(dǎo)層制制定和牽牽頭，全全公司共共同參與與的Developedandchampionedbyleadershipandsharedwiththeentireorganization.支持公司司的宗旨旨、價(jià)值值觀和文文化理念念，并與與其保持持一致AlignedwithandsupportstheCorporateVision,Values,andCulturalPriorities.全公司上上下理解解和全力力支持Understoodandcommittedtobyalllevelsoftheorganization審查策略略、行動(dòng)動(dòng)和體系系以保證證提供支支持Strategies,activities,andsystemsarereviewedtoensuretheysupportpeople’’seffortstoreachthemission.需支持公公司的業(yè)業(yè)務(wù)目標(biāo)標(biāo)Supportsthebusinessgoalsandobjectives.有定期評(píng)評(píng)審使命命陳述的的流程AprocessisinplacetoperiodicallyevaluatetheMissionStatement.定義：實(shí)施一系系列的行行為、措措施、政政策和方方法以幫幫助員員工工實(shí)現(xiàn)一一個(gè)健康康無(wú)傷害害的工作作環(huán)境。。Definition:Implementationofbehaviors,actions,policies,andpracticesthathelpouremployeesrealizeahealthy,injuryfreeenvironment.目的：以安全是最重要要的、所有的的事故都是可可預(yù)防的理念為指導(dǎo)，采取取切實(shí)的措施施保證員工良良好的健健康狀況況和健康無(wú)害害的環(huán)境Purpose:Toensureweprotectthewellbeingofourpeoplethroughactionsconsistentwiththebeliefthatsafetyisouroverridingpriorityandallaccidentsarepreventable.3.健康和安全全優(yōu)先HealthandSafetyPriority核心要求：：CoreRequirements:領(lǐng)導(dǎo)層對(duì)所所有健康和和安全核心心要素的實(shí)實(shí)施和監(jiān)控控負(fù) 責(zé)LeadershipisresponsibleforimplementationandmonitoringoftheseHealthandSafetycorerequirements工廠(chǎng)安全回回顧板PlantSafetyReviewBoard定期安全巡巡檢SafetyObservationTours安全作業(yè)（危險(xiǎn)的工工作，有健健康和安全全作業(yè)指導(dǎo)導(dǎo)書(shū)）SafeOperatingPractices(HealthandSafetystandardizedworkinstructionsaredocumentedandimplementedforjobswhereriskstoemployeeswarrant)事故調(diào)查（“5個(gè)為為什么”問(wèn)問(wèn)題解決流流程)IncidentInvestigation(““5Why”problemsolvingprocess)嚴(yán)格遵守安全規(guī)章Abidebythesafetyrulesstrictly4.合格的員工工QualifiedPeople目的：確保員工的的能力與競(jìng)競(jìng)爭(zhēng)性的生生產(chǎn)制造角角色和和職責(zé)責(zé)相匹配Purpose:Toensurethebestpossiblefitofpeople’sabilitieswiththeexpectationsofthecompetitivemanufacturingrolesandresponsibilities.核心心要要求求CoreRequirements：制定定行行為為規(guī)規(guī)范范，，體體現(xiàn)現(xiàn)公公司司核核心心價(jià)價(jià)值值觀觀，，書(shū)書(shū)面面形形式式交交流流Competencies(RequiredBehaviors)aredefinedforeachleveloftheorganization選擇擇Selection培訓(xùn)訓(xùn)Training激勵(lì)勵(lì)I(lǐng)nspirit發(fā)展展Development5.員工工支支持持系系統(tǒng)統(tǒng)/班班組組原原則則PeopleSupportSystem/TeamConcept定義義：：賦予予各各班班組組主主人人翁翁和和基基本本工工作作單單位位的的功功能能使使小組組成成員員共共同同承承擔(dān)擔(dān)職職責(zé)責(zé)相相互互支支持持，通通過(guò)過(guò)不不斷斷改改進(jìn)進(jìn)達(dá)達(dá)到到共共同同的的目目標(biāo)標(biāo)Definition:Smallgroupsofemployeesthatareempoweredtofunctionastheownersandbasicworkunitwhosharecommontasks,supporteachother,andachievecommongoalsthroughcontinuousimprovement.目的：通過(guò)團(tuán)隊(duì)合作作使員工參與與整個(gè)工作過(guò)過(guò)程，不斷改改進(jìn)自自身表現(xiàn)，產(chǎn)產(chǎn)品質(zhì)量和工工作環(huán)境，最最終樹(shù)立員工自豪豪感和和工作成就感感并促進(jìn)員工個(gè)個(gè)人的發(fā)展Purpose:Toinvolveemployeesintheworkprocesstocontinuouslyimproveperformance,productquality,andworkingconditionsthroughteamwork.Todevelopemployeepride,jobsatisfaction,andpersonalgrowth.核心要求CoreRequirements：制定各級(jí)和職職能塊的職責(zé)責(zé)Rolesandresponsibilitiesforeachlevelandfunctionoftheorganizationaredefined.履行,交流T/M,T/L,G/L職責(zé)Teammembers,teamleaders,andgroupleadersfulfillresponsibilitiesoftheirposition.班組原則Teamcriteria.業(yè)務(wù)系統(tǒng)和實(shí)實(shí)踐操作支持持小組原則的的實(shí)施Businesssystemsandpracticessupportimplementationoftheteamconcept.班組長(zhǎng)的選擇擇Teamleaderselection.班組長(zhǎng)支持小小組和班組目目標(biāo)的標(biāo)準(zhǔn)化化任務(wù)TeamLeadersarenotassignedstandardizedworkbutareassignedstandardizedtasksthatsupporttheteamandobjectives.支持部門(mén)對(duì)于于班組的支持持（HR,財(cái)務(wù)，工程程部，質(zhì)量部部等）Supportorganizations(e.g.HR,Finance,Engineering,Quality,etc.)understandandexecutetheirresponsibilitytotheteams.6.人員參與PeopleInvolvement定義：一整套鼓勵(lì)員員工以積極的的態(tài)度參與公公司不斷改進(jìn)活動(dòng)動(dòng)的系統(tǒng)、程序序、實(shí)踐和方案Definition:Systems,procedures,practices,andprogramsthatinvolveallemployeesasactiveparticipantsincontinuousimprovementactivities.目的：營(yíng)造和保持一一種培育“自豪感”的氛圍。Purpose:Createandmaintainanenvironmentwhichfostersa"spiritofpride”.核心要求：實(shí)施計(jì)劃幫助助員工作出有有依據(jù)的決策策和改進(jìn)Programsandactivitiesareimplementedtohelppeoplemakeinformeddecisionsandimprovements.實(shí)施活動(dòng)（合理化建議議，Gofast(加速），持持續(xù)改進(jìn)等））Implementactivities(e.g.suggestionprogram,GoFastActivities,CIPPrograms,etc.)建立小團(tuán)隊(duì)參參與持續(xù)改進(jìn)進(jìn)Smallgroupsareestablishedandparticipatein improvementactivities.給予員工/團(tuán)團(tuán)隊(duì)認(rèn)可Recognitionisprovidedtoemployees/teams.個(gè)人、小組和和公司績(jī)效應(yīng)應(yīng)與福利待遇遇系統(tǒng)掛鉤Individual,team,andcompanyperformanceisfactoredintothecompensationsystem.7.開(kāi)放式式交流流流程程O(píng)penCommunicationProcess定義：：為營(yíng)造造一種種所有有層次次都能能暢所欲欲言和和有效效交交流的的氛圍的的手段段和方方法。。Definition:Behaviorsandpracticesthatcreateanenvironmentthatfostersafreeandopenflowofcommunicationatalllevels.目的：：交流信信息使使各級(jí)級(jí)員工工作出出有依依據(jù)的的決策策和改改進(jìn)進(jìn)部門(mén)門(mén)的表表現(xiàn)。。Purpose:Toexchangeinformationthathelpspeopleatalllevelsmakeinformeddecisionsandimproveorganizationalperformance.核心要求CoreRequirements：會(huì)議交流Conductregularlyscheduledmeetingstocommunicate交流媒介（（Notes，暗燈板，其它可行行的交流工工具）Usecommunicationmediaeffectively(e.g.Notes,Andonboards,oranycommunic－ationtoolsavailable).營(yíng)造公開(kāi)交交流的辦公公環(huán)境（開(kāi)開(kāi)放式辦公公室，玻璃璃分隔，支支持部門(mén)靠靠近制造生生產(chǎn)部門(mén)，，小組會(huì)議議區(qū)域，關(guān)注操作人人員信息的的及時(shí)獲取?。〦nsurethephysicalenvironmentfostersopencommunication(e.g.openoffices,glasspartitions,supportdepartmentsincloseproximitytothemanufacturingorganization,groupmeetingareas,concernabout).領(lǐng)導(dǎo)層以身身作則（平平易近人，，能主動(dòng)聽(tīng)聽(tīng)取意見(jiàn)和和深入車(chē)間間）Theleadershipstyledemonstratesbehaviorsexhibitingopencommunication(e.g.accessibility,activelisteningskills,floorpresence).信息快速速傳遞的的結(jié)構(gòu)程程序Astructuredprocessisinplacetoquicklydisseminateinformation(motionannouncement,cancellationofovertime).8.車(chē)間現(xiàn)場(chǎng)管理定義：管理和支持小小組的行動(dòng)要要在工作現(xiàn)場(chǎng)場(chǎng)進(jìn)行，便于于理理解，支持持和管理操作作Definition:Thebehaviorofmanagementandsupportgroupstogotowheretheworkisperformed,tounderstand,support,andmanagetheoperations.目的：：確保所所有的的決策策均在在工作作現(xiàn)場(chǎng)場(chǎng)利用用相關(guān)關(guān)、實(shí)實(shí)際、、正正確確的第第一手手材料料作出出Purpose:Toensurethatdecisionsaremadeattheworksitebyutilizingrelevant,factual,accurate,andfirst-handinformation.核心要要求：：定期的的管理理評(píng)審審（SPQRC)和流流程評(píng)評(píng)審(5S,標(biāo)準(zhǔn)準(zhǔn)化工工作））每個(gè)員工都了解SPQRC的狀態(tài)

SPQRCstatusindicatorsarevisiblesoeveryemployeecanseeandunderstandcurrentconditions.

管理支持人員幫助班組成員通過(guò)直接觀察相關(guān)工藝/工作區(qū)域來(lái)解決問(wèn)題

ManagementandSupportPersonnelassistTeamMemberstosolveproblemsbydirectlyobservingtheprocess/workareawhereconcernsexist

問(wèn)題的通報(bào)流程（問(wèn)題升級(jí)）

Problemescalationprocessesaredeveloped車(chē)間辦公室到達(dá)所有生產(chǎn)區(qū)域，TeamRoom設(shè)置在線(xiàn)旁

Shopofficesmustbeaccessibletoallproductionareasandteamleaderworkstationsarelocatedlineside.

會(huì)議/休息息區(qū)域域能容容納所所有員員工且且在一一線(xiàn)主主管（（工段段長(zhǎng)/值班班長(zhǎng)））的控控制/責(zé)任任范圍圍內(nèi)Meeting/breakareasaretobesizedtoaccommodateallmemberswithinthefirstlinesupervisor’sspanofcontro定義和消除浪費(fèi)（七種浪費(fèi)）

Wasteisactivelyidentifiedandeliminated.

目視化管理VisualManagement： -偏離標(biāo)準(zhǔn)的情況對(duì)每個(gè)人可見(jiàn)

makedeviationsfromstandardsvisibletoeveryone

-用顯而易見(jiàn)的方式顯示操作狀態(tài)

displaytheoperatingstatusinaneasytoseeformat

-提供指示和/或信息給員工

provideinstructionand/orinformationtoemployees標(biāo)準(zhǔn)化化標(biāo)準(zhǔn)化化是不不斷改改進(jìn)的的基石石4個(gè)要要素4Elements工作場(chǎng)場(chǎng)地有有序布布置WorkplaceOrganization節(jié)拍定定額時(shí)時(shí)間管管理Management標(biāo)準(zhǔn)化作業(yè)StandardizedWork

目視化管理VisualManagement

9.工工作場(chǎng)場(chǎng)地有有序布布置WorkplaceOrganization核心心要要求求CoreRequirements：5S標(biāo)準(zhǔn)員工的參參與Peopleinvolvement去除多余余物品Excessornon-essentialthingsareeliminated.評(píng)估和改改進(jìn)AuditandadressSort分類(lèi)Sift篩選Sweep清掃Sustain保持Self-discipline自律物在其位位，位有目的：通過(guò)工作場(chǎng)地的布置和保 持，使“不符合標(biāo)準(zhǔn)”的情況 顯而易見(jiàn)。Purpose:

Toputordertoandmaintain theworkplacebymaking "outofstandard"conditions readilyvisible.定義：用于調(diào)節(jié)節(jié)和均衡衡滿(mǎn)足銷(xiāo)銷(xiāo)售需求求的生產(chǎn)產(chǎn)產(chǎn)量的的測(cè)量體體系系。Definition:AmeasuremenTT=生產(chǎn)時(shí)間（秒）/客戶(hù)需求（件）目的：均衡生產(chǎn)計(jì)劃且生產(chǎn)所需的產(chǎn)量。Purpose:

Toleveltheproductionscheduleandproducewhatis neededwhenitisneeded.

作用：杜絕七種浪費(fèi)之：“過(guò)量生產(chǎn)，等待”zl:結(jié)合開(kāi)動(dòng)動(dòng)率，分分析一下下TT,ATT,CT,JPH之間間的關(guān)系系。10.節(jié)節(jié)拍定額額時(shí)間管管理ManagementByTAKTTime核心要求求CoreRequirements：ATT近似滿(mǎn)足足需求，，TT與AT在某一段段時(shí)間內(nèi)內(nèi)（至少少一個(gè)月月）保持持節(jié)拍定定額時(shí)間間和實(shí)際際節(jié)拍定定額時(shí)間間固定。。Takttimeandactualtakttimeremainsfixedforaperiodoftime––onemonthminimum.應(yīng)對(duì)變化化的流程程（具體體的流程程）Proceduresmustbeestablishedtomanagetakttimeandactualtaketimechanges(detailedprocess).相關(guān)文件件的修改改Relevantdocumentsmodificatio輔助設(shè)施Assistantfacility11.標(biāo)標(biāo)準(zhǔn)化作作業(yè)SOS定義：Definition:

Thedocumentationofworkfunctionsperformedina repeatablesequence,whichareagreedto,developed, followed,andmaintainedbythefunctionalorganization.目的：為持續(xù)改進(jìn)建立可重復(fù)，可預(yù)測(cè)的基礎(chǔ)并使操作者 參與最初和不斷的改進(jìn)過(guò)程以便獲得最高水平的安 全，質(zhì)量和生產(chǎn)率。Purpose:

Toestablisharepeatable,predictablebaselinefor continuousimprovementandtoinvolvetheoperatorin boththeinitialandongoingimprovementstoachievethe highestlevelsofsafety,quality,andproductivity.核心要求求CoreRequirements:記錄并且且標(biāo)準(zhǔn)化化所有重復(fù)復(fù)性工作作Allrepeatableworkmustbedocumentedandstan需記錄的要素

Thefollowingcriteriaaredocumented

所有班次的同意（保證不同班次、不同的人做的一樣）

Allelementsanddetailofstandardizedworkmustbeagreedtoacrossallshifts.清晰可見(jiàn)Visuallydisplayed評(píng)審和改進(jìn)Auditandadress生產(chǎn)和支持人員共同參與

Manufacturingandsupportpersonnelinvolvementzl:可以在標(biāo)準(zhǔn)準(zhǔn)化作業(yè)單單中體現(xiàn)出出改版的歷歷史。12.目視視化管理VisualManagement目的：使工作場(chǎng)地地的標(biāo)準(zhǔn)和實(shí)際際狀況一目目了然Definition:Aprocessinwhichstandardsandactualconditionsbecomequicklyvisualintheworkplace.特點(diǎn)Specialty：1.作為一一種管理手手段Workasanmeasureofmanagement2.管理差差異性Managethediscrepancy3.是即時(shí)時(shí)的Instantaneous核心要求CoreRequirements：目視管理使使用和范圍圍theextentanduseofvisualmanagement在標(biāo)注化作作業(yè)中，關(guān)關(guān)鍵或規(guī)范范的程序應(yīng)應(yīng)有特別的的目視標(biāo)示示Criticalorregulatedprocessesreceivespecialvisualidentificationsonthestandardizedwork.更新并維護(hù)目目視管理表格格和工具Visualmanagementformsandtoolsarecurrentandmaintained用于相同應(yīng)用用的目視化方方法必須標(biāo)準(zhǔn)準(zhǔn)化Themethodstovisualizecommonapplicationsmustbestandardized當(dāng)前和標(biāo)準(zhǔn)的的（指標(biāo)或目目標(biāo)）的狀態(tài)態(tài)必須清晰可可辨Boththecurrentandstandard(targetorgoal)conditionsmustbeclearlyidentifiable.簡(jiǎn)單明了Easilyunderstood難以立即改正正，應(yīng)記錄、、張示并交流流其相應(yīng)對(duì)策策Countermeasuresforobservedout-of-standardconditionsthatcannotbeeasilyrectifiedmustbedocumented,displayed,andcommunicated.（與問(wèn)題解決決的鏈接）應(yīng)用：工位地地址牌，標(biāo)簽簽，線(xiàn)標(biāo)識(shí)，，暗燈板Application:stationaddressbrand,label,lineindication,Andonboard5個(gè)個(gè)要要素素5Elements產(chǎn)品品質(zhì)質(zhì)量量標(biāo)標(biāo)準(zhǔn)準(zhǔn)ProductQualityStandards制造造工工藝藝認(rèn)認(rèn)證證ManufacturingProcessValidation工序序內(nèi)內(nèi)控控制制及及驗(yàn)驗(yàn)證證In-ProcessControl&Verification質(zhì)量量反反饋饋/前前饋饋QualityFeedback/Feedforward質(zhì)量量系系統(tǒng)統(tǒng)管管理理QualitySystemManagement13.產(chǎn)產(chǎn)品品質(zhì)質(zhì)量量標(biāo)標(biāo)準(zhǔn)準(zhǔn)ProductQualityStandards定義義：：產(chǎn)品品特特性性可可測(cè)測(cè)的的要要求求，，這這些些要要求求如如能能滿(mǎn)滿(mǎn)足足，，將將確確保保我我們們的的產(chǎn)產(chǎn)品品達(dá)達(dá)到到內(nèi)內(nèi)/外外部部客客戶(hù)戶(hù)的的要要求求Definition:Measurablerequirementsforproductcharacteristics,whichwhensatisfied,ensureourproductsmeetinternal/externalcustomerrequirements.目的：提供產(chǎn)品品評(píng)估的的標(biāo)準(zhǔn)Purpose:Toprovidecriteriaforproductevaluation.核心要求求CoreRequirements:制定,批批準(zhǔn),修修改的流流程(PTQ-1-00-0021.012004.12.30)Adocumentedprocessisinplacetodevelop,approve,andrevisetheproductqualitystandards.(PTQ-1-00-0021.012004.12.30)質(zhì)量標(biāo)準(zhǔn)準(zhǔn)qualitystandards滿(mǎn)足用戶(hù)戶(hù),工程程,法規(guī)規(guī)的要求求Productqualitystandardsmustsatisfycustomer用于反饋饋給工程程部的正正式的流流程Aformalprocessexiststofeedback工具tools：KPC,SOS,VisualAids，邊界樣品品，工序序檢查記記錄表表，，質(zhì)量檢檢驗(yàn)規(guī)范范，冷試試規(guī)范，，熱試規(guī)規(guī)范14.制制造工藝藝認(rèn)證ManufacturingProcessValidation定義：在開(kāi)始全全面生產(chǎn)產(chǎn)前進(jìn)行行工藝準(zhǔn)準(zhǔn)備和認(rèn)認(rèn)證的方方法Definition:Themethodbywhichprocessesarepreparedandvalidatedbeforestartingfullvolumeproduction.目的：確保每道道制造工工序在完完成生產(chǎn)產(chǎn)計(jì)劃的的同時(shí)達(dá)達(dá)到既定定的的產(chǎn)品質(zhì)質(zhì)量標(biāo)準(zhǔn)準(zhǔn)Purpose:Toensurethateachmanufacturingprocessiscapableofmeetingdefinedproductqualitystandards,whileachievingschedule.核心要求求CoreRequirements:符合GPDP工具Tools：ProcessFlowDiagram（Review)ProcessControlPlan（Review)PFMEA（RPN））PTRBucketBuildPPAP，Pilot，F(xiàn)irstpiece15.在在線(xiàn)控制制及驗(yàn)證證In-ProcessControl&Verification定義：通過(guò)預(yù)防防，檢測(cè)測(cè)和遏制制非正常常狀況在在工位上上造入質(zhì)質(zhì)量的系系統(tǒng)Definition:Thesystemofbuildingqualityinstationthroughprevention,detection,andcontainmentofabnormalities.目的：：減少工工序的的波動(dòng)動(dòng)以確確保在在工位位上的的所有有產(chǎn)品品都符符合質(zhì)質(zhì)量要要求，，并且且盡盡可能能快地地在制制造后后的下下道工工序得得到確確認(rèn)以以減少少缺陷陷相關(guān)關(guān)的浪浪費(fèi)費(fèi)Purpose:TominimizeprocessvariationtoensurethatallproductsareOKinstationandareconfirmedassoonaspossiblefollowingmanufactureandtoreducewasteassociatedwithdefects.核心要求:預(yù)防Prevention檢測(cè)Detection遏制Containment下述情況前饋缺陷外溢備用工具/設(shè)備問(wèn)題解決（（經(jīng)驗(yàn)借鑒鑒）產(chǎn)品/工藝藝變更下述情況反饋缺陷確定問(wèn)題解決為問(wèn)題解決決提供流程程記錄跟蹤工具：暗燈燈，問(wèn)題解解決跟蹤系系統(tǒng),CARE前饋：對(duì)于于可能發(fā)生生的質(zhì)量問(wèn)問(wèn)題進(jìn)行事事先的控制制反饋：對(duì)于于已發(fā)生的的質(zhì)量問(wèn)題題進(jìn)行控制制16.質(zhì)量量反饋/前前饋QualityFeedback/Feedforward目的：確保質(zhì)量信息達(dá)到需要這這些信息的的人員手中中Purpose:Toensurethatinformationonqualityreachesthosewhoneedit.核心要求CoreRequirements:文件形式確確定:每道工序的的客戶(hù)和供供應(yīng)商客戶(hù)和供應(yīng)應(yīng)商所需的的時(shí)間表,內(nèi)容等工序內(nèi)測(cè)量量(FTQ等)17.質(zhì)量量系統(tǒng)管理理QualitySystemManagement目的：定義和規(guī)范范質(zhì)量活動(dòng)動(dòng)的既定操操作Purpose:Todefineandregulatetheintendedoperationofthequalityactivities.包括：QS-9000體系，質(zhì)量量閥流程，，GPDP（（GQS））Including:QS-9000system,Qualityvalveprocess,GPDP(GQS)核心要求CoreRequirements:質(zhì)保向工廠(chǎng)廠(chǎng)領(lǐng)導(dǎo)匯報(bào)報(bào)HeadofqualitydepartmentreportstoManager/Directoroftheplant.質(zhì)保有足夠夠的資源Assureresourceallocationforqualityactivitiesissufficient與質(zhì)量體系系相符compliantwiththeappropriatequalitysystemstandard(s)與質(zhì)量相關(guān)關(guān)職能的合合適的組織織結(jié)構(gòu)AnappropriateorganizationalstructureisinplaceforqualityrelatedfunctionsBPD來(lái)管理和跟跟蹤TheBPDprocessisusedtomanagemeasurementsandtrackprogresstogoals.17.質(zhì)量量系統(tǒng)管理理QualitySystemManagement產(chǎn)品質(zhì)量標(biāo)標(biāo)準(zhǔn)清晰易懂clearlycommunicatedtotheuser融于標(biāo)準(zhǔn)化化作業(yè)中incorporatedinstandardizedwork統(tǒng)一的common不能比前前道工序序應(yīng)用的的標(biāo)準(zhǔn)更更苛刻nottighterthanthoseappliedinupstreamprocesses在工藝的的每一階階段都有有定義和和應(yīng)用defined&appliedateachstageoftheprocess對(duì)于已經(jīng)經(jīng)建立的的標(biāo)準(zhǔn)是是可測(cè)量量,可比比較measurableand/orcomparablewithestablishedcriteriaGPDP結(jié)合防錯(cuò)錯(cuò)到工藝藝/產(chǎn)品設(shè)計(jì)計(jì)中在工藝開(kāi)開(kāi)發(fā)過(guò)程程（至少少:關(guān)鍵鍵工藝））中使用用FEMA方法法確定和實(shí)實(shí)施工序序控制來(lái)來(lái)符合工工程要求求（KPC工藝藝控制計(jì)計(jì)劃）有人、機(jī)機(jī)、料、、法和環(huán)環(huán)的變更更時(shí)，對(duì)對(duì)工藝進(jìn)進(jìn)行認(rèn)證證(PTS-0101.012000-4-24工藝驗(yàn)證程序序)在生產(chǎn)情況下下實(shí)施制造認(rèn)認(rèn)證(PPAP)使用前認(rèn)證工工具、設(shè)備、、料箱、檢具具和方法(PTS-0101.012000-4-24工藝驗(yàn)證程序序)在系統(tǒng)完成之之前實(shí)施TPM計(jì)劃預(yù)防Prevention標(biāo)準(zhǔn)化作業(yè)(生產(chǎn),維修修,檢查)SOS(Manufacture,Maintenance,Inspection)TPM遵循零件質(zhì)量量控制計(jì)劃Followpartsqualitycontrolplan符合標(biāo)準(zhǔn)的部部件才能運(yùn)到到生產(chǎn)線(xiàn)旁(來(lái)料檢查)Onlyqualifiedpartscanbedeliveredtotheline(materialcheck)關(guān)鍵設(shè)備的檢檢查Keyequipmentchecking驗(yàn)證工序改變變后的有效性性Effectivenessvalidationforprocesschanging在標(biāo)準(zhǔn)化過(guò)程程中對(duì)相似過(guò)過(guò)程進(jìn)行借鑒鑒。Usesimilarprocessforreferenceduringstandardization防錯(cuò)計(jì)劃，防錯(cuò)清單，，防錯(cuò)驗(yàn)證error-proofingplan,error-proofinglist,error-proofingvalidation檢測(cè)Defection把所需的質(zhì)檢檢納入標(biāo)準(zhǔn)化化作業(yè)中（裝裝配）Requiredqualitychecksareincludedinstandardizedwork(assembly).質(zhì)檢項(xiàng)目有標(biāo)標(biāo)準(zhǔn)Qualitycheckitemsarebasedondefinedcriteria根據(jù)質(zhì)量計(jì)劃劃配備足夠的的資源Sufficientresourcesareallocatedinaccordancewiththequalityplan更新系統(tǒng)Qualitychecksystemsareupdated制定重要工序序的檢測(cè)頻次次Inspectionfrequenciesofcriticaloperationsareestablished檢查站Inspectionstation把檢查方法（（觸摸，聽(tīng)，，看）納入標(biāo)標(biāo)準(zhǔn)化作業(yè)（（裝配）Point,touch,listen,andcountinspectionmethodsareincorporatedinstandardizedwork.用聲光信號(hào)Audio/visualsignalsareimplemented遏制CONTAINMENT采用暗燈AnAndonsystemisimplemented本工位控制缺缺陷Aprocessisstoppedwhendiscrepanciesthatimpactdownstreamactivitiesmustbecontrolledinstation.問(wèn)題解決流程程確定有效的的長(zhǎng)期措施Aproblemsolvingprocessisinitiatedtoidentifypermanentcorrectiveactionthatisverifiedasbeingeffective.縮短制造周期期整體制造周期期(從得到訂訂單到收到貨貨款）產(chǎn)品發(fā)展周期期（從概念到到投產(chǎn)）過(guò)程制造周期期（從原材料料到最終裝配配）9個(gè)要素9Elements簡(jiǎn)易的工藝流流程SimpleProcessFlow少量包裝SmallLotPackaging固定周期定貨貨系統(tǒng)/定購(gòu)購(gòu)零部件FixedPeriodOrderingSystem/OrderParts受控的外部運(yùn)運(yùn)輸ControlledExternalTransportation有計(jì)劃的交運(yùn)運(yùn)/收貨ScheduledShipping/Receiving臨時(shí)物料儲(chǔ)存存-CMA（中心物料區(qū)區(qū)域）TemporaryMaterialStorage(CMA–CentralMaterialArea)拉動(dòng)式式系統(tǒng)統(tǒng)PullSystems均衡已已定購(gòu)購(gòu)車(chē)輛輛的生生產(chǎn)計(jì)計(jì)劃LevelVehicleOrderSchedules供應(yīng)鏈鏈管理理SupplyChainManagement18.簡(jiǎn)易易的工工藝流流程SimpleProcessFlow定義:以獲得得一個(gè)個(gè)簡(jiǎn)易易的物物料與與信息息流為為目的的的流流程Definition:Aprocessthatincorporatesaconstantdrivetoattainasimplesequentialprocessflowofmaterialandinformation.目的的:設(shè)計(jì)計(jì)和和實(shí)實(shí)行行流流程程，，來(lái)來(lái)維維護(hù)護(hù)““先進(jìn)進(jìn)先先出出”，，可追追溯溯，，可可視視，縮縮短短制制造造周周期期，，檢檢查查降降低低成成本本時(shí)時(shí)的的問(wèn)問(wèn)題題，，降降低低庫(kù)庫(kù)存存和和按按流流程程工工作作。。(簡(jiǎn)簡(jiǎn)易易的的物物料料和和信信息息流流））Purpose:TodesignandimplementprocessesthatmaintainFIFO,allowtraceability,arevisual,reduceleadtime,easilydetectsproblemswhileoptimizingcost,andreducesinventoryandworkinprocess.核心要求求CoreRequirements：所有操作作中體現(xiàn)現(xiàn)“先進(jìn)先出出”FIFOpresentinalloperations.工序和緩緩沖區(qū)（（車(chē)輛，，零件））是受控控，優(yōu)化化和目視視的Work-in-processandbuffers(vehicles,parts)arecontrolled,optimized,andvisualized.需要批量量或少量量生產(chǎn)時(shí)時(shí)，盡量量減少規(guī)規(guī)模。Whenbatchorsmalllotproductioniseconomicallynecessary,batchorlotsizemustalwaysbechallengedforreduction.布局和工工藝要有有助于形形成直接接，持續(xù)續(xù)和簡(jiǎn)易易的物料料流Layoutsandprocessesfacilitateadirect,continuous,andsimplematerialflow.操作工的的工作區(qū)區(qū)域設(shè)置置必須考考慮安全全有效的的零部件件擺放Operatorenvelopesaresettoallowsafe,efficientpartspresentation.生產(chǎn)目視視化輔助助（載貨貨單，屏屏幕，拉拉動(dòng)式系系統(tǒng)，等等等）以以簡(jiǎn)潔的的格式顯顯示在車(chē)車(chē)間現(xiàn)場(chǎng)場(chǎng)Productionvisualaids(manifest,screens,pullsystems,etc.)arepresentontheshopfloorinasimpleformat.移動(dòng)設(shè)備和生生產(chǎn)設(shè)備要有有助于形成簡(jiǎn)簡(jiǎn)易的流程Mobileequipmentandproductionequipmentfacilitatesimpleflow.19.少量量包裝SmallLotPackaging定義:確定，分配配或設(shè)計(jì)合合適的標(biāo)準(zhǔn)準(zhǔn)數(shù)量和料料箱Definition:Determining,assigningordesigningtheappropriatestandardquantityandcontainer.目的：以在運(yùn)輸，，儲(chǔ)存和運(yùn)運(yùn)送中不易損壞，，容易控制制的“用戶(hù)喜喜歡”的包包裝方式為為操作工提提供零件件。Purpose:Toprovidepartstotheoperatorinauser-friendlypackagethatfacilitatesdamage-freeandeconomicalhandlingduringshipment,storageanddelivery.核心心要要求求CoreRequirements：料箱箱設(shè)設(shè)計(jì)計(jì)ContainerDesign標(biāo)準(zhǔn)準(zhǔn)包包裝裝數(shù)數(shù)量量應(yīng)應(yīng)能能滿(mǎn)滿(mǎn)足足多多次次重重復(fù)復(fù)運(yùn)運(yùn)輸輸?shù)牡男栊枰猄tandardpackquantityprovidesforfrequentdelivery.a.手工處理的料料箱，使用點(diǎn)點(diǎn)庫(kù)存：2小小時(shí)Pointofuseinventorytargetis2hoursformanuallyhandledcontainer.b.大件料箱，使使用點(diǎn)庫(kù)存：：少于4小時(shí)時(shí)Pointofuseinventoryforbulkcontainerstargetedfor4hoursorless.將料箱裝滿(mǎn)（（沒(méi)有多余空空間）Containercontentsshouldfillthecontainer(noair).核心要求CoreRequirements：盡可能使用通通用的可回用用料箱Useofthecommonreturnablecontainersismaximized.人工搬運(yùn)的料料箱和部件間間襯墊應(yīng)滿(mǎn)足足人機(jī)工程提提升準(zhǔn)則（把把手孔，重量量等）Manuallyhandledcontainersanddunnagemeetergonomicliftingguidelines(e.g.handholes,weight,etc.).物料在生產(chǎn)性料箱中運(yùn)輸Materialshouldbeshippedinproductioncontainers最小化/消除除重新包裝Repackingisminimized/eliminated.核心要求CoreRequirements：空箱返回區(qū)域域Emptycontainerreturnareas指定的收集，，分類(lèi)和分級(jí)級(jí)運(yùn)輸區(qū)Aredesignatedforcollecting,sortingandstaging地址和目視化化識(shí)別（“分分類(lèi)”，“分分級(jí)”區(qū)域，，供應(yīng)商，箱箱蓋說(shuō)明等）Areclearlyidentifiedwithappropriateaddressesandvisualcontrols(e.g.typeofarea"Sort","Stage",supplier,returnschedule,cappinginstructions,etc.)能容納納計(jì)劃劃數(shù)量量的料料架、、托板板和料料箱Accommodateplannedquantitiesofracks,palletsandcontainers每個(gè)供供應(yīng)商商（和和/或或供應(yīng)應(yīng)商組組）的的料箱箱有指指定區(qū)區(qū)域Aredesignatedforeverysupplierand/orcontainercombination減少運(yùn)運(yùn)輸距距離和和標(biāo)準(zhǔn)準(zhǔn)化作作業(yè)流流程Arelocatedtominimizetraveldistanceandstandardizetheworkflow核心要要求CoreRequirements：空箱處處理準(zhǔn)準(zhǔn)則確保操操作工工把空空箱放放置在在合適適的返返回裝裝置中中Assureoperatorplacesemptycontaineronappropriatereturndevice遵循書(shū)書(shū)面形形式的的內(nèi)部部襯墊墊處理理流程程Conformtoawrittenprocessforhandlinginternaldunnage遵循書(shū)書(shū)面形形式的的分類(lèi)類(lèi)，分分級(jí)，，裝載載和卸卸載工工作流流程Conformtoawrittenprocessforpropersorting,staging,loading,andunloading防止錯(cuò)錯(cuò)用料料箱Preventmisuseofcontainers確保在在運(yùn)送送至供供應(yīng)商商之前前，空空箱中中無(wú)碎碎屑物物Assureemptycontainersarefreeofdebrisbeforeshippingthemtosupplier確認(rèn)損損壞的的料箱箱并制制定處處理的的方式式Identifyandroutedamagedcontainersforrepair/disposal核心要要求CoreRequirements：驗(yàn)證新新包裝裝或改改進(jìn)已已有包包裝的的流程程Processexiststovalidatenewpackagingorchangestoexistingpackagingforimprovementopportunities.20.固定周期訂訂貨系統(tǒng)/定購(gòu)零零部件FixedPeriodOrderingSystem/OrderParts定義：為了能夠在在均衡基礎(chǔ)礎(chǔ)上有效地地提供物料料而預(yù)先先確定零零部件定購(gòu)購(gòu)的固定周周期。Definition:Pre-determined,fixedperiodforpartsorderingallowingfortheeffectivesupplyofmaterialonaleveledbasis.目的：確保物流供供應(yīng)可靠，，可預(yù)測(cè)。。Purpose:Toensurepredictable,reliableflowofmaterialsthroughthepipeline.固定周期訂訂貨系統(tǒng)/定購(gòu)零零部件FixedPeriodOrderingSystem/OrderParts核心要求CoreRequirements：零件訂貨和和發(fā)運(yùn)固定定周期Establishfixedperiodforpartsorderinganddelivery.根據(jù)雙方協(xié)協(xié)定的時(shí)間間期限，與與供應(yīng)商及及運(yùn)輸部門(mén)門(mén)商定物料料日程Materialschedulesarecommunicatedtothesupplierandthetransportationcontactperagreedupontimehorizon.物料計(jì)劃單單應(yīng)注明標(biāo)標(biāo)準(zhǔn)包裝數(shù)數(shù)量Materialschedulesarestatedinstandardpackquantities.處理緊急事事件的流程程Anexceptionprocessexiststocoveremergencies.零部件訂購(gòu)購(gòu)流程的內(nèi)內(nèi)部管理Partsorderingprocessismanagedlocally.21.受控控的外部運(yùn)運(yùn)輸ControlledExternalTransportation定義：相關(guān)物流部部門(mén)管理的的有計(jì)劃的的可控的物流流程程。Definition:Scheduledlogisticspipelinewithestablishedcontrolsmanagedbyaleadlogisticsprovider.目的：為經(jīng)常性物料的運(yùn)送送提供可預(yù)預(yù)測(cè)的方法法，最大大化資資源利用。Purpose:Toprovideapredictablemethodforfrequentmaterialmovementthatmaximizesuseofresources.核心要求CoreRequirements：主要物流流部門(mén)（（LLP)或者者對(duì)口部部門(mén)：LLP和和工廠(chǎng)應(yīng)應(yīng)建立重重點(diǎn)業(yè)務(wù)務(wù)的審查查標(biāo)準(zhǔn)和和定期審審查制度度AprocesstomeasurekeyperformancecriteriaandregularperformancereviewswithLLPandplant工廠(chǎng)里的的常駐人人員aresidentintheplant建立并維維護(hù)運(yùn)輸輸路線(xiàn)計(jì)計(jì)劃Astrategicrouteplanandmaintainsrouteboard進(jìn)一步降降低成本本的流程程Aprocessforfurthercostreduction為貨運(yùn)和和/或運(yùn)運(yùn)輸商提提供培訓(xùn)訓(xùn)Trainingforcarrierand/ortransportationproviders將工廠(chǎng)的的目標(biāo)融融入LLP的BPD中中Thattheplant’sobjectivesareintegratedintotheLLP’sBPD以小時(shí)-小時(shí)，，天-天天和周-周來(lái)分分層衡量量運(yùn)送周周期Thewindowdeliverytimestoplantarelevelhour-to-hour,day-to-day,week-to-week.將所有零零部件運(yùn)運(yùn)輸至工工廠(chǎng)和/或分配配中心，，有計(jì)劃劃地定期期供貨Allpartsaredeliveredtotheplantand/ordistributioncentertoscheduledwindows.建立立不不斷斷提提高高運(yùn)運(yùn)送送方方式式空空間間效效率率的的流流程程Processisinplacetocontinuouslyimprovecubeefficiencyofalltransportationmodes.根據(jù)據(jù)經(jīng)經(jīng)濟(jì)濟(jì)性性和和可可靠靠性性,為為每每一一條條路路線(xiàn)線(xiàn)確確定定現(xiàn)現(xiàn)場(chǎng)場(chǎng)卸卸貨貨還還是是中中轉(zhuǎn)轉(zhuǎn)卸卸貨貨"Live"unloadingvs."dropandswap"isdeterminedforeachroutebasedoneconomicsandtransportationreliability.有相相應(yīng)應(yīng)的的流流程程保保證證運(yùn)運(yùn)貨貨司司機(jī)機(jī)執(zhí)執(zhí)行行規(guī)規(guī)定定的的流流程程檢檢查查(在在供供應(yīng)應(yīng)商商處處提提貨貨時(shí)時(shí)根根據(jù)據(jù)零零件件號(hào)號(hào)檢檢查查料料箱箱數(shù)數(shù))Processisinplacetoconfirmthattheroutedriverperformstheagreedprocesschecks(suchasverifyingthecontainercountbypartnumberfortheshipmentatthetimeofpick-upatthesupplier).有正正確確劃劃分分供供應(yīng)應(yīng)商商責(zé)責(zé)任任導(dǎo)導(dǎo)致致的的額額外外運(yùn)運(yùn)輸輸費(fèi)費(fèi)用的的流流程程Processisfollowedtoproperlyclassifysupplier-responsiblepremiumtransportation.執(zhí)行以下流程程Aprocessisinplaceto:貨運(yùn)延誤或發(fā)發(fā)貨錯(cuò)誤確保保貨運(yùn)公司及及時(shí)通知工廠(chǎng)廠(chǎng)有關(guān)部門(mén)Assurethatcarriersnotifytheplantpromptlyifadeliveryisdelayedorincorrect當(dāng)供應(yīng)商在PRR中提貨貨延誤時(shí)，要要求其采取相相應(yīng)的整改措措施Requiresupplierstoprovidecorrectiveactionsduetodelaysinmaterialpick-upatsuppliersplantPRR’’s協(xié)調(diào)特殊的或或緊急的發(fā)運(yùn)運(yùn)Coordinatespecialoremergencyshipments22.有計(jì)劃劃的發(fā)運(yùn)/收收貨ScheduledShipping/Receiving定義：貨物運(yùn)輸根據(jù)據(jù)指定的時(shí)間間到達(dá)/離開(kāi)開(kāi)Definition:Transportationcarriersarrive/departatdesignatedtime.目的：均衡和標(biāo)準(zhǔn)化化發(fā)運(yùn)/收貨貨活動(dòng)以及資資源要求Purpose:Tolevelandstandardizeshipping/receivingactivitiesandresourcerequirements.22.有計(jì)計(jì)劃的的發(fā)運(yùn)運(yùn)/收收貨ScheduledShipping/Receiving核心要要求CoreRequirements：貨運(yùn)在在指定定的計(jì)計(jì)劃時(shí)時(shí)間達(dá)達(dá)到/離開(kāi)開(kāi)指定定的地地點(diǎn)Carriersarrive/departatthedesignatedlocationatthescheduledwindowtime.制定定和和公公布布標(biāo)標(biāo)準(zhǔn)準(zhǔn)作作業(yè)業(yè)程程序序(作作業(yè)業(yè)單單中中描描述述貨貨運(yùn)運(yùn)和和工工廠(chǎng)廠(chǎng)的的角角色色