如何做好異常管理課件

異常管理

AbnormalityManagement管理體系培訓(xùn)

ManagementSystemTraining課程目的

Objectives–AbnormalityManagement認(rèn)識(shí)異常并解釋快速反應(yīng)的重要性解釋標(biāo)準(zhǔn)化作為目視化控制和異常管理的前提的重要作用.描述異常管理中領(lǐng)導(dǎo)者的角色.解釋為何異常的管理和對(duì)策對(duì)以下方面關(guān)系重大:問責(zé)維持持續(xù)改善本課程學(xué)習(xí)后,學(xué)員將能夠:

Aftersuccessfullycompletingthismodule,participantswillbeableto:2IdentifyabnormalitiesandexplaintheimportanceofrapidresponseExplaintheimportanceofstandardworkasaprerequisitetovisualcontrolsandabnormalitymanagementDescribetheleader’sroleinabnormalitymanagementExplainwhyabnormalitymanagementandcountermeasuresareessentialintermsof:AccountabilitySustainmentContinuousImprovement日程何為異常?目視化管理的本質(zhì)實(shí)施步驟異常管理問題對(duì)策的策略管理者的角色小結(jié)3AgendaWhatisanabnormality?EssenceofVisualControlsImplementationStepsAbnormalitymanagementCountermeasureStrategiesLeader’sroleSummary異常管理

AbnormalityManagement異常:與標(biāo)準(zhǔn)相偏離的部分異常的管理:針對(duì)異常的識(shí)別和快速響應(yīng)的能力4Abnormality:ADeviationfromtheexpectedstandardsAbnormalityManagement:Theabilitytoidentifyandrapidlyrespondtoanabnormality為何要停線解決問題?邏輯偏離標(biāo)準(zhǔn)(糾正的浪費(fèi))原則提高質(zhì)量一次合格率策略停線解決問題

(決不接受缺陷流到下序)方法

在停線處解決問題并

改進(jìn)支持體系提高解決問題的緊迫度鼓勵(lì)發(fā)現(xiàn)問題業(yè)績(jī)衡量指標(biāo)質(zhì)量一次合格率生產(chǎn)產(chǎn)出,l每日停線次數(shù)評(píng)審結(jié)果

PerformanceMeasureFirst-timequality,productionoutput,linestop

timeauditresultsdaily精益工具安東(Andon)，自動(dòng)化，標(biāo)準(zhǔn)化，問題解決，培訓(xùn)

LeanToolsAndon,jidoka,standardisation,problemsolving,training控制方法目視化控制,標(biāo)準(zhǔn)化作業(yè),質(zhì)量審核

ControlmethodVisualcontrols,standardwork,qualityaudits效果減少系統(tǒng)浪費(fèi)構(gòu)建利于改進(jìn)的相互協(xié)作的工作環(huán)境

ResultSystemwastereducedCostreducedCooperativeenvironmentForimprovement5PhilosophyDeviationfromStandard(WasteofCorrection)PrincipleGetqualityRightFirstTimeStrategyStoptofixproblems(Neverknowingly

passonadefect)MethodFixstoppositionand

supportstructureReasonIncreaseurgencyand

correctproblemsEffectMotivatetoidentifyproblems為何異常管理至關(guān)重要?

WhyAbnormalityManagementisImportant?秒小時(shí)班次每日每周每月有清晰的KPI指標(biāo)衡量我當(dāng)前狀況(檢查什么)

ClearcriticalKPI’stojudgemycondition(Whattocheck)為了確保健康狀況持續(xù)改善檢查的頻次如何?(如何檢查)

Howoftenshouldyoucheckmydatatoensuremyconditioncontinuestoimprove?(Howtocheck)生產(chǎn)線停止很類似于心跳停止

Whentheprocessstopsitislikehavingacardiacarrest6SecondsHoursShiftDailyWeeklyMonthly實(shí)施步驟

StepstoImplementation標(biāo)準(zhǔn):確立標(biāo)準(zhǔn)–能夠檢測(cè)出異常檢測(cè):實(shí)施目視化控制以識(shí)別正常和異常檢測(cè):建立安東系統(tǒng)響應(yīng):建立針對(duì)異常問題的快速響應(yīng)系統(tǒng)解決措施:實(shí)施解決措施維持:評(píng)審系統(tǒng)的有效性7Standard:Establishthestandard–soabnormalitycanbedetectedDetection:ImplementvisualcontrolstodistinguishnormalfromabnormalDetection:EstablishanAndonsystemResponse:EstablisharapidresponsesystemtoaddressabnormalitiesResolution:ImplementCountermeasureStrategiesSustainment:Audittheeffectivenessofthesystem實(shí)施步驟

StepstoImplementation8標(biāo)準(zhǔn):確立標(biāo)準(zhǔn)–能夠檢測(cè)出異常檢測(cè):實(shí)施目視化控制以識(shí)別正常和異常檢測(cè):建立安東系統(tǒng)響應(yīng):建立針對(duì)異常問題的快速響應(yīng)系統(tǒng)解決措施:實(shí)施解決措施維持:評(píng)審系統(tǒng)的有效性Standard:Establishthestandard–soabnormalitycanbedetectedDetection:ImplementvisualcontrolstodistinguishnormalfromabnormalDetection:EstablishanAndonsystemResponse:EstablisharapidresponsesystemtoaddressabnormalitiesResolution:ImplementCountermeasureStrategiesSustainment:Audittheeffectivenessofthesystem標(biāo)準(zhǔn)的范例

ExamplesofStandards產(chǎn)品質(zhì)量特性過程參數(shù)操作工標(biāo)準(zhǔn)化作業(yè)9ProductQualitySpecificationProcessParametersOperatorStandardWork步驟一:確立標(biāo)準(zhǔn)

StepOne:EstablishtheStandard103種產(chǎn)品

3份標(biāo)準(zhǔn)化作業(yè)表

RMFGACB必須要確定節(jié)拍時(shí)間和標(biāo)準(zhǔn)作業(yè)順序

TaktTimeandstandardworkmustbedefined1236543ProductModels3StandardOperationSheets步驟一:確立標(biāo)準(zhǔn)–流程行業(yè)

StepOne:EstablishtheStandard–ProcessIndustry11每100磅2.5分鐘作業(yè)每500磅5.0分鐘作業(yè)每1000磅2.0分鐘作業(yè)可用時(shí)間=60分鐘

實(shí)際作業(yè)時(shí)間=39.5分鐘2.5mintaskevery100lbs5.0mintaskevery500lbs2.0mintaskevery1000lbsAvailableTime=60min ActualTaskTime=39.5min實(shí)施步驟

StepstoImplementation12標(biāo)準(zhǔn):確立標(biāo)準(zhǔn)–能夠檢測(cè)出異常檢測(cè):實(shí)施目視化控制以識(shí)別正常和異常檢測(cè):建立安東系統(tǒng)響應(yīng):建立針對(duì)異常問題的快速響應(yīng)系統(tǒng)解決措施:實(shí)施解決措施維持:評(píng)審系統(tǒng)的有效性Standard:Establishthestandard–soabnormalitycanbedetectedDetection:ImplementvisualcontrolstodistinguishnormalfromabnormalDetection:EstablishanAndonsystemResponse:EstablisharapidresponsesystemtoaddressabnormalitiesResolution:ImplementCountermeasureStrategiesSustainment:Audittheeffectivenessofthesystem步驟二:實(shí)施目視化控制

StepTwo:ImplementVisualControls一旦定義了何謂正常,需要將流程目視化使流程一目了然目視化s使得我們能觀察到異常為持續(xù)改進(jìn)提供快速響應(yīng)13Oncenormalisdefined,thentheprocessmustbemadevisualVisualataglanceVisualControlsallowustoobservetheabnormalitiesProvidesimmediateinputforimprovement確立了標(biāo)準(zhǔn)–建立目視化

EstablishtheStandard–ThenMakeitVisual14目視控制&持續(xù)改進(jìn)文化

VisualControls&ContinuousImprovementCulture試想保齡球的球瓶如果被遮擋起來，保齡球如何投擲?誰(shuí)應(yīng)該知道得分?如果你每天/每周/每月才得知得分會(huì)怎樣?如何知道我們獲勝?我們?cè)鯓蛹?lì)自己去改進(jìn)?15目視化管理創(chuàng)建了團(tuán)隊(duì)的氛圍–使每人都知道比分

Visualcontrolscreateateamatmosphere–

everyoneknowsthescore

Whatwouldbowlingbelikeiftherewasacurtainblockingyourviewofthepins?Whowouldknowthescore?Whatifyouwereonlytoldyourscoreonceperday/week/month?Howwouldweknowifwewerewinning?Howmotivatedwouldwebetoplayorimprove?338271ActTar目視化控制–未達(dá)成節(jié)拍時(shí)間

VisualControl–NotAchievingTakt16每小時(shí)產(chǎn)量管理表

AdministrativeHourByHourChart17對(duì)于需求的響應(yīng)ResponsetoDemand流程行業(yè)小時(shí)產(chǎn)量管理表

ProcessIndustryHourbyHourPerformance18異常管理和目視控制

AbnormalityManagementandVisualControls

19如沒有目視化,未達(dá)到標(biāo)準(zhǔn)的問題不會(huì)被發(fā)現(xiàn)

Withoutvisualcontrols,aviolationfrom

standardwouldnotbeknown實(shí)施步驟

StepstoImplementation20標(biāo)準(zhǔn):確立標(biāo)準(zhǔn)–能夠檢測(cè)出異常檢測(cè):實(shí)施目視化控制以識(shí)別正常和異常檢測(cè):建立安東系統(tǒng)響應(yīng):建立針對(duì)異常問題的快速響應(yīng)系統(tǒng)解決措施:實(shí)施解決措施維持:評(píng)審系統(tǒng)的有效性Standard:Establishthestandard–soabnormalitycanbedetectedDetection:ImplementvisualcontrolstodistinguishnormalfromabnormalDetection:EstablishanAndonsystemResponse:Establisharapidresponsesystemtoaddress

abnormalitiesResolution:ImplementCountermeasureStrategiesSustainment:Audittheeffectivenessofthesystem步驟三:建立安東系統(tǒng)

StepThree:EstablishanAndonSystem21是一種安裝在流水線上能夠檢測(cè)問題的信號(hào)燈裝置，通常運(yùn)用聲光的方式。

Andon:Adeviseforsignalingthereisaproblemintheproductionflow.Usuallybothvisualandaudible.1Help!234步驟三:安東系統(tǒng)

StepThree:AndonSystem安東必須要在異常發(fā)生時(shí)立即發(fā)揮作用最好是自動(dòng)地報(bào)警報(bào)警必須要一目了然(和發(fā)出報(bào)警聲音)必須明確設(shè)定好異常的響應(yīng)系統(tǒng)每個(gè)人都經(jīng)過了異常響應(yīng)的培訓(xùn),都已明確異常發(fā)生時(shí)各自的職責(zé)所有問題相關(guān)信息被追蹤和記錄針對(duì)數(shù)據(jù)的趨勢(shì)進(jìn)行分析,持續(xù)改進(jìn)針對(duì)問題制定了改進(jìn)對(duì)策并追蹤其效果22AndonmustbeimmediateinassociationwiththeabnormalityPreferably,shouldbeautomaticMustbevisible(and/oraud