三步法.ppt

The Three Step Approach Integrating Principles and Tools “三步”法综合理论和工具 Johnson Controls Manufacturing System 3 Step Approach_SHW_E_Sep 2 Reality 现实? 10% 关于技术 10% Technical ? 90% 关于人 90% About People The principles of Lean can most likely be absorbed in a one half day classroom session! 精益制造的理论非常可能在一天半的课堂教学里就掌握! The difficult part is putting the principles into practice! 困难的是在实践中应用这些理论! 3 Step Approach_SHW_E_Sep 3 The 3 Steps Process “三步”法? Stabilize 稳定化? Standardize 标准化? Simplify 简化 3 Step Approach_SHW_E_Sep 4 ? People 人? Process 过程? Product 产品 Instability – 3 sources 不稳定的三个来源 3 Step Approach_SHW_E_Sep 5人员的不稳定 People Instability ?关键是尽可能使人员对精益的改变都保持一致。 Making sure people are as consistent as possible is key to any lean conversion. ?为什么会有人旷工/人员流动 Absenteeism / turnover- (Why are people gone?) ?反对改变 Resistance to change ?反馈--(交流–计划 vs. 实际) Feedback-(Communication – Plan vs Actual) ?过度信赖技能水平(高度的重复,复杂性等) Over-reliance on skill level (high repetition, complexity, etc) ?超负荷劳动(需要轮班) Overburdened (Rotation needed) ?知识水平(我们提供了什么培训?) Knowledge level (what training have we provided?) ?没有遵守规则 Not following rules 3 Step Approach_SHW_E_Sep 6过程的不稳定 Process Instability ?你的过程靠什么保证每次都执行的方法都是相同的? What keeps your process from being performed the same way, every cycle? ?标准化工作做的不好或者没有做到。 Poor or missing Standardized Operations ?布局正在变更或处于不断变化之中 Layouts changing or in flux ?太多零件。。。太少零件 Too many parts ….. Too few parts ?工作单元设计的不够好 Poor work cell design ?设备是不可靠的/不可重复的 Machines that are unreliable / unrepeatable ?工作单元有差异 Work cells that allow for variation ?很难说什么样是正常状况 Hard to tell what ‘ Normal ’ looks like ?缺乏好的防错 Lack of good Errorproofing 3 Step Approach_SHW_E_Sep 7产品的不稳定 Product Instability ?是什么产品特征让我们的过程有困难。 What Product features make our process difficult? ?我们的系统有缺陷 Defective parts in our system ?零件随环境状况而变化 Parts that change with the environmental conditions ?零件搬运困难(烫手的零件,刷油漆的零件) Parts that are difficult to han