精益生产推行案例.ppt

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1、ConfidentialGK130Help Chain in Manzoni19/04/10 to 23/04/10 精益生产推行案例精益生产推行案例-帮助链帮助链Confidential2 Team团队名称团队名称手拉手手拉手Hand in Hand 团队成员团队成员Team numberConfidentialHelp Chain Definition帮助链定义帮助链是一种对于生产、质量、物流、维修出现的问题力争将损失降到最低的快速反应体系Help Chain is a routine of interaction and involvement of several levels of

2、the organization,aiming to solve or contain a problem quickly,to restore the normal flow.Confidential4Objectives and Goal 目的与目标目的与目标Objectives 目的To organize the daily routine,the identification,register and to solve problems with“quick reaction plan”.组织每天例会，查看记录的问题并制定解决方案 Increase the productivity f

3、rom 74%to 82%untill Sep.2010提高生产率从74%到82%（2010-9月）74%82%Confidential帮助链流程 Help chain sequence1.问题发生 Detection Problem3.进行帮助链Support of preparer to start the help chain when needed4.问题记录 Problems registering2.按安灯Turn on the Andon(Visual management)5.分析解决问题Staff works to solving problems(acting in the

4、 route causes)Confidential6Help Chain帮助链Quality 质量质量Maintenance 维修维修Production&Logistics 生产生产&物流物流分析帮助链的主要方面分析帮助链的主要方面Analysis sides of Help ChainSafety安全安全Confidential7数据收集数据收集了解生产了解生产&物流、质量、维修现状物流、质量、维修现状Stat.data about the production&logistic、quality、manintenanceConfidential8快速反应计划快速反应计划 Quick Re

5、action Plan维修质量生产对经常发生的问题分生产&物流、质量、维修三方面制定快速反应计划According the main problem to make quick reaction plan about production&logistic、quality、maintenance 负责人ConfidentialBefore Kaizen改善前有时会出现设备停机需要帮助时信心传递延迟Sometime delay in communication To ask help when the press is stopped给维修，操作工，检验员，生产领班配置对讲机Radio for

6、communication between production and MaintenanceWaiting or SearchingAfter Kaizen改善后改进改进 ImprovementConfidential10Andon改进改进 Improvement设备停机时先将黄灯打开，超过规定时间问题依旧没有解决的话将红灯打开Open the yellow light first when the machine stopped and if its over than regulating time open the red lightConfidential11帮助链展板Help C

7、hain Board改进改进 Improvement展板信息 Information on the board快速反应计划Quick reaction plan每天停机信息Stop time of daily on notes相关人员照片Photos of related people每班异常分析表Shift occurance report1000T每月生产率Productivity in Manzoni per monthConfidential12改进改进 Improvement所有的停机（除了换料不超时的停机）都要记录在展板上，超过规定时间的问题需填写每班异常分析表All the st

8、opped time should record on the board except change coil withen the regulated time,if the time of solving problem over the regulated,need to fill in shift occurance reportConfidential13Training record 培训记录培训记录对三个班的生产领班，维修，操作工对三个班的生产领班，维修，操作工进行了帮助链的培训包括展板上的问进行了帮助链的培训包括展板上的问题如何记录，异常分析表如何填写等题如何记录，异常分析表

9、如何填写等Training productive supervisor,maintenance people and operator about how to record on the help chain board and how to fill in the shift occurance reportConfidential14Action Plan 行动计划行动计划共制定共制定28项行动计划，项行动计划，1项未完成项未完成 Made 28 action plan and 1not finishedConfidential15Productivity control 生产率控制生产

10、率控制2009sep-dec一月二月三月四月五月六月七月八月九月十月十一月 十二月累计100.0%90.0%80.0%70.0%60.0%50.0%40.0%30.0%20.0%10.0%0.0%65%74%59%64%71%66%1000T每月生每月生产率率Productivity Manzoni 1000T-Monthly2009年History目标Goal实际Real82%Confidential16Next Step 下一步计划下一步计划建立安全快速反应计划Make quick reaction plan about safetyConfidential17Implement 实施实施

11、帮助链的实施从4月27日开始，每天8：40冲压主任同生产领班，质量领班，维修领班，工艺工程师到帮助链展板前开例会，对上一天的停机情况进行查看分析The implement of help chain was started from this Tuesday.Daily meeting time:8：40Attending people:Stamping Chief、Productive supervisor、Quanlity supervisor、Maintenance Supervisor、EngineerContent:Review the stop time and analysisC

12、onfidential18Gemba Kaizen Results 改善结果改善结果Gemba Kaizen Results(GK)现场改善收益统计表现场改善收益统计表Indicator项目项目Before GK改改善前善前Goal GK目标目标Results of GK改善收益改善收益Value%Value%生产能力生产能力 Production Capacity(百万百万 台台/年年 Mi unidades/year)7482换型时间换型时间 Change over Time(m)OEE(%)OEE(%)生产速度 Production Rate(p/h)11161231加班费节省加班费节省

13、 Overtime Saving(IOP)(h)防错防错 Poka yoke人因工程人因工程Ergonomic 安全安全 Safety可视化可视化VisualVisual22环境环境 EnvironmentConfidential19Presentations TitleMonitoring 改善结果跟踪改善结果跟踪 Espao(opcional)para concluso 1 mn 13 pts.)Espao(opcional)para concluso 2(fnt mn 13 pts.)实施改善后的一个月内，实施改善后的一个月内，LPO和精益传播者每周一次对改善项目进行跟踪和精益传播者每周

14、一次对改善项目进行跟踪Confidential20Presentations TitleThoughts 感言感言团结就是力量手拉手，心连心，效率更上一层楼工作再忙也要查因改善Confidential21Presentations TitleQ&A问题和解答问题和解答GK130ConfidentialANDONAndonWHAT IS THE PROBLEM?WHEN I TURN ON THE ANDON?ANDONIll start the help chainHELP CHAIN:Maitenance Quality Planning Materials Engeneer etc.Timer 20 MinutesProblem