LeanManufacturingWK3精益生产3英文.pptxVIP

lean manufacturing training week 3[]lean manufacturing foundationsBest Quality – Lowest Cost – Shortest Lead Time – Best Safety – High MoraleThrough shortening the production flow by eliminating waste Just-in-TimeRight part, right amount, right timeTakt timeContinuous flowPull systemQuick ChangeoverIntegrated logistics People Teamwork*Selection *Rigid decision making*Common goals *Cross-trained Jidoka(In-station quality)Make problems visibleAutomatic stopsAndonPerson-machine separationError proofingIn-station-quality controlSolve root cause of problem (5 Why’s) Continuous Improvement Waste Reduction*Genchi Genbutsu *Eyes for waste*5 Why’s *Problem solvingLeveled Production (Heijunka)Stable and Standardized ProcessesVisual ManagementTPS – Total Production Managementone-piece flowalso known as “single piece flow”ideal state where items are processed and moved directly to the next process one piece at a timeeach processing step completes its work just before the next process needs the item and the transfer batch is oneTakt Time:the heart beat of one-piece flowone-piece flowbenefits of one-piece flow:builds in qualitycreates real flexibilitycreates higher productivityfrees on floor spaceimproves safetyimproves moralereduces cost of inventoryone – piece flow “If some problem occurs in one-piece-flow manufacturing then the whole production line stops. In this sense it is a very bad system of manufacturing. But when production stops everyone is forced to solve the problem immediately. So team members have to think, and through thinking team members grow and become better team members and people.”Teruyuki Minoura, former President, Toyota Motor Manufacturing, North AmericajidokaStopping the process to build in quality“A method to detect defects when they occur and automatically stop production so an employee can fix the problem before the defect continues downstream.”Poke Yoke – Error Proofingone – piece flowredesign work processes to achieve high value-added, contin