主管手册(Supervisor Manual NEW).docx

制造部的目标详解
核心目的
Ø 提供专业的制造服务以帮助客户成功.

目标描述
Ø 捷普广州制造部致力于成为业界最好的制造部门,具体表现为:
o 最强的团队 - 专业人员,专业的训练,专业的管理制度,专业的表现,人尽其才,物尽其用.愉快的工作环境,上下一心的组织.
o 最好的纪律 - 广义的纪律包括公司制度,员工守则,部门规定和现场作业指导书,相关操作规程等. 好的纪律表现为人人自觉守法,管理人员敢于执法.
o 最多的创造力 - 创造力的表现是开动脑筋,发明创造,在任何有益于公司利益的方面提供建议,推行改善.
o 超越客户的期望 - 客户的期望包括工厂5S和生产数量,质量,成本等数据表现.客户包括下一工序,上司,W/C以及最终客户.

为什么制造部设立这些目标

Ø l团队和组织建设的重要性 For Organization develop
o 人是企业最重要的资源,选拔和培训人才,设立好的工作体系使人乐于工作,人的才能得到充分地发挥和提高是公司成功的根基. (人是达成目标的关键)
Ø l纪律的重要性 For discipline
o 国有国法,家有家规;没有规矩,不成方圆,百万之师,没有纪律也是乌合之众,不能成事,人员管理必以纪律为先. (纪律是达成目标的基础)
Ø l创新的重要性 For creativity
o 不断改进是令客户满意的基石,更会推动我们发展和提高竞争力. (创新为我们提供力量)
Ø l超越客户期望For customer satisfaction
o 客户是公司利润的来源,是我们存在的理由. (是否超越客户期望是衡量我们成功的标准)

目标的具体描述

Ø l我们将成为本行业及公司内部最受尊敬的部门;
Ø 我们拥有志向远大,精通本职工作的成员,我们充满活力和锐气,对工作有着宗教一样的狂热, 一方面纪律严明,认真负责,做事井井有条,另一方面孜孜不倦于改良和创新,这里的人主动工作,乐在其中;
Ø l我们的成员目标一致,通力合作,在团队中不断学习,努力挑战和提高自己的潜能,我们为自己 是制造部的一员而骄傲,公司内外最有发展前途的人会主动要求加入我们的组织;
Ø 客户惊讶和欣赏我们的专业服务,对此大加褒奖;
Ø 我们的组织将成为成功的典范为业内人事和管理专家所津津乐道!我们是人所共知的“业界最好的制造部门”!

为什么员工要支持部门的目标

Ø 设定这些目标有助于提高生产力,减少浪费,从而增强公司竞争力和最终客户满意度,使公司收益,公司生意兴隆,我们的工作将更加有保障,相关福利也会稳步增长.
Ø 作为公司一份子,努力实现这些目标有助于提高工作趣味,工作满意度,提升个人工作能力和工作职位.

制造部员工行为准则细则
Ø 正直可信 To be honest - 正直就是诚实，不欺骗,前后一致，可以信赖,以负责的态度采取某种行动;面对错误和失误，勇于主动承担责任,不掩饰、不推诿、不抱怨。
Ø 热爱工作 Passion for job.
o 热情使你乐在其中!
o 热情使你与众不同!
o 热情会传染和激发热情!
o “只有偏执狂才能成功”--英特尔前CEO格罗夫!
Ø 精通本职工作Professional of own area - 对自己所从事的职业无所不知,无所不能.
Ø 纪律意识 sense of discipline – 纪律(严格遵守规定,规程,制度)是制造部一切表现的根基.
Ø 热爱创新 never stop to seek innovation –“如果你说不出你能怎样使公司受益的建议,那你就该走人了” <汤姆彼德斯论创新>.
Ø 主人翁责任感 Ownership – 想象自己是公司的老板.
Ø 团队合作 Team work – 没有人可以独自成功.
Ø 终身学习 Continue Learning – 海纳百川,乃成其大;不学习则不进步,不进步则个人和公司皆没有前途!
Ø 客户导向 Customer-oriented - 客户就是上帝.
Ø 成本导向 Cost-oriented – 消除企业所有环节上的不增值活动以降低成本.
Ø 充分授权 Empowerment – 组织的活力来源于每个员工被授权而发挥能量.
Ø 互相尊重respect each other - 我们尊重所有的同事,一如我们希望被他人尊重.
Ø 坚决执行 Execution - 执行就是全心全意, 奋不顾身,排除一切干扰,想尽一切办法,用最快的速度去达到了目标.
Ø 紧迫感 Urgency - “速度是我们成功的关键”,我们要如同在F1赛车,分秒必争.

Ø 把问题暴露出来以及大声呼救 Speak up and escalation - 世上没有自动”波”,问题不会自己解决,我们必须加以推动.

Ø 个人成长与公司发展并进 Balance personal growth and company development - 个体的努力将推动公司的发展而员工本身也将从中受益.

捷普制造人应有的能力
Ø 沟通能力 团队建设发展能力 控制执行能力
Ø 问题解决能力 冲突管理能力 压力管理能力
Ø 领导能力 时间管理能力 目标管理能力
Ø 教练能力 绩效评估能力 激励能力
Ø 創新能力 计划能力 组织能力

日常工作程序书
Pre- Production Run Check 生產前的准備.
z Come in a minimum of 15 minutes prior to the beginning of your shift (maximum 1/2 hr.).
每個班的主管应最少提前15分鐘(最多30分鐘)來到生產線
z Check email for important information.檢查E-mail,看是否有重要的信息.
Ø Check general message一般性的信息
Ø Check schedule change message生產計划有沒有改變
Ø Previous shift communications.与上一個班有關的信息
z Review Build Plan 查看生產計划.
z Check the shift hand off notebook.閱讀班次交接本.
z Review “"white board”, check all pertinent information. (I.e.. FPY & Efficiency related issues). Review the previous shift’s run.
檢查白板,有沒有潛在的問題.(如效率, 直通率等).回顧上一班的生產情況.
z Talk with the previous shift supervisor.和上一班的主管進行交接
z Walk the line 巡視生產線.
Ø Look for anything out of the ordinary 生產線是否整齊有序.
Ø Housekeeping. 檢查5S 狀況.
Ø Are all WI&VA where they should be? 工程操作指示是否齊全.
Ø Does the line have all necessary documentation? 必要的文件生產線是否都有.
Ø Are there any new “Alert” or “Deviation”? 有沒有新的“品质警報”和“差异”.
Ø Do all inspection station have their magnifier? 是否所有的檢查位都有使用放大镜.
Ø Are tools and jigs located at the correct places? 所有的工具和夹具是否都在合适的位置.
Ø Do parts bin need replenishing? 物料柜是否需要補充.
Ø Is the equipment, test gear, etc. in operational condition? 所有的設備是否都可以正常的使用.
Ø Has all MRB material been properly tagged and moved to appropriate area? MRB 的物料有沒有合適的標識,有沒有放在正确的地方.
Ø Inventory solder paste and glue, pull solder paste and glue from the cold storage? 查看錫漿和膠漿的目錄,要使用的錫漿和膠漿有沒有預先从冷柜取出.
z Check MES data 檢查MES 數据.
Ø from the previous shift 上一班的數据.
Ø check OBA data for the previous run of the same assembly 上一班的OBA情況.
Ø check data from your shift’s previous run for(24 hrs ago or more, to see the trend)
檢查本班前一天的生產情況, (數据)有沒有一定的趨勢 (24小時以前甚至更長時間的報告)
z Re-set the MES system
重新設定MES 系統.
z Check WIP numbers
檢查WIP數
z Check parts availability
檢查相關的物料是否可用.
z Check the employee ESD check sheet
檢查ESD的測試紀錄.
z Call for Start-up meeting
准備開早會.

Start up Meeting 開早會
z Announce product to be run on the shift (include quantity). 宣布本班要生產的產品和數量.
z Announce efficiency & FPY goals. 宣布該產品的效率目標和直通率目標.
z Discuss previous performance include the correct actions. (I.e.. Efficiency & FPY). 討論上一班的生產表現(如生產效率和直通率等). 包括一些纠正行動.
Ø Previous day’s run. 前一天的生產情況.
Ø Previous shift’s performance. 前一班的生產表現.
Ø Previous run of product (including quality issues & areas for improvement).前一班的質量問題和需要改進的地方.
z Review and share the feedback from the previous shift, things to watch out for, potential problem spots, any other applicable issues and news. 根据前一班的情況,宣布本班要密切注意的一些問題和事情.
z Discuss overtime if applicable. 討論可能的加班.
z Discuss any process alert, deviations, ECN and any changes. 討論工序警報和差异,以及工程變更和其他的一些重要變化.
z Special instructions. 強調一些重要的指示.
z Feedback from OBA and customer. 宣布從OBA 和客戶反馈回來的一些重要的信息.
z MRB-quantity and reason. MRB 的數量和原因.
z Introduction of new people. 介紹新的同事
z Check attendance and assign manpower as necessary. 檢查人員出席情況.
z General issues (i.e.. Employee concerns, Company announcement, weekend schedules, meeting schedules). 一般信息.(如員工關心的一些事情.公司的一些重要通告,工作安排,會議日程等)
z Employee morals booster-end of meeting in a positive spirit and motivate your folks.
. 在會議結束時, 激勵和鼓舞每個員工的士气

Manufacturing Run Check 生產過程中的檢查.
z Pre-production and changeover checks. Note: perform the items in this group during production, also. 生產前檢查和轉换產品時的檢查.注意:在生产其间也要执行此项目.
Ø Verify compliance with process flow, control plan, WI, Deviation. 檢查生產工藝流程,控制計劃,WI,差异,等等.
Ø Ensure documentation up to date (WI, feeder list, Deviation, Quality alert etc.) 确保所使用的所有文件都是最新版本.(如WI,上料單,差异,質量警報,等等.)
Ø Verify PLV/QM set up and components, including parts availability 確認PLV/QM已設置好,所使用的物料都是正确無誤的.
Ø Verify components bins; tools; fixtures 檢查物料柜;工具;夾具等等.
Ø Verify mechanical components- hardware, templates, labels 核對生產要使用的一些輔助工具.如模板,各种五金器具,標簽,等等.
Ø Verify that the machine is running correct programs. 檢查机器運行的程序是否正确.
Ø Verify the process settings, such as temperature profiles on Reflow oven and Wave oven are correct 核對工序設置:如热风爐和波峰爐的溫度曲線等.
Ø Verify that the line is complying with all deviations, and other change notices. 如有重要的變更或差异,檢查是否与实际生產的產品相符.
Ø Assure preparation of back up feeders. 确保備用的上料架已准備好.
Ø Ensure all data collection system are reset(CIQ, Test, Packout , QM, etc. 确保所有的數据收集系統都被重新设定.(如CIQ, Test, Packout,QM等等)
z Re-set product shift count 重新設定生產計數.
z Maintain data entry on the “white board” 數據及時記入白板．
z Monitor CIQ/QM-yields and reason for defects at all process points用CIQ/QM系統监控所有工序的直通率變化,缺陷及原因.
z Monitor that the operator input data to CIQ/QM system real time and correctly檢查員工是否及時準確地把数据輸入CIQ/QM系統.
z Monitor that the operator are watching their CIQ/QM process monitors确保員工要隨時監控面前的CIQ/QM系統里面的信息
z Monitor actions for previous process issues-follow up and support對前一個工序進行跟蹤並提供支持
z Monitor “Kanban” and assure parts availability for all points in the process監控“看板”，確保生產線每個工序的物料到位.
z Monitor downtime-fill out downtime report-demand support監控停机時間，填寫停机（拉）记录，尋求相应的支援．
z Maintain process control sheet維護工序控制表格
z Assure that line audits are performed and documented確保對生產線的實核被執行并有文件支持
z Monitor results of the production line-output (at all station)監控生產線每個位置的生產出數
z Assure that the Ionograph is being utilized and data recorded. (for clear process only ) 确保使用清洁度测试仪并记录数据.(只针对水洗工位)
z Check that all operator and line personnel are using proper ESD protection.确保生產線上的員工和其他人都采用正确的靜電防護措施
z Monitor housekeeping during the shift随时監控整個生產線的5s狀態
z Monitor that all-checking lists, data sheets, and logs are being utilized correctly, and timely監控所有的檢查項目,數據表格,記錄等都被及時準確的运用.
Ø 3 defect triggering record. 3d缺陷的記錄及執行
Ø Yield triggering record.直通率的記錄及執行
Ø WIP triggering record. WIP的記錄及執行
z Monitor process parameters in all applicable areas of process 監控所有工位的工序參數
z Assure product is moving to subsequent steps-down the line確保所有的半成品及時準確地輸送到下一個工位.
z Monitor WIP levels and control limit監控WIP,及其控制界限
z Verify FIFO and communicate issues確保先進先出及有關的溝通渠道
z Assure the real time debug, real time rework壞機及時修理,及時反工
z Ensure all operator has proper skill and the certified skill card.確保所有的員工都經過培訓并有相關的認証卡
z Ensure all employee understand the duties expected of them確保每個員工都理解她們的責任和義務
Ø Ask at least 3 job specific questions of each employee while walking the line 巡拉時至少提3個与工作相关的問題
z Compile pertinent data for shift report為生產報告收集相關的數據.
z Must clear MRB on daily basis清理當班的MRB物料
z Must ensure anyone take materials must get confirm from leader or supervisor. 任何人從生產線取走物料,必經征得助理或主管的同意
z Ensure wear finger cots before holing PCB. (任何人)拿板前必須載手指套.

End of Shift 下班
(15 minutes prior end of shift) 提前15分鐘完成生產報告

Complete and publish the Shift report . 完成和发出生產報告.
Ø The report should be written throughout the shift, put in as much information as is available during the shift (as things happen, etc.) so that the preparation time at the end of the shift is kept to minimum. This will make the report available to the no-coming shift folks.在生產過程中逐漸完成生產報表, 減少完成報表的時間,讓生產報表(信息)盡快被下一班的同事分享及知道
Ø Make sure that as much detail and data is captured as possible. This is to avoid confusion and lack of information for the day shift, since sometimes, there is no face to face contact during the shift change. 確保重要的細節和數據都能在生產報告中體現出來,這能避免誤解和本班信息的丟失
z Check housekeeping .檢查5S狀況
z Match CIQ/QM data. 核對CIQ/QM系統里面的數據
z Verify that the “White board” is completed.檢查白板是否完成
z Assure that all MRB material is handled properly, and complete the MRB travelers . MRB物料是否已正確處理並已開單
z WIP report. 完成WIP報告
z Walk the line with the oncoming shift folks. (Peers) 和下一班的主管一起巡拉.

Communication 沟通
z Communication, in general, is a vital process for our success. Informed people have a chance to make smart and timely decisions. You cannot handle things that you don’t know about; they usually hit you like a train – when you are not looking. For our own sake, we must communicate well.
某種程度上,沟通是我們事業成功的關鍵.沟通能夠讓我們變得更聪明和果断, 幫助我們做出明智而及
時的決定.如果你不了解一件事, 那么你就无法处理它, 当你不注意的时候, 它会象一列火车一样撞向你,
为了我們自己,必須做好沟通.
z It is necessary and expected that shift supervisors communicate well with their leaders. Also the leaders must communicate well with their supervisors and their coworkers – other leaders in the manufacturing process – as well as the line operators. 每班的主管都要和助理進行很好的沟通,每個助理也要和他们的主管和合作者---生產線的工人進行必要的充分的沟通,在制造部的组织架构上,助理和生產線的工人一樣也是生產線的一份子.
z Communication between “Front” and “Back” of a manufacturing process (line) must be frequent and accurate. Items that need to be communicated are:沟通也同樣适用于生產線的前后工序之間,這樣的沟通必須是連續而準確的,它们包括:
Ø Downtime 停机(線)時間
Ø Parts availability 物料的可用性,有效性
Ø Line changeover 生產線轉机
Ø FIFO 先進先出的原則
Ø Deviation 差異
Ø Red line documents 控制文件
Ø Program alerts (程序)工序警報
等等…
Other important points其他重要的地方
z Product quality means that the product moving to the next point, and ultimately to the customer, will not require any repair or rework due to “built in” defect, and that it meets all specifications. 產品的質量是指流到下一個工序或客戶手中的產品,不會因為一些缺陷而導致返工或者退貸,並且符合客戶的要求(規格).
z It is in our control to prevent all defects. It may not sound “reasonable” but consider it for a moment. 我們必須控制所有的缺陷,我們的產品不能只是看起來是合格的.(也就是說,我們的產品必須是真正合格的)
z As the management of the manufacturing process (line manager, supervisor, senior leader and leaders) we are in control of the tasks we were assigned and are responsible for. We are able to provide help, guidance, on the job training, and support to our employees. By following the actions and elements outlined in this document we should be able to handle a large portion of the issues. In addition to this we must: 做为制造部的管理人员(生产线经理,主管,高级助理和助理)我們必須盡到自己的責任管理好生產線,在員工的培訓方面我們應該提供幫助,指導並對我們的員工表示支持.只要我們遵循下面的程序去作,我們就能解決工作中的大部分問題.
Ø Stay informed of the issues within the area of our responsibility. 在我們的職責范圍內盡量防止問題的發生.
Ø Continually guide the operators to pay attention to their jobs – functions. 對工人的工作給以持續的指導.
Ø Provide positive encouragement to the folks, and listen to them and their needs – support them. 給予積極的鼓励,傾聽她們的需求,給她們以幫助.
Ø View the line as a chain made up of many individual factories. Each process within the line is a mini “factory”.生產線可以看作是由許多各自獨立的小工厂組成的.生產線的每一道工序就是一個小小的工厂.
Ø Each process point is a supplier as a customer. Each point on the line receives product from the previous process and sends it on to the next process. The product leaving each “factory” must be perfect before it is passed on to the ”customer”.每一工序既是前一工序的客戶,又是下一工序的供應商.我們應該确保自己送到下一工序(客戶)的產品是完美的.
Ø The “customer” must provide instant feedback to the “supplier” if there are any defects or discrepancies defect in the product. The supplier must know what the customer” wants.在生产中客戶(下一工序)如果发现任何缺陷和差异應及時反饋相關的信息給供應商(上一工序).供應商(上一工序)必須清楚知道我們的客戶(下一工序)需要的是什么樣的產品.
Ø To accomplish this, the workers and process within each of the “factory” must be in a good shape. This means both good training and good properly set up process. 為了達到這一點,生產線的每一個員工都應保持良好的精神狀態.有良好的培訓,良好的技能.
Ø This means that each “factory” must make sure that they have all the material, training, tools and support necessary to produce defect free product.這意味着我們的每一個工位都必须做好充分的准備.如對工人的良好的培訓,相關部門和人的支持, 齐备的物料和工具等. 只有這些都具備了,我們才能生產出沒有缺陷的產品.
Ø This requires that all folks follow the prescribed procedures, instruction, WI etc. 每一個員工都應遵守相關的(規定的)程序,指示,WI 等等.
Ø If there is not enough information, or it is incorrect, we must not rest until it has been provided corrected etc.我們有權力要求這些都已完全具備,否則我們就要尋求強有力的支持.
Ø This also means that we must never allow the process to run without the proper tools, gear, fixture, documentation, or any item that are necessary to produce defect free product, unless we have an authorized deviation.这也意味着如果没有正确的工具,夹具,治具,文件和其它生产线需要的东西,我們有權停拉.直到相關問題被解決.或者相關部門發出的“Deviation”文件.
Ø Although, it may not seem like it, it makes much more business sense to wait for an issue to be resolved or proper support tools, etc. to be provided, then to rush and create large amounts of rework by running a marginal or out of control process.雖然,這看起來有點不近人情. 但為了我們公司的前途,我們必須這樣做. 如果不這樣做, 就會導致我們的生產出現失控, 就有可能導致我們的產品大批返工
Ø It is tremendously expensive and timely to perform rework. Rework increases chances for scrap. This means that the money we were expecting from the customer for our labor and effort is lost. Also our credibility and that of the product are affected negatively.返工會導致成本的升高和時間的浪費.報廢率也會大大升高.這极大地浪費了我們的資源.客戶也會對我們的能力產生怀疑.
Ø Common sense and good business sense must prevail. In some instances, the good sense dictates (o