通用大宇持续改进培训材料（优）.ppt

GMS,Orientation,Continuous Improvement,GMDAT/DIMC Confidential,Version Date 2003.3.15,Slide,*,DIMC,GMS,Continuous Improvement,GMS,持续改进,员工参与,标准化,制造质量,缩短制造周期,持续改进,32,GMS,Continuous,Improvement,Built-InQuality,Short LeadTime,PeopleInvolvement,Standardization,Continuous Improvement,Health andSafety Priority,Qualified People,Team Concept,PeopleInvolvement,OpenCommunicationProcess,ControlledExternal,Transportation,ManufacturingProcess Validation,ProductQualityStandards,QualitySystemManagement,ScheduledShipping/,Receiving,Level VehicleOrder Schedules,SupplyChain,Management,Values,Vision,/Mission,Shop FloorManagement,Internal,Pull/,Delivery,Andon,Concept,ProblemSolving,SimpleProcessFlow,In-ProcessControl&,Verification,StandardizedWork,Small LotPackaging,TemporaryMaterialStorage,QualityFeedback/Feed-,forward,VisualManagement,Managementby TAKT,Time,Work-,placeOrganization,Early Mfg.and DesignIntegration(DFM/DFA),ContinuousImprovementProcess,Lean Design of Facilities,Equipment,Tooling and Layout,Business Plan,Deployment,Total,ProductiveMaintenance,Fixed Period Ordering System/,Order Parts,Continuous Improvement Company,持续改进的公司,Small,steady,improvements to,constantly improve,The Standard!,从细小、稳定的改进到,标准的不断提高,No Company Today Can Survive Without,Having All Employees Focused on,Continuous Improvement,没有改进就难以生存,Continuous Improvement,What Is Absolutely Necessary Before Continuous Improvement Can Occur?,在能够进行持续改进前什么工作是绝对必要的？,Stability Through Standardization!,通过标准化获得稳定发展,Standardization,Improvement,改进,Standardization,Standardization,Standardization,Improvement,改进,Improvement,改进,Continuous Improvement,Standardization Before Continuous Improvement!,在进行持续改进前的标准,标准化,标准化,标准化,标准化,Plan,计划,Do,实施,Check,检查,Action,运作,Grasp the Situation,掌握情况,The PDCA Cycle,PDCA,The PDCA Cycle is One Of The Most Important Concepts In A Company,P,D,REACT,P,Poor companies do,little planning,mostly,doing,do not check their status and then,react,to everything,没有远见的公司很少做计划，大多数情况是直接实施，从不检查实施情况，此后对每件事都是如此,D,C,A,World-Class companies do,excellent planning,always,perform checks,that enable to take,corrective action,and stay on schedule,世界级的大公司会做非常周详的计划，对每件工作进行跟踪检查以便及时采取纠正措施并按进度表运行,BAD,GOOD,Lets go to,Kyong,Ju,!,Plan,计划,Prepare for the trip,Two days before leaving,check engine OIL LEAK!,Fix oil leak&leave on time,Our Family Has Not Had A Vacation In A Long Time!,PDCA Can Be Used For Anything,Do,实施,Grasp the Situation,掌握情况,Check,检查,Action,运作,ManufacturingProcess Validation,ProductQualityStandards,QualitySystemManagement,In-ProcessControl&,Verification,QualityFeedback/Feed-,forward,StandardizedWork,VisualManagement,Managementby TAKT,Time,Work-,placeOrganization,ControlledExternal,Transportation,ScheduledShipping/,Receiving,Level VehicleOrder Schedules,SupplyChain,Management,Internal,Pull/,Delivery,SimpleProcessFlow,Small LotPackaging,TemporaryMaterialStorage,Fixed Period Ordering System/,Order Parts,Health andSafety Priority,Qualified People,Team Concept,PeopleInvolvement,OpenCommunicationProcess,ValuesVision,Shop FloorManagement,Continuous Improvement,Andon,Concept,ProblemSolving,Early Mfg.and DesignIntegration(DFM/DFA),ContinuousImprovementProcess,Lean Design of Facilities,Equipment,Tooling and Layout,Business Plan,Deployment,Total,ProductiveMaintenance,Andon,Concept,ProblemSolving,Early Mfg.and DesignIntegration(DFM/DFA),ContinuousImprovementProcess,Lean Design of Facilities,Equipment,Tooling and Layout,Business,Plan Deployment,Total,ProductiveMaintenance,暗灯概念,TPM,业务计划实施,解决,问题,持续改进的过程,早期管理及综合设计,(,DFM/DFA),厂房，设备，工具及布置的精益化设计,ManufacturingProcess Validation,In-Process,Control and,Verification,Product,Quality,Standards,QualityFeedback/Feed-,forward,StandardizedWork,VisualManagement,Managementby TAKT,Time,Work-,placeOrganization,Andon,Concept,ProblemSolving,ContinuousImprovementProcess,Business Plan,Deployment,Total,ProductiveMaintenance,ControlledExternal,Transportation,ScheduledShipping/,Receiving,Level VehicleOrder Schedules,SupplyChain,Management,Internal,Pull/,Delivery,SimpleProcessFlow,Small LotPackaging,TemporaryMaterialStorage,Fixed Period Ordering System/,Order Parts,Health andSafety Priority,Qualified People,Team Concept,PeopleInvolvement,OpenCommunicationProcess,Values,Vision,Shop FloorManagement,Continuous Improvement,Business Plan,Deployment,业务计划实施,QualitySystemManagement,Early Mfg.and DesignIntegration(DFM/DFA),Lean Design of Facilities,Equipment,Tooling and Layout,A common process which enables our Global Organization made up of multiple parts,to act in unison to achieve company wide goals in five key categories:,Definition,Business Plan Deployment,定 义,Safety,People,Quality,Responsiveness,Cost,BPD,是一种共有的方法，它能使多个部分组成我们的全球团队，通过五个核心范畴统一行动以达到公司的总体目标：,安全,员工,质量,响应,成本,?,Division Director,?,different directions,no ownership,conflicting goals,MISSION,?,?,?,?,duplication,Before,BPD,部门主管,通过不同的途径,没有落实责任,目标向冲突,任务,重复,ONLY HE KNOWS THE GOALS,MISSION,TRACK PERFORMANCE,DEPLOY RESOURCES,GME-BPD Guide,FOCUS,TARGETS,CLEAR DIRECTION,COMMON GOALS,任务,对工作进行跟踪,调动资源,关注,目标,思路清晰,共同目标,Division Director,部门主管,EVERYONE KNOWS THE GOALS,After,BPD,Concrete,GOALS,Regular and Consistent Reviews,Coordination,Vision/Mission,Achieving Our Vision,In Order for GMDAT/DIMC to Achieve Its VISION,we have to achieve our goals,SPECIFIC,OBJECTIVES,CLEAR&MEASURABLE,TARGETS,A,METHOD,TO RESEARCH THE TARGETS,为了,实现,GMDAT/DIMC,的宗旨,，我们,必须,实现我们的目标,宗旨,/,任务,定期坚持审议,协调,具体目标,明确目标,清晰的，可量化的目标,有搜寻目标的方法,我们的宗旨,Safe working environment for all employees,Regular and Consistent Reviews,Coordination,Vision/Mission,Achieving Our Vision,In Order for GMDAT/DIMC to Achieve Its VISION,we have to achieve our goals,No safety incidents,零事故,Lost Work Day,没有损失工作日事故,Increase Compliance of PPE,增加对,PPE,的使用,定期坚持审议,协调,我们的宗旨,宗旨,/,任务,为所有员工创造安全的工作环境,为了,实现,GMDAT/DIMC,的宗旨,，我们,必须,实现我们的目标,Why Engage the Workforce?,为何要雇佣工人,?,Why?,Why?,Why?,Why?,Why?,1-6,6-10,10-20,20-40,40-100,50%,40%,30%,20%,10%,%,of People Involvement,%,of Possible Improvement,员工的参与率,参与的可能性,为什么,?,为什么,?,为什么,?,为什么,?,为什么,?,Who is involved in BPD?Everyone!,那些人与,BPD,有关？,每个人！,Division Managers,Mission/Strategy,Goals&Objectives,Clear Targets,Action Plans,Review Process,任务,/,对策,目标,实施计划,The Cascading Process,(catch balling,抓住要点,),Level 2,Level 3,Level 4,Level 1,Detailed Action Plans and Countermeasures,Cascading Strategies and Objectives,详细的实施计划及应急措施,层层实施计划并实现目标,Group Leader,Action Plans,Clear Targets,Review Process,实施计划,目标清晰,Team,Clear Targets,Review Process,目标清晰,回顾流程,层层递进的流程,Department Manager,Goals&Objectives,Clear Targets,Action Plans,Review Process,目标,目标清晰,实施计划,Each Level of Leadership Must Hand Down Targets to Their Team,Bupyung,100,Press-10,Body-30,Paint-15,G.A.-45,For Example,Defects Per Hundred Vehicles(DPHV),Trim 1-10,Trim 2-15,Trim 3-10,Trim 4-10,Production Director,Shop Manager,Plant,Shop,Group,Team,Teams,Group Leader,Teams,Teams,But The Targets Dont Always Have To Measure The Same Thing,But Something That Will,Affect,the Next Level Up,对于同一目标中相同的事情不需要都量化，但有些事情却会影响到下一层次的改进,S.M.A.R.T,.,Targets,:,S,pecific,M,easurable,A,ligned,R,ealistic&,T,imed,目标是：,特,定的，可测量的，校正的，现实的 定时的,Targets Have To Have,Meaning,To People!,目标对员工必须有意义！,Team Leader,I have to achieve 0.000135 Hours/Vehicle?,GMDAT/DIMC,Cost per Vehicle,TEAM-COCKPIT INSTALL,Top Scrap Item,(#of Gloves Consumed),GROUP LEADER TRIM 1,Top 3 Scrap,SHOP MANAGER G.A.,Budget Accounts,CHANGWON PLANT,Total Manufacturing Cost,I understand my,piece of the pie?,我知道自己应得的馅饼有多大,班组驾驶座安装,主要耗材（手套）,GMDAT/DIMC,每辆车的成本,大宇昌原整车厂,总制造成本,总装车间主任,预算,调整一工段工段长,三种主要耗材,Target Cascade-Example,Everyone Gets A Piece Of The Pie That Is Easy To Bite Into!,S.M.A.R.T,.,Targets,:,S,pecific,M,easurable,A,ligned,R,ealistic&,T,imed,指定的，可测量的，校正的，现实的 定时的,Targets Are A Good Start,But We Need Good Methods To Achieve Them,目标是个好开端，但需要好方法才能达到。,GOAL,=Lead a Healthy Lifestyle,以一种健康的生活方式生活,OBJECTIVE,Maintain a Light Weight,保持苗条,TARGET,65 kg,METHODS,-Exercise Regularly(3x/week),有计划地锻炼,(每周,3,次,),-,Cut Down On Fast Food(1x/week),减少吃快餐的次数（每周,1,次）,The Concept Can Be Applied To Anything In Life!,GOAL=,OBJECTIVE=,TARGET=,METHOD(S)=,BPD Exercise,Think of an example at work or at home where you can establish a Goal,Objective,Target and at least one Method,想想工作或生活中设立的目标及实现方法。,Discuss as a team and report Take 10 minutes,团队讨论及汇报-十分钟,Plan,计划,Do,实施,Check,检查,Action,运作,Grasp the Situation,了解情况,PDCA is the foundation of BPD,PDCA,是,BPD,的基础,Below Expectations,Needs Improvement,Meets Expectation,How does it work?,Actions,Annual Business Plan,X,Activities,行动,PLAN,DO,PROBLEM,SOLVING,问题解决,CHECK,ACT,PDCA,如何运作,?,未完成,需要改进,完成,Regular Reviews,Goals,Objectives,Targets,Methods,Countermeasures,对策,Open,Team Discussion,Coaching&Learning,Get Support&Resources,Go To See,BPD We Will Be Successful When Everyone Focuses On What,They,Can Control!,当每个人都集中力量做事，我们就一定能成功做到,BPD。,Why cant they design better cars?,What can I do in my area to improve?,Ask Not What Others Can Do Ask What Can,You,Do On,Your,B.P.D.!,不追问别人做的，关键在你的自己,BPD,能做的。,Visual Management Status at a Glance,可视化管理,让信息容易读取,-,Makes out of standard condition highly visible.,突出超标的情况,Open Communication/Team Concept,-Enables all to focus on action plan/countermeasures,and discuss as a team.,让所有人像一个团队一样共同关注某个行动的计划或对策并参与讨论,。,KEY BPD CONCEPTS,BPD,的核心理念,BPD a critical tool to achieve Continuous Improvement.,BPD,是评定是否获得持续改进的工具,-,Achieve targets and then“raise the bar”.,达到了目标，接着制定更高的目标。,PDCA,-Discipline&Follow-up,一种规则并需要持续进行,“,Go-To-See”Leadership Style,“,Go-To-See”,领导模式,-,Dont just sit at desk and receive reports.,不要只是坐在办公室等待别人来汇报,。,ManufacturingProcess Validation,QualitySystemManagement,QualityFeedback/Feed-,forward,StandardizedWork,VisualManagement,Managementby TAKT,Time,Work-,placeOrganization,Andon,Concept,ProblemSolving,Early Mfg.and DesignIntegration(DFM/DFA),ContinuousImprovementProcess,Business Plan,Deployment,Total,ProductiveMaintenance,ControlledExternal,Transportation,ScheduledShipping/,Receiving,Level VehicleOrder Schedules,SupplyChain,Management,Internal,Pull/,Delivery,SimpleProcessFlow,Small LotPackaging,TemporaryMaterialStorage,Fixed Period Ordering System/,Order Parts,Health andSafety Priority,Qualified People,Team Concept,PeopleInvolvement,OpenCommunicationProcess,Values,Vision/,Mission,Shop FloorManagement,Continuous Improvement,Andon,Concept,暗灯,概念,Lean Design of Facilities,Equipment,Tooling and Layout,In-Process,Control and,Verification,Product,Quality,Standards,What is an,Andon,System?,什么是暗灯系统,?,The ANDON System allows team members to,pull the cord,and call for help,when there is a problem or out of standard situation.,The ANDON System is an enabler to,control quality,while,keeping the line running,by pulling in support to address problems before they stop the line,暗灯系统允许员工在出现问题或有超标情况时拉绳索以寻求帮助,暗灯系统可以在保持流水线继续运行的情况下，员工拉下绳索寻求支持人员在停线前到出现问题的工位解决问题，以满足对质量的控制。,Always Remember The Priorities,S,afety,(,安全,),P,eople,(,员工,),Q,uality,(,质量,),R,esponsiveness,(,响应,),C,ost,(,成本,),Importance,重要性,For Example,Sometimes We Have To Sacrifice Responsiveness to Achieve Quality,比如，有时我们为了达到质量要求而不得不放弃响应,10,13,12,11,FPS,FPS,FPS,Zone 2,Step 1-,Andon,cord is pulled,station light goes on and music begins,第一步：拉暗灯控制绳索,工位的指示灯会亮起并伴随着音乐,When there is a problem or out of standard situation which can not be fixed by the team member,then,当员工不能单独解决出,现的问题或超标的情况,时,Andon,Steps,Andon,Steps(Contd),Step 2-Zone light on main,Andon,board turns yellow,Team Leader responds to the,Andon,第二步：,在暗灯系统主看板上相应区域的指示灯变成黄色，班组长对暗灯系统的信号做出反应,Step 3-Help comes immediately and problem solving begins.Team Leader takes the,Andon,responsibility,第三步：支持人员立刻到达并开始解决问题,，,班组长对此负责,Andon,Steps(Contd),Step 4-Line continues to move to fixed position stop,第四步：生产线继续运行直到,定点停,10,13,12,11,FPS,FPS,FPS,FPS,Zone 2,Andon,Steps(Contd),Step 5-Problem is addressed,Andon,is deactivated by Team Leader to keep the line running.,第五步：问题解决,，,班组长解除暗灯信号以保持生产线继续运行。,SHORT,CONV,EQUIP,FULL,5,4,1,2,3,TRIM 1,EQUIP,Q1,Q2,Q3,Andon,Steps(Contd),Step 6 If,Andon,is not deactivated by Team Leader when vehicle reaches FPS,line stops and board flashes red,-Downtime clock begins,第六步：如果车辆到达,定点停,时班组长仍然没有解除暗灯信号，生产线停止并且主看板上红灯开始闪烁，停线铃开始响起,Downtime Clock,SHORT,CONV,EQUIP,FULL,5,4,1,2,3,TRIM 1,EQUIP,Q1,Q2,Q3,Andon,Steps(Contd),FPS,FPS,FPS,Set Line at 70%,of,Takt,or Cycle Time,&Relate to Specific,Step in Standardized Work,Pull the,Andon,as Early As Possible(at or before 70%Line)to Address Problems Before They Stop the Line在线停之前，尽早拉动暗灯线宣告出现问题。（在70%线位或之前），,Purpose of“70%Line”,70%,Line,Reaction Time,Mgr,Group Leader,Team Leader,Team Member,Decision,Decision,Decision,Pull,Andon,Support,Support,Support,Needs help,Function of everyone including managers and staff is to support production team members.,主管及所有人员都有职责支持生产一线的员工,班组成员,班组长,工段长,主管,寻求帮助,支持,支持,支持,决定,决定,决定,拉下暗灯拉索,Andon,Concept,Role of Team Member,Follow Standardized Work,Actively Watch for Out-of-Standard Situations,If an Abnormality or Defect Is Discovered That Cannot Be Immediately Corrected,Pull the,Andon,and Continue With Rest of Cycle Until Support ArrivesSupport Team Leader With Problem Solving As Required,.,班组成员的职责,按照标准化要求作业,主动查找超标情况,如果发现了异常状况或缺陷但无法及时解决，拉下暗灯拉索，并继续做自己的工作直到支持人员到达。,支持的班组长按要求解决问题,Focus On,Standardized Work!,Andon,Concept,Role of Team Leader:,Team Leader goes immediately to area of,Andon,call to investigate and support.,Team Leader begins immediate correction of the problem.,Team Leader releases the,Andon,when TL has determined a correction can be made.TL begins problem solving with support of TM.,Team Leader manages the,Andon,system,班组长职责,在暗灯信号发出后立刻赶到发生问题的区域查明原因并实施支持,到达问题区域后立刻开始解决问题,当班组长认为可以把问题解决时解除暗灯信号。班组长与班组成员共同开始解决问题。,班组长,管理暗灯系统,Address Non-Standard,Conditions!,Andon,Concept,Role of Group Leader,Support Team Leader if(s)he is not able to countermeasure the problem,and get the line running as soon as possible.,Call additional support as needed(i.e.maintenance,quality,etc.),Work with team leader to make sure root cause is,identified and countermeasures implemented.,Monitor downtime,identify problem areas and work,with all,available resources to eliminate problems.,工段长职责,当班组长不能解决问题时要提供支持并尽快让生产先运转起来,如果需要可以寻求外部支持（如：维修，质量等部门人员）,与班组长一起确定问题的起因是否已经被确认出来并且保证解决措施得到实施,在停线时进行监控，确定问题区域并调动一切可利用资源解决问题,Support The Team!,Andon,Concept,Team Concept,Small Team Size,Standardized Work,Clear Quality Standards,Problem Solving Process,Employee Training,Mutual Trust/Respect,Constant,Takt,Time,Fixed Position Stop,Decouplers,/Buffers,Process Capability,ENABLERS,Irreversible correction action,Quality in station,Inspection and Feedback,Open Communication,Teamwork,Improved Productivity,BENEFITS,Motion,Correction,Waiting,5,1,2,3,4,5,6,PROCESS NO.,3,3,O.D.Reference 4,团队概念,缩小团队规模,工作标准化,(,FPS),明确质量标准,职员培训,相互信任,/,尊重,保持单件工时,停线点,缓冲架,加工能力,好处,实施的纠正措施不能复原,在工位控制质量,检查和反馈,开放式交流,团队合作,提高,生产力,Why is,Andon,Part of C.I.?,Use,Andon,Data to Continuously Improve by Identifying Bottlenecks and Issues Affecting Throughput,使用暗灯数据通过确定瓶颈及影响产出的问题来达到持续改进,TRIM 1 GROUP,Andon,Report,2003/1/24,Station 001R 10,Station 003L 4,Station 004R 2,Analyze Reports,分析报告,Discuss Countermeasures,讨论对策,Improve!,改进,Andon,Is Not Just a System Of Wires and Lights,暗灯系统不仅仅是一个由