1、Lean / DMS OverviewLean / DMS Overview Lean (Exercise) 精益（练习） Exercise: By table / group come up with your definition of 揕ean 练习：按课桌/小组给出您对“精益”的定义 What is Lean? 什么是精益？ What is Lean? 什么是精益？ Lean 精益 lean adj. 精益：形容词 1 a: lacking or deficient in flesh. b: containing little or no fat a:无肉或少肉 b: 少脂肪或无脂肪
2、2: lacking richness 不富裕 3: deficient in an essential or important quality or ingredient 在必要性、重要 性、质量或成分方面稀缺 4: charac-terized by economy of style or expression 文体或措辞简练 syn. thin, skinny, lanky, scrawny, gaunt, bony, emaciated, svelte, lank 同 义词：薄、极瘦、过分瘦长、骨瘦如柴、瘦削的、似骨的、消瘦的、细长的、 瘦长的 ant. fat, fleshy, o
3、verweight, flabby, obese, plump, chunky, corpulent, soft 反义词：肥胖的、多肉的、过重的、不结实的、过分肥胖的、丰满的、粗 短的、肥大的、软的 Lean 精益 What is Lean? - Womack 什么是精益 1. Define value precisely from the perspective of the end customer 从最终用户的角度准确地定义价值 2. Identify the entire value stream for each product or product family and elimi
4、nate waste 确定每一种产品或产品系列的整个价值流，消除浪费 3. Make the remaining value creating steps flow 理顺创造价值的步骤 4. Design and provide what the customer wants only when the customer wants it 只在客户需要时设计和提供他们所需的东西 5. Pursue perfection 追求完美 Lean 精益 At Delphi, Lean is. A business strategy for maximizing profit by energizing
5、 people to respond to customer demand in the shortest possible time by eliminating waste in everything we do. 在德尔福公司，精益表示 一种经营战略，它激励人们在所做的任何 事情中消除浪费，在尽可能短的时间内对 客户需求作出反应，从而使利润最大化。 Mass Production vs.Lean Manufacturing Mass Production vs.Lean Manufacturing With Lean Production You Can Get: 7 of 30 90%
6、 Reduction in Production Time 90% Reduction in Inventories 50% Reduction in Errors Reaching Customers 50% Reduction in Scrap 50% Reduction in Job Related Injuries The amount of human effort, time, space, tools, and inventories needed to design and provide a given service or good can typically be cut
7、 in half very quickly, and steady progress can be maintained from this point onward to cut inputs in half again within a few years. Lean Thinking, Womack & Jones What is DMS?What is DMS? 什么是德尔福制造系统什么是德尔福制造系统 Change in ManufacturingChange in Manufacturing 制造业的演化制造业的演化 Henry Ford 亨利福特 Assembly line ma
8、ss production 装配线大批量生产 Produce in high volume with low variety 生产数量多、品种少 Single skill 单一技术 Toyota Production System (TPS) 丰田公司制造系统 Just-In-Time?Production (produce only what is needed) “准时生产制”（只生产所需要的） Pull System 拉动系统 Produce enough volume to meet customers?needs 生产足够的数量以满足客户的需要 High variety to mee
9、t customers wants 多品种以满足客户的要求 COMMON Manufacturing System to Delphi Divisions Vision and Operating Principles Six Interdependent Elements The six interdependent elements provide the basic framework of the manufacturing system. They are the focus of our activities: Developing profound knowledge, plan
10、ning and implementation, and continuous improvement. 德尔福各分部共同的制造系统 前景展望和运行原则 六个相互依存的要素 六个相互依存的要素构成了该制造系统的基本结构。它 们是我们活动的中心：拓展丰富的知识、规划和实施以 及不断改进。 What is DMS?What is DMS? 什么是德尔福制造系统什么是德尔福制造系统 Transform & Continuously improve our operations to a Quality Network based, globally dominant manufacturer 转变并
11、持续地改进我们的业务从而使其成为基于质量网络的在全球处于主导 地位的制造厂商。 Reduce Total Manufacturing Costs降低总的制造成本 Reduce Customer Response Time 减少对客户的反应时间 Reduce Inventory 减少库存 Reduce Non-Value Added Activities 减少非增值活动 Increase Productivity 提高生产效率 Improve Quality 提高质量 Reduce Structural Costs 降低结构成本 Engage the work force in the proc
12、ess 让员工参与这一过程 DMS ObjectivesDMS Objectives 德尔福制造系统目标德尔福制造系统目标 Operating PrinciplesOperating Principles 运行原则运行原则 Define the Fundamental Basis of the Manufacturing System 确定制造系统的主要基础 Ensure that the Health and Safety of all our people is our priority. 确保所有员工的健康和安全是我们的首要任务 Aggressively improve Customer
13、 response time. 积极缩短对客户的反应时间 Implement Quality at the Source. 从源头处保证质量 Create a Learning, Supportive, and Cooperative Culture. 创造一个相互学习、相互支持和相互协作的企业文化 Competitively manufacture at any volume and be Flexible to any quest. 在任何制造批量下都具有竞争力并能灵活地满足客户需求 Relentlessly pursue the Elimination of Waste. 不懈努力，消除
14、浪费 Establish process measurements that contribute to Business Goals. 建立有助于实现业务目标的过程衡量指标 Drive the Transformation Process through Knowledgeable and Involved Leadership. 通过知识渊博和全身心投入的领导人员推动变革进程 Define and Understand Roles and Responsibilities. 确定并理解岗位和责任 Optimize the Manufacturing System through balan
15、ced Implementation of the Interdependent Elements. 通过均衡地实施六个相互依存的要素来优化制造系统 Correction Overproduction Material Movement / conveyance Motion Waiting Inventory Processing 7 7 Types of WastesTypes of Wastes 7 7种类型的浪费种类型的浪费 改正 过度生产 物料的移动和运输 动作 等候 库存 加工过程的浪费 Definition: Producing More Than Needed Producin
16、g Faster Than Needed Waste of OverproductionWaste of Overproduction 过度生产的浪费过度生产的浪费 定义: 生产超过了需求 生产快过了需求 Characteristics 特点: Inventory Stockpiles 库存积压 Extra Equipment 额外的设备 Extra Storage Racks 额外的仓储架 Extra Manpower 额外的人力 Additional Floor Space 更多的工作场地 Causes 原因: Incapable Processes 过程能力低下 Lack of Comm
17、unication 缺乏交流 Long Tool Changes 工具更换周期长 Low Uptimes 计划工时利用率低 Lack of Stable / Consistent Schedules 缺乏稳定 / 连贯的计划安排 Waste of OverproductionWaste of Overproduction 过度生产的浪费过度生产的浪费 Definition: Rework of a Product or Service to Meet Customer Requirements Waste of CorrectionWaste of Correction 改正的浪费改正的浪费
18、定义: 为满足客户的要 求，对产品或服 务进行的返工。 Characteristics 特点: Extra Time Required by Workforce to Inspect / Rework / Repair 工 人需要额外的时间来检查/返工/修理 Missed Shipments / Deliveries 错过了装运/交货时间 Organization Becomes Reactive (Fire Fighting, Expediting Vs. Prevention Orientation) 使组织变得被动 (疲于“救火”，而不是采取各种预防措施) Causes 原因: Inca
19、pable Processes 过 程能力低下 Operator Control Error 操作者控制失误 Insufficient Training 缺 少足够的培训 Waste of CorrectionWaste of Correction 改正的浪费改正的浪费 Definition: Any movement of material that does not directly support a lean system. Waste of Material Movement / ConveyanceWaste of Material Movement / Conveyance 材料
20、移动材料移动/ /传送的浪费传送的浪费 定义: 任何不直接支持 一个精益系统 的材料移动。 Characteristics 特点: Extra Fork Trucks 额外的叉车 Multiple Storage Locations 多处储存地点 Extra Facility Space 额外的设施空间 Incorrect Inventory Counts 不正确的存货清点 Opportunity for Damage / Floor Loss 存在损 坏/丢失物品可能 Causes 原因: Unleveled Schedules 计划安排不平衡 Long Change Over Times
21、更换品种时间长 Lack of Work Place Organization 工作场 地缺乏组织 Improper Facility Layout 设备布局不当 Larger Buffer and Banks 缓冲库存区过大 Waste of Material Movement / ConveyanceWaste of Material Movement / Conveyance 材料移动材料移动/ /传送的浪费传送的浪费 Definition 定义: Any movement of people or machines which does not contribute value to
22、the product or service. 任何对生产和服务没有带来价值的人员或机器的运动。 Waste of Motion Waste of Motion 动作的浪费动作的浪费 Characteristics 特点: Looking for Tools 寻找工具 Excessive Reaching / Bending 过度伸展/弯腰 Machines / Material Too Far Apart (Walk Time) 机器/材料距离过远（步行的时间） Shuttle Conveyors Between Equipment to Carry Parts 零件在设备间传送带上的来回传
23、送 Extra 揃usy?Movements While Waiting 等候期间的额外“忙乱” 动作 Causes 原因: Equipment, Office & Plant Layout 设备、办公室和工厂的布局不当 Lack of Work Place Organization 工作场地缺乏组织 Poor Person / Machine Effectiveness 人员/机器效率不高 Poor Ergonomic Design 人机工程方面的设计不好 Inconsistent Work Methods 不一致的工作方法 Large Batch Sizes 加工批量过大 Waste of
24、 Motion Waste of Motion 动作的浪费动作的浪费 Definition: Idle Time That Is Produced When Two Dependent Variables Are Not Fully Synchronized. Waste of Waiting Waste of Waiting 等候的浪费等候的浪费 定义: 当两个相关的变量 不完全同步时产 生 的停顿时间。 Characteristics 特点: Person Waiting for Machine 人员等候机器 Machine Waiting for the Person 机器等候人员 On
25、e Person Waiting for Another Person 一个人等候另一个人 Unbalanced Operations (Work) 不平衡的操作（工作） Unplanned Equipment Downtime 计划外停机 Causes 原因: Inconsistent Work Methods 不一致的工作方 法 Long Machine Change Over Times 机器设置 时间长 Poor Man / Machine Effectiveness 人员/机器 效率不高 Lack of Proper Machines 缺乏合适的机器 Lack of Equipment Resources 缺乏设备资源 Waste of Waiting Waste of Waiting 等候的浪费等候的浪费 Definition: Any supply in excess of process requirements necessary to produce
