A Basic Introduction to FMS伟创力制造系统伟创力制造系统FMS介绍介绍Awareness Session for DL直接员工认知课程直接员工认知课程Flex Manufacturing SystemBanish WastesCreate ValueFlex E2E Value StreamA Brief Introduction to FMSFMS 简介简介 TPS, DFT, & Lean丰田生产系统,需求流程技术,&精益生产 Integrating Lean & DFT FMSFMS是精益生产&需求流程技术的集成2TPS*: Present Day Structure丰田生产系统的结构vQuality, Cost, Delivery 品质品质,成本成本,交期交期4Shorten Production Flow by Eliminating Waste通过消除浪费缩短生产流程vJust In Time 准时生产准时生产4Right Part at the Right Time in the Right Amount只在正确的时间生产正确的产品和数量4Continuous Flow 连续流4Pull Systems拉动系统4Level Production分级生产vBuilt-In Quality (Jidoka)过程品质控制过程品质控制(自动化自动化)4Error Proofing Poka Yoke防错法4Visual Controls目视控制vOperational Stability 操作稳定性操作稳定性4Standardized Work 标准化作业4Robust Products & Processes 强大的产品&工艺4Total Productive Maintenance 全员生产性维护保养4Supplier Involvement 供应商参与4Kaizen改善45S/Visual Management 5S/可视化管理vHighly Motivated and Creative Peoplev高主动性高主动性和创造性的人员和创造性的人员*Toyota Production System3DFT* in Flex Today 伟创力目前实施的需求流程技术*Demand Flow Technology 需求流程技术需求流程技术4/Value价值价值Correctly Specify Value of Product/Service with Customer in mind从正确识别产品/服务的价值,始终考虑客户的需求/Value Stream价值流价值流Identify the Value Stream and remove all the Wastes 识别价值流,消除浪费/Flow流程流程Make the Product and Value Flow Smoothly理顺产品关系和价值流/Pull拉动拉动Produce only to the Pull of Customer Demand以客户需求拉动生产/Perfection完成完成Wastes Elimination as an Ongoing Process towards Perfection浪费消除,流程趋于完善The Universal Lean Principles普遍的普遍的精益原则精益原则5 The Origin of FMS : Flex Manufacturing System伟创力制造系统的起源Toyota Production System丰田生产系统DFT需求流程技术LEAN精益生产Flex Manufacturing System伟创力制造系统Banish WastesCreate ValueFlex E2E Value Stream6Flex Manufacturing System (FMS)伟创力制造系统伟创力制造系统Lead Time Improvement + Banish Wastes Drive Value Creation 缩短生产周期缩短生产周期+消除浪费以驱动价值创造消除浪费以驱动价值创造7Lean is a manufacturing philosophy that recognizes WASTE as the primary driver of cycle time, and employs techniques to continually drive out the waste in processes. 精益生产是这样一种制造业哲学,它认为生产周期,员工的操作方法是造成浪费的主要原因,并致力于消除这些浪费PRODUCTSHIPMENT出货出货Total Lead Time生产周期生产周期Business as Usual正常工作正常工作Waste浪费浪费CUSTOMERORDER客户订单客户订单Lean Manufacturing精益制造精益制造PRODUCTSHIPMENT出货出货CUSTOMERORDER客户客户订单订单Lead Time (Shorter)生产周期生产周期(更短更短)Waste浪费浪费Why Lead Time is crucial to become Lean?为什么生产周期在精益生产中如此的至关重要Cycle Time and Waste生产周期和浪费Types of Waste*1 七种浪费七种浪费Transportation 运输Inventory库存Motion动作Waiting等待Over production过量生产Over-processing不必要的过程Defects缺陷*1 Prompter: Who is “TIM WOOD”?敦促者:谁是”TIM WOOD”Waste浪费Waste浪费MUDA* = WasteMUDA=浪费*Japanese91. Overproduction过量生产过量生产Making more-earlier-faster than the next process or customer needs it相对相对于下一工序或客户过早过快生产于下一工序或客户过早过快生产- Just in case logic以防万一的逻辑- Unbalanced workload工作量不平衡- Improper scheduling不适当的计划2. Defects缺陷缺陷Not doing work Right the First Time没有做到第一次就把工作做对没有做到第一次就把工作做对- Not using Poka-yoke*1没采取防错法没采取防错法- Lack of Standardization, inconsistent work methods缺乏标准化,不一致的工作方法- Ineffective communication 无效的沟通- Little investment in training 缺乏培训3. Inventory库存库存Any supply in excess of one-piece flow一个流之外的任何供给品一个流之外的任何供给品- Often the result of “Overproduction” 常常是”过量生产”的结果- Unbalanced workload工作量不平衡- Improper scheduling不适当的计划- Unreliable suppliers不可靠的供应商7 Types of Waste七种浪费*1 - also called mistake or error-proofing107 Types of Waste七种浪费4. Over-processing不必要的过程不必要的过程Processing beyond the customers (internal or external) requirements过程过程超过客户超过客户(内部或外部内部或外部)的要求的要求- Poor knowledge of specs or customer requirements缺乏对客户规格或要求的知识- Inconsistent work methods (non-standardization) 不一致的工作方法(非标准化)- Ineffective communication 无效的沟通Examples:举例举例:- Manually cleaning product because of dirt用手清除产品上的尘土- 100% visual inspection at end-of-line线末100%目视检验5.Transportation运输运输Inefficient movement of people, materials and information in the organization人员人员,物料和信息的低效率的移动物料和信息的低效率的移动- Poor layout差的工厂布局- Inefficient “flow” 低效的流动- Carrying large inventories大量库存- Exposes product to potential damage/loss during transportation产品在运输过程中遭受潜在的损害/损失Examples:- Anywhere sequential operations are broken任何连续作业中断的地方- Material stored too far from workstation物料存储离工作站太远- Too many conveyors, forklifts, pallet trucks, etc.过多的传送带,铲车,叉车117 Types of Waste七种浪费6. Waiting等待等待Waiting for man, machine, materials, information, etc.等待等待人人,设备设备,物物料料,信息等信息等- Unbalanced workload工作量不平衡- Unplanned downtime无计划的停机时间- Poor workplace discipline工作场所无纪律Examples:举例举例:- Looking for tools to repair machines寻找工具维修设备- First piece waiting for the entire batch to finish第一件等待整批完成- People idle because of no materials to work on因为缺料造成的人员空闲- Waiting for instructions to proceed等待继续的指示7. Motion动作动作Unnecessary movement of people, parts or machines within the process生产过程中生产过程中,不必要的人员不必要的人员,工件或机器的移动工件或机器的移动Poor layout不好的工厂布局Inefficient Workplace Organization工作场所缺乏组织Lack of Standardization, inconsistent work methods缺乏标准化,不一致的工作方法Increase operator fatigue leading to other wastes e.g. defects 增加作业员疲劳造成浪费,如缺陷Ergonomic issues causing health e.g. repetitive motion injuries, etc.工效问题对健康的影响,如重复的动作性伤害12 Understand the different types of waste理解不同的浪费种类理解不同的浪费种类 Identify them识别浪费识别浪费 Carry out your process according to procedure按照程序实施你的方法按照程序实施你的方法 Proper handling of PCB and materials恰当的处理物料恰当的处理物料 Follow the takt time, work to cycle time of the process跟随跟随节拍时间工作以形成过程的周期时间节拍时间工作以形成过程的周期时间Report to supervisor if you spot any of the “ waste”, like “ I am waiting”当你发现任何浪费应该报告给你的主管当你发现任何浪费应该报告给你的主管 How can I contribute to eliminate waste?怎样才能消除浪费13Flex Manufacturing System (FMS)伟创力制造系统伟创力制造系统(FMS) FMS Characteristics FMS的特点 FMS Tools and Techniques FMS的工具和技术14What FMS is 什么是FMSAn integrated system of principles, operating practices, and elements that drive the relentless pursuit of business excellence through waste identification, elimination and prevention. People makes it happen.FMS是一个集成了众多生产原理,生产实践的综合系统,它通过浪费的识别,消除和预防以求对卓越事业的不懈追求.其中人是最关键的因素. Outcome: Value Creation for the Company and Customer 结果:为公司和客户创造价值 Outcome: A Journey Towards Perfection 结果:是追求完善的旅程LEANFMS15 Characteristics FMS wants to achieve典型的FMS想要达到 People:人员人员:- Multi functional teams in design and production具备复合功能的设计和生产团队-People have wide variety of skills (flexibility)人员具备多种技能(柔性)- Teams perform whole tasks通过团队执行任务 Tools:工具工具:- Low/minimal set up times最少的设立时间- Availability & Maintainability有用性和可维护性 Production process:生产过程生产过程- Demand pull instead of schedule push需求拉动代替计划推动- Minimal Inventories 最小库存Fast, Flexible Flow16 Characteristics FMS wants to achieve Quality:品质品质- Information collected during production生产过程中的信息收集- Problems are solved during production生产过程中解决问题 Volume flexibility:产量的机动性产量的机动性- Switching between products is easy易于更换产品进行生产- Production loads are leveled生产负荷分等级 Organization:组织组织- Optimize the chain: assembler and supplier work closely together优化供应链:组装员工和供应商密切协作ProductionCustomer DemandFast, Flexible Flow17FMS Tools & TechniquesFMS工具和技术工具和技术18FMS Tools and Techinques FMS工具和技术Among others, these are FMS tools and techniques that will help us to eliminate wastes and increase Flextronics Success:以下这些以下这些FMS工具和技术将帮助我们消除浪费和增加工具和技术将帮助我们消除浪费和增加FLEX的成功的成功:1.Value Stream Mapping价值流程图价值流程图 - To identify value stream and waste 用于识别价值流和浪费192.Continuous Flow 连续流连续流-To reduce overall 7 sources of waste用于减少7种浪费AMaterialInventoryBInventoryCFinishProduct InventoryInventory A B C MaterialFinishProduct 3.Cellular Manufacturing 细胞制造细胞制造-To reduce overall 7 sources of waste 用于减少7种浪费ReceivingSawMillLathePaintGrinderStoragePlatingAssemblyStorage4.Kaizen 改善改善 Its a technique for continuous improvement 持续改善的技术持续改善的技术201 SeiriSort整理2 SeitonStraigthen整顿3 SeisoSweep清扫4 SeiketsuStandardize清洁5 ShitsukeSustain自律From This从这里.To This到这里Eliminate WasteMaintain the Discipline5.5S - Basic step for the waste elimination消除浪费的基本步骤- To improve safety and productivity提高安全性和生产力216.Pull system 拉动系统拉动系统 To make value flows at pull of the customer根据客户的需求建立价值流XXXXXFlow of workFlow of informationUpstreamDownstream7.Single Minute Exchange Die (SMED) 快速换模快速换模 A process for equipment changeover and set-up time reduction in under 10 minutes. 设备换模和设立的时间缩短至十分钟的方法FastenhereAttach and remove plate hereExamples of setup wastes elimination associated with finding, replacing and motion 22Common Mistake proofing Devices Guide Pins Blinking lights and alarms Limit switches Proximity switches Counters Checklists SensorsLightTransmitterReceiverObjectCHECKLISTCHECKLISTPoka Yoke 防错防错 Its a technique to prevent human mistakes 防止人类错误的技术Example : Forgetfulness, misunderstanding, wrong identification etc.例:健忘的,误解,错误辨认Total Productive Maintenance 全员生产性维护保养全员生产性维护保养 - To increase up time of the machine增加设备运转时间 - Operator involvement in repairing the machines 作业员直接参与设备维修 - Reduce the maintenance cost减少维护费用23The 6 Kanban Practices关于看板的六个实践1. You cannot send bad product to the next operation不能将不良品传至下一操作 2.Only withdraw what is needed只取所需的产品3. Only produce what is used 只生产所要用的产品4. Make the workload consistent使工作量一致5. Standardize标准化6. Keep improving持续改善24Flex Manufacturing System (FMS)伟创力制造系统伟创力制造系统(FMS) Aligning Six Sigma* to FMS 将Six Sigma 和FMS相结合*Also a Flex key initiative25FMS + Six Sigma = “Lean & Capable” FMS+Six Sigma=“速度和能力”Speed速度Accuracy精确度+Waste elimination消除浪费Value Added Activity有增值的活动Information/ Process Flow信息/工艺流Customer Pulls客户拉动FMS FMS 伟创力制造系统伟创力制造系统伟创力制造系统伟创力制造系统=Six SigmaSix Sigma六西格玛六西格玛六西格玛六西格玛Variation reduction减少浪费Scrap / rework elimination消除报废/返工Process control过程控制$Customer Satisfaction and Focus客户满意和关注客户满意和关注27Organizational Goal组织目标Maximize Shareholder Value股东利益最大化(Increase Share Price)增加股价Quality品质Inventory库存Sales销售OTD准时交货Cost成本Assets资产Maximize Return on InvestmentROI投资回报最大化How the Value Stream Performs?价值流的表现怎样价值流的表现怎样?28See You There!到那儿见!Thank You for Your Time谢谢参与!LEAN精益精益FMS29