福特生產系統(tǒng)的使命我們將教導,吸引,以及激發(fā)福特汽車公司的所有組織和每一個人來了解以及應用精實的行為原理和方法 -以促使連續(xù)不斷的改進安全,品質,速 度,和總成本 -更而帶給顧客更多的價值一個不斷學習的組織Ateachingorganization….從大量生產到精實生產的轉變...

TransformationfromMasstoLean…附加價值與非附加價值附加價值是顧客願意出錢購買一些事物而這些事物帶給他外觀舒適功能

非附加價值=浪費何謂附加價值?範例:鑽孔裝設凸緣驅動螺絲

有附加價值2%浪費60%無附加價值,但是必要的38%時間12639範例:

走去取零件等待時間儲存零件運輸範例:拿取鑽孔機放下扳手挾住或鬆綁工具它是一個能改變產品之型式、裝配、及功能以合乎消費者之規(guī)格的程序。Processesthatchangetheproductform,fit,orfunctiontomeetcustomerspecifications.消費者願意付費的工作

Workthecustomeriswillingtopayfor.何謂附加價值?只增加成本及工時未增加附加價值之部份消費者不願意付費的工作問題之癥兆而非問題之根源瞭解與認知才是找出浪費的根源

Therecognitionandunderstandingofwasteiskeyindefiningtherootcause必須認識浪費才能減少浪費Toeliminatewaste,youhavetobeabletorecognizewaste何謂浪費?MOVEITOVERTHEREUNTILWENEEDIT___________________________________________________________________________________________________七大浪費SUPPLEMENTD1MOVEITOVERTHEREUNTILWENEEDIT等待過度加工庫存移動搬運矯正生產過剩SUPPLEMENTD2七大浪費Makingmorethanthenextprocessneeds生產過剩什麼是生產過剩剩?生產的數數量比下下一工程程所需用用的還多多以比下一一站還快快的速度度生產以比下一一工程所所需的速速度還快快的生產產InventoryInventoryInventoryInventoryMotionInventoryExtraProcessingDefectsTimeWaitingInventory生產過剩剩InventoryInventoryInventory生產過剩剩為什麼這這一類的的浪費會會發(fā)生?勞動成本本及間接接成本的的指標可可驅使人人員和設設備的使使用率LaborandOverheadMeasurabledrivingutilizationofpeopleandequipment庫存而引引起的損損失Lossesfromoutofstockconditions堵塞及斷斷線而引引起的損損失Lossesfromblockedandstarvedconditions特殊材料料的需求求MaterialproducedtospeculativedemandRejects,rework,reruns改善Correction改善Correction為什麼這這一類的的浪費會會發(fā)生?品質回饋饋太慢Poor,slowqualityfeedback增加生產產線外之之撿察工工作Incrementalinspectiondoneoutsideprocessstation認可檢修修工作Repairoperationsareviewedasacceptable缺乏有效效之錯誤誤防止措措施FeweffectiveErrorProofingdevicesinuse未推行標標準作業(yè)業(yè)Standardizedworknotinplace產品與製製程不相相容Product/processincompatibility產品過度度複雜Productover-complexity沒必要的的步驟或或程序Unnecessarystepsorprocesses過度加工工OverProcessing過度加工工Overprocessing為什麼這這一類的的浪費會會發(fā)生?作業(yè)標準準不明確確Standardsunknown/uncleartooperators顧客之規(guī)規(guī)格不明明確或常常變動Customerspecificationsarevagueorfluctuate產品試驗驗過多Producttestingandre-testingoccurs部門間目目標不一一致且溝溝通不良良Functionaldepartmentshavemisalignedgoalsandpoorcommunication多多益善善的想法法Conceptthatmoreisbetter動作Motion多餘的移移動作業(yè)業(yè)員的走走動Excessmovement;operatorwalking動作Motion為什麼這這一類的的浪費會會發(fā)生?外觀及組組織不良良之工作作站Poorworkstationconfigurationandorganization工作量不不平衡Workimbalance未實施目目視化工工廠VisualFactorynotimplemented未實施標標準化StandardizedWorknotimplemented長距離或或重複搬搬運材料料Longdistanceordoublehandlingofmaterial“運輸工具具”Conveyance將它移到這裡等到我們需要時再動運輸工具具Conveyance為什麼這這一類的的浪費會會發(fā)生?工作間距距離過長長Longdistancesfromoperationtooperation物料輸送送未按排排訂路線線MaterialHandlersnotonscheduledroutes倉庫在工工廠內部部或外部部Warehouseonoroffsite收料點與與工作站站間距離離太遠Distancebetweenreceivingandpointofuse庫存過量量Handlingexcessinventory缺乏部品品作業(yè)或或看顧機機臺Lackofpartsorwatchingmachine等候Waiting等候Waiting為什麼這這一類的的浪費會會發(fā)生?等候支援援訊息及及物料Waitingforsupport,information,and/ormaterials總和設備備效率過過低，機機器停擺擺過高LowOverallEquipmentEffectivenessandhighmachinedowntime作業(yè)線不不平衡Unbalancedoperations長且不一一致的等等候時間間Longandinconsistentleadtimes生產時程程經常變變動Continualproductionschedulefluctuations看守自動動機臺Watchingautomatedmachines未事先安安排的會會議Undisciplinedmeetings過剩的原原材料半半成品或或成品庫庫存Excessrawmaterials,WIP,orfinishedgoods庫存Inventory過度庫存存Inventory(Excess)為什麼這這一類的的浪費會會發(fā)生?堅持大量量生產的的想法MassProductionmindset,batchandqueue產能無法法預估Unpredictableproductivity內外部材材料供應應不順I(yè)nfrequentdelivery/shipmentofmaterialsinternallyandexternally排程與製製程間不不相連結結Schedulesnotlinkedbetweenprocesses未啟用目目視化工工廠管理理VisualFactorynotinusetocontrol大料架或或大批量量Largecontainers/batchsizes改善的機機會躲藏藏於超額額庫存之之間Excessinventoryhidesopportunitiesforimprovement如汪洋大大海之庫庫存SeaofInventory過多之庫存EXCESSINVENTORY認知過度庫存存成本之之知多少少TheTRUECOSTofExcessInventory額外的運運送成本本ExtraCarryingCost額外的庫庫存成本本ExtraStorage額外的料料架ExtraContainers額外的管管理ExtraHandling額外時間間浪費ExtraTime額外損害害ExtraDamage不安全UnsafeConditions過度庫存存隱藏品品質問題題Excessinventoryhidesqualityproblems...無止盡的的改善Nocontinuousimprovement!其它浪費費OtherWastes人員People心態(tài)Minds想法Ideas能力Abilities科技Technologies有關安全全之浪費費Allwastesrelatetosafety精實製造造LeanManufacturing以消除浪浪費來說說縮短顧顧客之等等候時間間Amanufacturingphilosophywhichshortensthetimelinebetweenthecustomerorderandtheshipmentbyeliminatingwaste貨品送達達PRODUCTSHIPMENT顧客訂單單CUSTOMERORDER時間TimeBusinessasUsualLeanManufacturing貨品送達達PRODUCTSHIPMENT顧客訂單單CUSTOMERORDER時間〈縮縮短〉Time(Shorter)WasteWaste福特生產產系統(tǒng)FordProductionSystem福特生產產系統(tǒng)是是以減少少浪費來來穫致持持續(xù)的改改善TheFordProductionSystem(FPS)isdefinedasasystemofcommonprocessesandtoolsthatsupportcontinuousimprovementthroughtheeliminationofwaste.FTPMTrainingISPCMEEnvironmentalIMSHARPSMFWorkGroups福特生產產系統(tǒng)之之要素FPSElementsFTPMTrainingISPCMEEnvironmentalIMSHARPSMFWorkGroups福特生產系系統(tǒng)之要素素FPSElements精實之家HouseofLeanHighestQuality,LowestCost,ShortestLeadTime作業(yè)穩(wěn)定STABLEPROCESSES平準化生產LeveledProduction標準化作業(yè)StandardizedWork改善KaizenJITJidoka往未來圖五五個階段的的目的PurposeofFivePhasestoFutureStateContinuous連續(xù)的流動Flow後拉式系統(tǒng)PullSystem平準化生產LevelProduction同步生產SynchronousProduction穩(wěn)定性Stability福特原始的的生產哲學學Ford’sOriginalManufacturingPhilosophy(1926)標準化及持持續(xù)改善StandardizationandContinuousImprovement減少浪費EliminateWaste採用連續(xù)生生產模式UseContinuousFlowManufacturing物料在來源源處即採品品質管理PracticeQualityattheSource摘錄自亨利利福特的著著作今日與明日日FromTodayandTomorrowbyHenryFord人員互動ThePeoplePinionGear以小組作業(yè)業(yè)為基礎減減少浪費，，以求持續(xù)續(xù)改善AWorkGroup-basedorganizationalignedanddriventocontinuallyimprovebusinessresultsbyeliminatingwaste.FlexibleCapable,HighlyMotivated&EmpoweredPeopleExceedCustomerExpectationsQualityCostTime信賴度&產能維護TheReliabilityMaintainabilityPinionGear使用世界級級之設備設設計、維護護與製程，，以確保安安全、穩(wěn)定定、彈性及及品質，以以期達成並並或超越內內部及顧客客之須要Processesandequipmentdesignedandmaintainedataworldclassleveltoensuresafety,stability,flexibility,andin-stationqualitythatconsistentlymeetorexceedinternalandexternalcustomerrequirementsExceedCustomerExpectationsQualityCostTimeWorldClassReliability&Maintainability運轉不息的的轉輪TheContinuouslyFlowingPinionGear運用精實生生產與即時時供料觀念念，以維持持持續(xù)且有有順序的供供料，以附附合顧客要要求ApplicationofleanmanufacturingandJust-In-TimeprinciplestoprovideacontinuousflowofmaterialsandproductsinsequenceattherateofcustomerdemandExceedCustomerExpectationsQualityCostTimeContinuouslyFlowingMaterial&Products福特生產系系統(tǒng)模式TheFordProductionSystemModel絕竅Key:連結內3小小齒輪才能能帶動中央央齒輪Thethreepiniongearsarelinkedtodrivethecentralgear.所有3齒輪輪必須有效效運轉才能能達到目標標Allthreemustperformeffectivelytodeliverthegoal.FlexibleCapable,HighlyMotivated&EmpoweredPeopleExceedCustomerExpectationsQualityCostTimeWorldClassReliability&MaintainabilityContinuouslyFlowingMaterial&ProductsFord生生產產系系統(tǒng)統(tǒng)模模式式品質質成本本時效效超越越顧顧客客期期望望具彈彈性性,有能能力力,高度度被被激激勵勵&授授權權的的員員工工世界界級級的的信信賴賴性性&維護護保保全全連貫貫性性的的物物料料&產產品品流流動動如同同合合作作夥夥伴伴關關係係的的協(xié)協(xié)力力廠廠強健健的的產產品品及及作作業(yè)業(yè)制制度度(Ford產產品品發(fā)發(fā)展展系系統(tǒng)統(tǒng)<24個個月月車車輛輛推推出出)產能能規(guī)規(guī)劃劃訂購購到到交交貨貨<15天天Ford顧顧客客服服務務2000價值值流流圖圖的的循循環(huán)環(huán)周周期期ValueStreamMappingCycle...願景景VISIONPROCESSDATAgatheredCurrentStateMapdrawnFutureStateMapdrawnProcessandFlowKaizensidentifiedValueLoopsIdentifiedActionstakenFutureStateMapbecomestheCurrentStateMap減少少浪浪費費重重點點FocusedeliminationofWASTEDate:2/16newslidesafterthispage…福特特現現況況HarbouronFord...目前前重重點點RecentHighlights:Atlanta裝配配線線AssemblyValencia裝配配線線AssemblyChicago沖壓壓線線StampingKTP沖壓壓線線StampingLima引擎擎裝裝配配線線EngineCleveland引擎擎裝裝配配第第2線線Engine#2Bridgend引擎擎裝裝配配線線EngineLivonia變速速箱箱裝裝配配線線TransmissionBordeaux變速速箱箱裝裝配配線線Transmission福特特現現況況HarbouronFord...檢查查重重點點PlantTourChecklist標準準作作業(yè)業(yè)StandardizedWork防止止錯錯誤誤ErrorProofing目視視管管理理Visualcontrols預防防性性維維護護Preventivemaintenance工作作地地點點的的組組織織Workplaceorganization貨櫃櫃化化Containerization拉式式生生產產Pullsystems小批批量量生生產產Smalllotproduction低庫庫存存Lowinventory團隊隊精精神神Workteams現場場佈佈置置流流程程Layout/flow快速速換換模模換換線線Quicktoolchangeover產出出時時間間ThroughputtimeRichardChenVicePresidentPurchasing,FordLioHoMotorCompany,Ltd.AndExecutivePurchasingDirector,FordChinaOperationsChungLi,Taiwan方針展展開是是一個個可見見的,已已架構構的計計畫程程序,用用以做做為組組織因因策略略的優(yōu)優(yōu)先次次序所所做的的調整整及目目標PolicyDeploymentisavisible,structuredplanningprocessthatfocusesandalignstheorganizationonthestrategicpriorities.定義Definition為什麼麼要方針展展開?WhyPolicyDeployment?尋找,集集中以以及調調整組組織以以突破破目標標Identifies,focuses,andalignstheprioritiestoenablebreakthroughperformance.經由合合作發(fā)發(fā)展的的目標標提提供真真正員員工放放權授授能的的環(huán)境境Providesframeworkfortrue““EmployeeEmpowerment”throughcollaborativedevelopmentofobjectives.以主要要目標標為決決策及及解決決問題題的準準則Usesmajorobjectivesascriteriafordecisionmakingandproblemsolving.讓經營營計劃劃及其其細則則目視視化Visualizestheplansandassociateddetails利用系系統(tǒng)驅驅使持持續(xù)不不斷的的改善善Utilizesthesystemsapproachforcontinuousimprovement.使它和和管理理考績績系統(tǒng)統(tǒng)相連連接IntegratedwiththePerformanceManagementSystem.POM’sPlantMgrs.PolicyDeploymentObjectivePlantMgr.AreaMgrsPolicyDeploymentObjectivePlantMgr.AreaMgrsPolicyDeploymentObjectiveAreaMgr.Supt.PolicyDeploymentObjectiveAreaMgr.PolicyDeploymentObjectiveAreaMgr.Supt.PolicyDeploymentObjectiveAreaMgr.PolicyDeploymentObjectiveAreaMgr.Supt.PolicyDeploymentObjectiveAreaMgr.Supt.PolicyDeploymentObjectiveSupt.Supt.調整目目標的的方針針展開開AlignmentofObjectivesPolicyDeployment方針展展開在在A階段段的需需求如如下:廠內正正在進進行方方針展展開的的程序序目的的是:使全公公司不不論垂垂直的的及水水平的的跨部部門根根據方方針展展開調調整部部門目目標使方針針展開開傳遞遞到現現場主主任及及他的的部屬屬FPS的目目的包包括於於方針針展開開的程程序之之內每日的的營運運數據據,展展現現出來來的營營運績績效和和調整整後的的目標標做比比較並並且傳傳遞管管理的的第一一層管理的的第一一層於於一固固定時時間和和他的的下屬屬討論論績效效和目目標的的差距距方針展展開A階段段的需需求PolicyDeploymentCheckpointARequirements企業(yè)經經營計計劃的的傳承承BUSINESSPLANCASCADE營運計計劃的的傳承承主要要是要要顯示示出製製造部部門(代表表相當當比例例的固固定及及變動動成本本)如如何何根據據營運運計劃劃作調調整TheBusinessPlanCascadeisintendedtoshowhowmanufacturingoperations(whichrepresentasubstantialpercentageoffixedandvariableoverhead)canbealignedwithBusinessPlanobjectives.根據營運計計劃調整生生產型態(tài)ALIGNMENTOFOPERATIONSWITHTHEBUSINESSPLAN每一直接或或間接生產產部門,都都必需根根據營運計計劃設定目目標以及衡衡量基準,並且持持續(xù)的朝目目標改善TobealignedwiththeBusinessPlaneachdepartmentwhichoperatesorsupportsproductionequipment/facilitiesneedtosetanappropriateobjectiveandmeasureperformanceusingkeymeasurables.Continuousimprovementtowardtheseobjectiveswill:根據營運計計劃調整生生產型態(tài)ALIGNMENTOFOPERATIONSWITHTHEBUSINESSPLAN根據營運計計劃調整生生產型態(tài)ALIGNMENTOFOPERATIONSWITHTHEBUSINESSPLAN排除價值鏈鏈上的浪費費Eliminatewasteintheentirevaluechain,includingoverhead降低生產的的基本成本本Reducetheanufacturer’scostbase增加目前產產品的獲利利率Improveitsprofitabilityonexistingbusiness.以更低的成成本來吸引引顧客,以以及在銷銷售的增加加情況下獲獲利率也同同時增加Makethemanufacturermoreattractivetocustomers(viaalowercostbase)andprovideforincreasedsaleswithacommensurateincreaseinprofits.9、靜夜四無無鄰，荒居居舊業(yè)貧。。。12月-2212月-22Thursday,December29,202210、雨中黃葉葉樹，燈下下白頭人。。。14:34:5614:34:5614:3412/29/20222:34:56PM11、以我我獨沈沈久，，愧君君相見見頻。。。12月月-2214:34:5614:34Dec-2229-Dec-2212、故故人人江江海海別別，，幾幾度度隔隔山山川川。。。。14:34:5614:34:5614:34Thursday,December29,202213、乍見翻疑疑夢，相悲悲各問年。。。12月-2212月-2214:34:5614:34:56December29,202214、他他鄉(xiāng)鄉(xiāng)生生白白發(fā)發(fā)，，舊舊國國見見青青山山。。。。29十十二二月月20222:34:56下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