2. 目的 Objectives阐述目视管理: 目标,定义,和标准
Describe Visible Controls: goal, definition,
and criteria
了解如何运用 Understand how to use them
讲解4种做法
Define the 4 categories
展示与持续改进的联系
Show connection to
Continuous Improvement Process2Cummins 目视管理 Visible Controls
3. 与CPS*的联系 CPS Connection隐藏问题,不能使问题受到重视并得到解决。我们必须能够很快地标识问题,并立即做出反应。问题点必须可以一目了然。
— CPS 员工手册 1991,24页
*CPS-康明斯生产系统
“Hidden problems will not get attention and will not be fixed. We must be able to identify problems quickly and respond to them immediately. Trouble spots must be obvious at a glance.”
— CPS Employee Manual, 1991, pg. 243Cummins 目视管理 Visible Controls
4. . 注意!ATTENTION!
下面两种方法对于信息运用管理可能会有很大的区别:
How information is organized is perhaps the most distinguishing feature between…
信息共享 目视交流
Information Sharing Visible Communication4Cummins 目视管理 Visible Controls
5. 目视管理目标 Visible Controls Goal1. CPS 质量目标是:
“使过程成效指标和问题均目视化”
A CPS quality objective is to “make performance
to processes and problems visible.”
2. 持续改进是我们的生存之道
Continuos Improvement is a way of life
3. 建立发展一个部门区域间交互责任的体系
Developing a system of overlapping responsibilities between functional area 5Cummins 目视管理 Visible Controls
6. 目视管理 VISIBLE CONTROL DEFINITION 目视管理就是信息展示,全面直观地、方便地
能看见,以便对其做出反应,进行调整控制。
A visible control is defined as a display of information devised to be in full view or readily seen in order to allow reaction or regulation to the source or cause of information.6Cummins 目视管理 Visible Controls
7. 基本准则 Essential Criteria 使重要的信息以最快的速度方便地传递到决策和措施制定的地方
They are used to facilitate the transfer of important information as quickly as possible at the point where decision and action can be made.
1、简洁陈述 Simplicity of presentation
2、可视测评 Visibility of measurements
情况目视通报到每位员工
situation are visible to everyone
目标和责任目视通报到每位员工
goal and rules are visible to everyone 7Cummins 目视管理 Visible Controls
8. 基本准则 Essential Criteria3、每位员工进行参与
Everyone’s involvement
4、基础信息数据的真实收集
Undistorted collection of primary information
5、重要数据的直接测评(至关重要的几个)
The straightforward measurement of what’s important (The Vital Few)
6、对紧急情况有全面的了解掌握
Achieve an overall feel of urgency
7、针对变异有完善计划和受训练的反映
Planned and disciplined response to abnormalities8Cummins 目视管理 Visible Controls
9. 行GO停
STOP我该如何做??
What should I do???9Cummins 目视管理 Visible Controls
14. 目视管理准则The Rule of Visible Controls 班组必须审核和认可目视管理
The team has to review and approve any visible control
“…提交目视管理文件进行公开评议—使员工获得认知,提供员工发表建设性意见的机会”
“…submitting a visible control document to a process of public scrutiny --result in better ownership of the knowledge and opportunities for constructive criticism.”14Cummins 目视管理 Visible Controls
15. 公开式传达信息Openness of Communication问题状况的明确展示使每位员工知道目前过程的状态“Visible display of problem status lets everyone know the current status of the process.”度假, 一周后返回On vacation Return in 1week15Cummins 目视管理 Visible Controls
16. 生产计划展示 例1 Handout Solution for Situation 1 -Production Schedule for Plant B, Example #116Cummins 目视管理 Visible Controls
17. 生产计划展示例2 Handout Solution for Situation 1 -Production Schedule for Plant B, Example #217Cummins 目视管理 Visible Controls
18. 人力计划举例 Handout Solution for Situation 1 -Workforce Planing A工厂 Plant A B工厂 Plant B18Cummins 目视管理 Visible Controls
19. 四种展示 The Four Categories目视生产控制
Visible Production Control
目视质量控制
Visible quality control
过程指示
Process indicators
进程显示
Making Progress Visible改进 Improvement :
节拍 cycle time
实际 Actual:
3.5 min reduction19Cummins 目视管理 Visible Controls
20. 生产管理 Production Control(…过程状态一目了然 understanding the process at a glance.)
看板或拉料卡显示材料状态
Chanson or Pull Cards showing material status
工作标准化 Standardized work charts
瓶颈工序标识出
Bottleneck operations identified
工序流程图 Process flow charts
预先确定场所
Predetermined locations
整洁、工装和设备定置摆放
clear, designated tool& equipment locations20Cummins 目视管理 Visible Controls
21. 生产管理 Production Control材料存储标识完善
well marked material storage
材料过量堆积 overflow areas
警示灯显示问题或异常情况
Andon displays to indicate problems or abnormal situations
生产量计数 Production count status
发交状况 Delivery status
料箱(架)限制零件装载量
Containers limiting the amount of parts21Cummins 目视管理 Visible Controls
22. 料架满装指示举例Example of Production ControlInstructions for filling a container错误 No 正确 Yes满装线
Fill line22Cummins 目视管理 Visible Controls
23. 警示灯板 Andon (a lighting panel)发生故障传送信息的装置
Which is an “information transfer device for trouble occurrence”.
同时可指示停止或故障解除警示
Also reference to as stop alarms, uptime lights23Cummins 目视管理 Visible Controls
24. 生产管理警示板 Production Control Board -Andon Board目标 345
Target实际 345
Actual时间损失 8min
Loss time最新消息:工作站 3材料短缺,
工作站 6有质量问题
Status update:Station 3 has a material
shortage, Station 6 has a quality problem 6789101234524Cummins 目视管理 Visible Controls
25. 生产警示灯有如下表示:Example of Production: Andon Lights-红色 Red : 生产线停止Line Stop
-黄色Yellow: 请求支持援助
Worker has called for help
-绿色Green: 正常 Normal operation25Cummins 目视管理 Visible Controls
26. 警示灯有如下表示:Example : Andon Lights-红色Red: 设备故障 Machine trouble
-白色White: 生产终止 end of production run
-绿色Green: 材料短缺停产
no work shortage of mat.
-兰色Blue: 有问题 defective unit
-黄色Yellow: 要求调整 set-up required26Cummins 目视管理 Visible Controls
27. 过程指示 Process Indicators (…用于监控工作进程的设施 devices for monitoring work progress)设备机油消耗 Machine oil consumption
班组培训矩阵表(技能水平/培训项目)
Team training matrix (skill level/training)
安全成效 Safety results
内部环境管理维护成效 Housekeeping results
库存周转 Inventory turns
色彩编码任务 时间安排卡片
Color coded job scheduling cards
在制品 Line side storage
节拍 Tat time, cycle time
调整时间 Set-up Time
SPC 图 SPC charts27Cummins 目视管理 Visible Controls
28. 过程标示举例: 发动机挂旗Example of process indicators:Engine Flags 红色 - 发动机质量问题要拆检
Red - Engine Quality Teardown
黄色 - 缺“自制”件
Yellow - Shortage of “made in works” part
兰色 - 缺“外协”件
Blue -Shortage of “bought out finished “ part
绿色 - 发动机准备做试验
Green -Engine ready for test
白色 - 等待检查 White -Awaiting inspection 28Cummins 目视管理 Visible Controls
29. 质量管理 Quality Control (…质量状况一目了然 understand quality status at a glance) 用户质量水平 Customer Quality Levels
工序控制纪录 Process Control Records
SPC图 SPC charts
CPC情况 CPC status (CPC triangles)
量检具检定状况 Gauge calibration status
接受/不可接受标样 Boundary Samples referencing
acceptable/non-acceptable quality
供应商质量成效 Supplier results
规定明确的不合格品区 Clearly defined non-conforming area
工艺文件 Process Documentation
检查计划 Inspection plans 29Cummins 目视管理 Visible Controls
43. 工作场地一目了然 A VISIBLE WORKPLACE谈论视觉图像信息却不用图片,似乎有些似是而非。这就是展示车间目视管理图片的原因。
It would be somewhat paradox to speak of visual communication without relying on an image. This is the reason for presenting a visual workplace.
上张图示不是固定不变的逐条要遵循的实际例子,每个工厂有各自不同的实际操作运行情况。没有理由完全按照图示中每个项目去实施。其他内容或展示可能更适合具体的情况。这里主要是提供目视交流、管理的一种思路。
The workplace depicted is not a practical example to be followed literally. Each firm has its own constraints and operating structure. There is no reason automatically to include everything appearing in this sketch. Conversely, other elements--or other forms of presentation--maybe more suitable for certain situation. In this portrayal, the intent is to present significant visual communication themes.43Cummins 目视管理 Visible Controls
44. 工作场地一目了然 A VISIBLE WORKPLACE班组板块 The Team’s Territory
1.板块标识 Identify territory
2.标识活动、资源和产品
Identify activities, resource,& product.
3.班组园地 Identify the team
4.地面标记 Marking floor
5.标识工装和工位器具 Marking of tools and racks
6.技术区域 Technical area
7.交流和休息区域 Communication & rest area
8.信息和指示 Info. & instruction
9.清扫工具 Neatness (broom)
目视文件 Visual Doc.
10.生产指导和技术程序
Manufacture Instruction & tech. procedure44Cummins 目视管理 Visible Controls
45. 工作场地一目了然 A VISIBLE WORKPLACE目视生产管理 Visual production control
11.计算机终端 Computer terminal
12.生产计划 Production schedule
13.维修计划 Maintenance schedule
14.零标识 Identification of components
目视质量管理 Visual quality control
15.设备监控信号 Machine monitor signals
16.SPC
17.记录
指标展示 Display Indicators
18.目标、结果和差距Objectives, results, and differences
进展 Rendering Progress Visible
19.改进活动 Improvement activities
20.公司方针、计划和任务
Company policy, project & mission 45Cummins 目视管理 Visible Controls
46. 实施改进 Making Improvements(目视板可使每个员工追踪改进工作的进展)(Display so that anyone can follow improvement work as it progresses)用户满意 Customer satisfaction
用户/供应商合作协议Customer/supplier working agreements
项目和状况 Projects and status
改进活动 Improvement activities
之前/之后 Before/After
培训计划 Training matrices
改进板 Improvement boards
问题解决过程 Problem solving process status
库存降低腾空场地
Floor space freed up due to inventory reduction
预防性维护计划 Preventative maintenance schedule46Cummins 目视管理 Visible Controls
47. 合适的搬运摆放作业指导Instructions for Proper Stacking Procedure不在正确 No 正确Yes47Cummins 目视管理 Visible Controls
48. 预防问题重新设计
Re-design for prevention
of problem 目视管理的实施Levels of Visible Controls Implementation工艺文件 Process documentation
环境维护管理 Housekeeping duties
图表-发交 ,员工培训计划
Charts - parts shipped, - operator training matrices检查计划 Inspection plans
不合格品报告 Reject reports色斑材料区
Color striped material zones
SPC 图 SPC charts
控制限 Boundary samples
发动机试验 Engine test活塞环颜色码 piston ring color code
特殊力矩复检
specialized torque overchecks预防 PREVENTION发现 DETECTION停线 灯machine down lights
装配红灯 assembly red lights
2预通道无线系统
2-way radio system最初展示运行状态
Initial display of
operational status质量信息和规范
Quality information &
specification工作环境探测异常
Work environment for
abnormality detection问题可视或可见警示
Visual or audible alerts
to problem防错 Failsafing自动
Automation48Cummins 目视管理 Visible Controls
49. “标准是一个参照点, 提供给班组追随的目标, 同时也提供了出发的起点.”“A standard is a point reference that simultaneously provides the group with a point to adhere to and a point of departure.” 通过信息展示, 建立了工作和改进有据可依的“标记牌”
By visibly displaying information we establish a “sign post” that can be worked to and improved upon.49Cummins 目视管理 Visible Controls
50. 评价和改进Evaluate and Improve实施改进
Implement Improvements确定改进区域
Define improved
system建立改进目标
Establish
improvement goal目视交流
Visual Communication 可见结果 成效
Visibility of results 文件易于 阅读
Easy to read documents50Cummins 目视管理 Visible Controls
51. 说明 Description建立改进目标--班组共所周知的
Establish Improvement Goals = Know as a group
交付的承诺 Delivery commitments
目标和时间进度计划 Goals and schedules
责任 Roles
实施改进--班组有目共睹的
Implement Improvement = Seeing as a group
延迟 Delays
库存状态 Inventory levels
评价和改善--集体实施
Evaluate and Improve = Action as a group
共同的责任和目标 Consensus on rules and objectives
参与实施改进 Participation in making improvements51Cummins 目视管理 Visible Controls
52. 为了提供一个反馈到工序的自控环境, 目视管理应该:
In order to provide an environment of self control
feedback to the operations should:
一目了然 Read at a glance
关注至关重要的几件事项
Deal with the Vital few
关注操作人员可控制的事项 (或缺陷)
Deal with operator controllable items (or defects)
提供提示作用
Provide prompt signals
提供纠正措施指南
Guide Corrective Action目视管理 Visible Controls单行道 ONE WAY52Cummins 目视管理 Visible Controls