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Production Preparation Process(3P) training material -Johnson Electric.pdf

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PRODUCTION PREPARATION PROCESS TRAINING MATERIAL JOHNSON ELECTRIC
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Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 1 Production Preparation Process ( 3P) 培训手册 The information covered in this manual contains proprietary 3P concepts from Shingijutsu Co. with their permission. This manual is the property of Johnson Electric and shall be used inside the company only. 此手册信息为经新技术公司许可而总结的其私有3P概念。此手册所有 权为德昌电机,信息仅为公司内部使用。 Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 2 JE’s Vision: We are the growth company in motors and related businesses. Come Grow with Us. Financial Perspective Customer Perspective Internal Perspective Learning AUTO:MD) (CMG:DI ; AUTO:MD) (TS) (JF) LEGEND: [PO] = Perspective Owner (TO) = Theme Owner Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 3 JE的远见: LEGEND: [PO] = Perspective Owner (TO) = Theme Owner 商务远景 客户远景 国内远景 学习和成长 远景 Delta CVA 收入增长 利润增长 鸿图远见 资产管理 市场份额 市场份额从7.3% 到 10.8% 提高JE形象 提 高 客 户关 系管 理 增加客户份额保持增长率 改善盈利结构 使产品系列多样化并 提 高利润 技术管理 新产品收入的30% 用于购买和使用技 术 资源支出 JCIP 合作项目驱动 商务和程序的 提高 外发 增强服务能力从以下三方 面: 技术上 生产上 供应上 能力行为发展和策 略 组织学习 学习组织 LMS Mini-Crotonville -ARCI 职员保留与 发展 创造成长及学习的机会, 来保留有高质素的人才, 并重视他们 知识管理 集中资源知识管理 RP,SP,BSC,NF 支持销售 改变/ 效率文化 战略赔偿 在 马 达 和相关商务 方面扩展的 公司 领导阶层 市场份额从7.3% 到 10.8% 从16% 增长 到23% 市场份额从7.3% 到 10.8% 提高ROCE 从17% 增加 到34% Generate US$144m Delta CVA in 3 Years CVA > 65% of OP (PT) 在技术和知识产业方面赶 上竞争对手 Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 4 1 2 3 4 5 Organization sees improvement 组织改善 BUT the speed is the difference !!! 但 速 度不同!!! Standard Approach 标准方法 ?Current Tools 灵活性的工具 ? Kaizen 改善 ?Lean Manufacturing 精 益生产 ?Re-engineering 重 整工程 ?Typical TQM 典型全面质量管理 Improvement Breakthrough Strategy 创造性策略 -Trained & Dedicated Individuals 训练有素及敬业的 员 工 - - Analytical Expertise >70% Improvement per Project - 通 过 专 业 性 分析来 使每个 项目的 改 善达到70% 以上 Breakthrough Thinking vs Standard Approaches 创造性 思 维 的 标 准方 法 JCIP Time in Years Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 5 No. of Engineering Changes 工程改变数量 Design & Development stage 设计和开发阶段 Mass Production stage 批量生产阶段 3Pconcept s applied 3P 理念的应用 Present method 目前方法 Time Comparison of number of Engineering changes in 3P design concepts versus present design methods 对照与3P 理念 相对的 目前的 设计方 法来看 工程改 变的数 量 Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 6 For Internal Use Only Introduction 简介 ? 3P is one of the JCIP breakthrough strategies to improve productivity and reduce costs. 3P是JCIP 提高生产力,减少成本的突破性战略之一。 ? Production preparation is a process whose purpose is to develop an appropriate “production system” in the shortest time possible to satisfy: Production preparation 是一项工程,其目的是要求在最短的时间内开发出适合的 “ 生产系统” ,并可满足: ? Design Quality Requirements 设计品质要求 ? Production Requirements 生产要求 ? Cost requirements 成本要求 ? “Production System” refers to not only machines / fixtures / hardware but also software such as people, inspection, maintenance and materials planning and handling. “Production System” 不仅包括硬件:机器/夹具,而且包括软件:人,检查,维护及材料计划和处理 ? The key concepts of 3P are: 3P的关键概念包括: ? Concurrent product design engineering, machine and fixtures design process. 同步进行的生产设计工程,机器和夹具设计过程。 ? Simple and low cost machines and fixtures to meet required production takt time. 可达成生产TAKT TIME 要求的简单的,低成本的机器和夹具。 ? Small flow line with longer takt time to enable use of low cost machines and fixtures. 用较长的TAKT TIME ,使用低成本的机器和夹具便可运转起来的小型生产线。 ? Use mock up models to improve machine and fixtures designs. 通过制作模拟模型来改善机器和夹具的设计。 Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 7 What is 3P ? 什幺 是3P? ? 3P is abbreviation for Production Preparation Process. 3P是Production Preparation Process 的缩写。 ? Establish a production system to satisfy the requirements of: 建立生产系统满足下列要求: Product Design Quality 产品设计品质 Required Production V olume 要求的生产量 Target Cost 目标成本 Target date 目标日期 ? Quality 品质 ? Quantity 数量 ? Cost 成本 ? Timing 时间 要点: * 每一步都是重要的 ? 目标不只是去设计产品,机器/夹具, 而是设计出制造最低成本,最符合 要求并可保证质量的产品。. ? 在原型设计阶段就要考虑产品的制造 若非如此,我们就会一直局限于我们 从前的做事方式。. Important points: Every step is important.The goal isn’t only to products and machines / fixtures. The goal is to design and build quality products that can be manufactured at the lowest cost and level of conformity. Consider the manufacture of the product during it’s prototype design stages. If we do not, we will fall back to the old ways we always have manufactured things before. ? The goal isn’t only to design products Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 8 Why do 3P ? 为什幺作3P? Production preparation process supports the Breakthrough Improvement and JIT principles of lean manufacturing: Production preparation process 支持突破性改善和简约制造JIT原则: ? Quality 品质: Building appropriate quality into the process 在每一道工序里面构筑适合的品质 * Develop component design with ease of manufacturing and assembly. 改善组件设计来达成制造和装配简便。 * Develop machines and fixtures capable of meeting the process requirements. 改善机器和夹具能力来符合工序要求。 ? Quantity 数量 : Establish machines and fixtures that must permit swift response to increases and decreases in production demand. 使机器和夹具能力可随生产量增减的要求来适当转换。 * Develop machines and fixtures to match the production takt time. 开发可满足生产TAKT TIME要求的机器和夹具。 ? Timing 时间: Shorten production preparation lead time 缩短生产准备LEAD TIME * Lead time compression is accompanied by simultaneous product development and machine / fixtures planning and development. LEAD TIME压缩与产品开发,机器/夹具计划和开发同步进行。 ? Cost 成本: Profit = Selling price - Cost 利润 = 销售价格 - 成本 * In a competitive market, price is set by the customer. We must lower cost to maintain profit. 市场竞争激烈,价格由客户确定。我们必须缩减成本来获取利益。 Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 9 When is 3P used? 何时用 3P ? Changes in demand 产量要求 变更时 Production Preparation Process New Product Introduction 新产品介绍 Product Design Changes 产品设计 变更时 New Plant Introduction 新 制 造 厂 开 办 Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 10 List and Review the Process Steps Breakdown the process steps required to process the material. Think basic processes NOT existing processes Design Process 3P Manufacturing Process Preparation Flow Construct the Fishbone Chart Show pictorially how the part is transformed at each process step. Again think basic process steps Layout the Parts If parts are available, lay them out as they would appear at the various process steps. If new part, post process drawings or prototyped parts Begin Processes at a Glance Sheet On the first row of this sheet, sketch the part appearance at each step of process. These should be similar to the Fishbone Chart Develop the 7 Ways For each process, everyone sketches seven different ways of doing that process on the 7 Ways Chart. These must be detailed enough to understand at a glance Construct Design Construct prototypes of the top 3 designs. These functioning models should be complete with poke yoke and hanedashi devices. Do not think machines yet Select the Top 3 or 4 Proposals From the evaluation, select the top 3 or 4 design proposals. Do not overlook attributes of non-selected designs that scored well Present and Evaluate the Processes Present the PAAG sheets and have everyone evaluate the 7 proposals based upon the evaluation sheet criteria. Complete 7 Process at a Glance Sheets For these 7 proposals devise & sketch methods to assure quality via poke- yoke or No-Go gage. Sketch tool, Jig/fixture and hanedashi Post, Group and Narrow Selection After all the 7 Ways sheets are completed, post and group similar ideas. Then vote to narrow selection to the seven best ones. Simulate Process Conduct Moonshine Testing of the designs through process simulation. Collect data and video process. Follow the steps used in Process at a Glance Sheet Refine Process at a Glance Sheets Update with changes made during the MOONSHINE exercise. Display and Evaluate Number and display designs with PAAG sheets to others. Evaluate criteria sheet. Evaluate each independently and not against each other. Select the Best Design Again using the criteria sheet, select the best design again looking at high scoring attributes of the non-select designs. Start Equipment Determination Layout the fixtures, jigs, parts, etc on a table and begin to determine machinery requirements. Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 11 列出并回览工序步骤 依据装配件分解工序 步骤。考虑基本的工序, 而不是已有工序。 设计工序 3P Manufacturing Process Preparation流程 构造鱼骨图 通过图画了解每一道 工序后零件的变化。再一 次 考虑基本的工序步骤。 零件布局 如已有零件,将其放于 工序步骤上。如为新零件 , 张贴工序图纸或模拟零件 。 开始Processes at a Glance Sheet 在此表第一行,草图画出 每一工位的零件 形状。应与鱼骨图类似。 开发7 种方法 针对每一道工序,每人 在7 Ways Chart 上草图画 出此工序的7 种不同做 法。 必须足够详尽,可以 一览便知。 构造设计 构造3 个最好设计的模 板。 这些结构模型应使用poke yoke和hanedashi devices 。先不 要考虑 机器。 选择3 或4 个最好的建议 评价后,选出3 或4 个 最好的设计建议。但不要 忽略未选择的 但评分好的建议。 介绍并评价工序 介绍PAAG sheets , 全员依据评标准来评价 7 个建议。 完成7 Process at a Glance Sheets 针对7 个建议,设计, 草图 画出方法使产品经由猪仔 模 或No-Go gage 来 保证品质。草图画出工具 , 夹具和HANEDASHI 。 张贴,分组,缩小 选择范围 完成7 Ways sheets 后, 张贴并分组类似的创意。 然后,投票缩小选择范围 , 选出7 个最好的。 模拟工序 实施Moonshine ,通过 工序 模拟来测试设计。 收集数据并录制工序。 依照PAAG的 步骤进 行。 精炼PAAG Sheets 更新MOONSHINE 练习过 程中 引发的变更。 展示并评价 编号并展示PAAG sheets 的设计给其他人。 评价尺度单。独立 评价每一个方案, 不反对彼此的方案。 选择最好的设计 再一次,用评价标准单, 选出最好的设计,同时 也要参考评分高单未被选 择 的设计。 开始确定设备 在桌子上布局夹具,零件 等, 开始确定机器要求。 Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 12 Find Examples in Natural World (3) Current Design Or New Design (Preliminary) Combine Ideas- Create Designs (6) Sketch Background (5) Sketch and Post These Examples (4) What are KEY Words (2) Hold Trial Select Top Design (11) Breakdown Product into its Parts Sign Your Contracts Post Designs Group by Similarity (7) Design or Redesign of Part Determine Function(s) (1) Keep Moonshining Gather Data (10) Present the Designs Select Best3 (9) Construct Prototypes MOONSHINE (8) Manufacturing Process Prep. Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 13 签合同 分出产品 的各 个零 件 确定功能 (1) 什么是关 键 字 (2) 用草图的 形 式确定例 子 (4) 在自然界 中 找到例子 (3) 草拟背景 (5) 进行创造 性 思维设计 (6) 凭想象创 建 原型 MOONSHINE (8) 据相似性 进 行设计分 组 (7) 从目前设 计 中选取三 种 最好的设 计 (9) 在此基础 上 收集资料 (10) 选取三种 最 好的设计 进 行试验 (11) 零件的设 计 或再设计 目前设计或 新设计 生产过程 准 备 Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 14 1. Determine function 确定功能 What is the theme & scope of your event 你 的 事 件 的主题和范围是什么 Resist the urge to examine the existing process This will only create a bias and stifle creativity. 抵 制 紧 急 检 查 目前 的流程 ,这只 会引起 一种偏 见, 并会抑制创造力 FUNCTION 1. Point 3P 3P 点 2. Line/Cell 3P 3P 线/单元 3. Plant-Wide 3P 厂范围的3P( 西) Post on Wall/Board 墙上/ 板上张贴 Notes Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 15 Guide 指南 Clamp夹钳 Swivel 转环 Oscillate 振 动 Turn 转动 Rigidity 刚度 Spin 旋转 Press 压 Drill 钻子 Roll 滚动 Brake 闸 Bond联结 Shear 剪切 Fasten 拴紧 Lock 锁 Slide 滑 Draw a sketch that best describes what’s happening. 画 一 幅能最 好描述 的草图 所需的 关键 Key words 关键 2. Define the essence of the function 定义功 能本 质 What are the key words 关 键 是什么 Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 16 3. Look for examples of keyword in nature 在 自 然界 中寻找 关键字 的例子 Nature has spend millions of years refining these phenomena 大 自然已 经存在 这些现 象成千 上万年 了 Resist all attempts to use man made examples. Nature’s examples are often simple and pure 抵 制 所有用 人做的 例子, 大自然 的例子 通常是 简单而 又质朴 的 Spin 旋转 Attach 使附属 Shear 钳 Crawl 爬行 Separate 分离 Grip 紧握 Adhere 粘附 Encapsulate 压缩 Cling 粘紧 Move移动 Production Preparation Process ( 3P) - version 2.1 For Internal Use Only 17 4. Sketch examples and examine what is happening. 草 拟 案例观查发 生的情况 Group common examples 对 相 同 的例子 进行分组 You must look deep into the phenomenon to understand. What must take place for this phenomenon to happen? 对 现 象进 行 深入 观 查并 加 以理 解 这些 现 象的 发 生会 造 成什 么 情况 的 发生 Examine in detail 观查细节 Do your homework 做你的作 业 Sketch the examples 草图例子 Attach 附上 Group common examples 对 相 同的例 子进行 分组 Hinge 铰链
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