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null德昌生产系统概念 Johnson Electric Production System Concepts德昌生产系统概念 Johnson Electric Production System ConceptsJEPS 办公室编写 Prepared by JEPS Office 2006/01/04利潤与成本 Profit and Cost利潤与成本 Profit and Cost 利潤 = 銷售价格 - 成本 Profit = Selling Price - Cost 为了提高利潤 In order to increase profit 1.提高銷售价格？不可以，因为這由市場決定。 Does we increase the selling price? NO, It is controlled by market. 2.降低成本？這要由改善制造方法去達成 Does we decrease the cost? Improve manufacturing method can be done. 銷售价格  利潤 + 成本 Selling Price  Profit + Cost銷售价格 Selling Price成本 Cost利潤 Profit銷售价格 Selling Price12及時化生產基礎 Just In Time Fundamentals及時化生產基礎 Just In Time FundamentalsJohnson Electric Production System - JEPSJohnson Electric Production System - JEPS德昌生产系统 - JEPS德昌生产系统 - JEPS机人作业T/T生产物“标准半制品” “物流和信息流的 看板系统”“一只流的生产” 拉引系统 超级市场报警装置 可操作性强 实用性高品质保障 转型号快平准化生产消除MUDA(浪费无附加值)，降低成本及時化生產 JIT(Just - in Time)及時化生產 JIT(Just - in Time)必要的產品 The Needed Products 必要的数量 The Exact Quantity 必要的时间 The Right Time 自化 JIDOKA(Autonomation)自化 JIDOKA(Autonomation)具有人的判斷力的“自化” Autonomation with human sense 逐步向上不断将人工作业转为机器任务 Continuously changing human tasks to machine tasks step by step and upwards自加工自动锁紧自进料自动停止自返回自动送出猪仔模(自动检查)縮短转型號時間步伐 Setup Time Shortening Setps縮短转型號時間步伐 Setup Time Shortening Setps“少人化” Flexible Production“少人化” Flexible Production使作業現場的作業人員數具有靈活性，意味著當生產的需求產生變化(減少或增加)時變更作業人員數。 Operator has flexible on plant, means we can change operator quantity(increase or decrease) with order demand changing. 必須滿足下面三個要素： Must have 3 basics as belows: 1.合適的設備佈置的設計。 Appropriate equipment layout 2.要有具備多方面能力訓練有素的作業人員，也就是多功能工。 Have the operator with multi functional skills and ability, multi-worker 3.標準作業組合不間斷的再評价和定期修訂。 Continuously review and periodic revise standard work combination sheet.生產方式的基本目的 Basic Purpose of Production Manner生產方式的基本目的 Basic Purpose of Production Manner 1.最終目的是通過降低成本产生效益。 The final purpose that produce benefit through reduce the cost. 2.消除製造過剩的浪費，降低成本。 Cost reduction through elimination over production. 3.數量管理，質量保证和人性化管理。 Quantity control, quality guarantee and humanity management. 4.“及時化生產”和“自化”。 “JIT” and “Jidoka(Autonomation)”. 5.“少人化”和創新方法。 “Flexible” and innovating. 支撐生產方式的六項措施 Six Steps Supporting Production Manner支撐生產方式的六項措施 Six Steps Supporting Production Manner1.生產的均衡化。 HEIJUNKA Production. 2.作業轉換時間的縮短。 Shorten setup time. 3.設備佈局的策劃。 Design equipment layout. 4.作業的標準化。 Work standardization 5.自化。 Jidoka(Autonomation). 6.改善活動。 Kaizen activity.Nakao San寄语 Nakao San’s WordsNakao San寄语 Nakao San’s Words百闻不如一见 It is better to see for oneself rather than to hear for many times百闻不如一见 It is better to see for oneself rather than to hear for many times三现和四用 3G & 4 Using三现和四用 3G & 4 Using用心 Using Our Hearts用眼 Using Our Eyes用手 Using Our hands用脑 Using Our Brains现地 Genchi 现物 Genbutsu 现实 Genjisu現場改善黃金法則 Golden Rule for Gemba Kaizen現場改善黃金法則 Golden Rule for Gemba KaizenWhen abnormality occurs 當生產線發生异常 Go to Gemba (3G: Gemchi ,Gembutsu ,Gemjitsu ) 即到現場(3G:現地,現物,現實) Take immediate counter measure 臨時應急措施 Ask yourself " Why" 7 times to pursure for root causes 用7 個" Why"找出根本原因,和解決方法 Prevent recurrence 防止再發生 1.Standardization 標準化 2.Self-discipline 自律现场改善  作战十条 Ten Principles In Gemba Kaizen现场改善  作战十条 Ten Principles In Gemba Kaizen一、不要找借口. Don’t make excuses for anything. 二、不要说不行,要想方法去做 Never say “it’s impossible, we can’t make it!” Just think and do it. 三、先不要担心. Don’t be worried about before taking action. 四、根据事实做议论,不要凭想像推论. Conclusions are made based on facts instead of imagination. 五、有困难才会有智慧. Difficulty makes wit. 六、不要追求完美,有60分也要勇敢去做. Don’t expect everything to be perfect. Sixty points is enough for trying. 七、立即去做,做后再提意见. Action first, question second. 八、不要用钱,要用智慧.没有智慧,多流汗,智慧就出来了. Use your wit instead of money. You’ll have wits by sweating more. 九、要把无价值的动作,移到有价值的劳动中去. Remove operation adding no value to products, only valuable operation left. 十、改善是无限的. Kaizen (Improvement) is forever and endless.改善是永無止境的 KAIZEN is Forever and Endless改善是永無止境的 KAIZEN is Forever and Endless 作业分析(改善前) Work Analysis Sheet(Before)作业分析表(改善前) Work Analysis Sheet(Before)时间观察表(改善前) Time Observation Form(Before)时间观察表(改善前) Time Observation Form(Before)标准作业组合图(改善后) Standard Work Combination Sheet(After)标准作业组合图(改善后) Standard Work Combination Sheet(After)操作人员时间直方图 Operator Time Bar Chart操作人员时间直方图 Operator Time Bar Chart改善新闻 Kaizen Newspaper改善新闻 Kaizen Newspaper改善个案 Kaizen Case改善个案 Kaizen Case作业分析表(改善后) Work Analysis Sheet(After)作业分析表(改善后) Work Analysis Sheet(After)标准作业组合图(改善前) Standard Work Combination Sheet(Before)标准作业组合图(改善前) Standard Work Combination Sheet(Before)改善前后对照表 Comparison Sheet Before and After Kaizen改善前后对照表 Comparison Sheet Before and After Kaizen