上海通用汽車生產(chǎn)系統(tǒng)SGMGMSCONCE.ppt

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Welcome！,An Overview to GMS,A Lean Manufacturing Management System 是一個精益制造管理體系,GMS,Like An Atom We Need All The Pieces Working Together!!,Background 背景介紹,,New Plant 新工廠 + New Product 新產(chǎn)品 + New Process新工藝 = Quality Problems 質(zhì)量問題,Not True with GMS ! GMS決不會這樣！,Vehicle Launch Concerns 新車型啟動關(guān)注點,During a Typical Launch一次典型的啟動:,Why Global Manufacturing Systems?為什么要采用GMS (通用全球制造體系)?,,New Plant 新工廠 + New Product新產(chǎn)品 + New Process新工藝 = Quality Problems 質(zhì)量問題,J. D. Power, Initial Quality Study J. D. Power, 初始質(zhì)量調(diào)查,1999 Mercedes-Benz,,2002 Cadillac CTS,,YES,NO,Mercedes-Benz 235 problems per 100 – near the bottom of the survey 每100輛車235個問題 － 在調(diào)查中排名靠近末尾 Cadillac CTS 88 problems per 100 – Ranked SILVER !!! 每100輛車88個問題 － 排名第二?。?！,,Background背景,The GM/Toyota Joint Venture GM/Toyota合資公司,New United Motors Manufacturing Inc. 新的聯(lián)合汽車制造公司 Est. February 1984 in Fremont, California 1984年2月在加利弗尼亞，弗里蒙特成立 GM wanted to learn the Toyota Production System (TPS) GM想學豐田生產(chǎn)體系（TPS) Toyota wanted to learn about manufacturing in the U.S. 豐田想學如何在美國造車 Each GM unit was free to study TPS and implement as they saw fit 每個GM的工廠都可以學習TPS,并按需實施,,Creation of GM-GMS GMGMS的產(chǎn)生,Five GM-GMS Principles 五項原則,,Thinking Way 精益概念,Traditional Way,‘GMS’ Way,People are hired hands Current State is embraced Function-driven organisation Go to Office & Guess Knowing Organisation Quality seen as a function Hide Mistakes Ego-driven leaders ‘Complex Sense’ - wasteful Spend time figuring out itself,People are investment in minds Current State is challenged Customer-driven organisation Go To See & Understand Learning Organisation Quality seen as a culture Learn from Mistakes Process-driven leaders ‘Common Sense’ - simple Spend time figuring out enemy,Purpose of GMS is to make lean-thinking People & lean Processes to deliver lean Results for the Customer,System Position 系統(tǒng)所在的位置,Goal Categories 目標種類,How WE are MEASURED 如何衡量我們的業(yè)績,Plant Performance Score Card工廠績效考核卡,,Goals目標 =,Method方法 =,,,People Involvement人員參與 -People Company人員參與的公司,Continuous Improvement Company持續(xù)改進的公司,Standard- ization 標準化,Built In Quality 制造質(zhì)量,Short Leadtime縮短制 造周期,,,,,,,,,,,,Strong Leadership 強有力的領(lǐng)導,GMS Supports Attaining Our Goals GMS 支持我們達到目標,,,,,Safety安全 People人員 Quality質(zhì)量 Responsiveness響應 Cost成本,,,GM-GMS,GMS Structure,,Goals目標,NA,APO,Principles原則,Core Requirements核心要素 (calibration statements),,,Tools工具,Tools工具,Elements原理,,LAAM,GME,,Methods標準,Tools工具,Tools工具,Global,Must be Global Common to Have ONE GM-GMS 必須是全球共同的 一個GM-GMS,,,,,,,Structure Explanation 結(jié)構(gòu)說明,,,,,,,,,,Goals 目標,Principles 原則,Elements 要素,Core Requirements 核心要求,Tools 工具,Goals: Describe the primary state which the corporation strives to achieve. Reaching these goals leads to the complete success of our company 目標：描述公司努力要達到的狀態(tài)。達到這些 目標可引導公司走向成功,Principles: The leading concepts / philosophy of the company which guide our activities in the pursuit of success for our company. 原則：公司的主導理念，可指導我們的行為，追求公司的成功。,Elements: Main strategies within each Principle, which must be implemented to ensure success of each principle. 要素：每個原則的主要策略，實施策略是每個原則成功的保證。,Core requirements: Details which must be followed to ensure the success of each Element 核心要求：實現(xiàn)每個要素成功必須要遵循的細節(jié),Tools: Methods, activities and systems which are used to support the Core Requirements. They may be used to support multiple Core Requirements. 工具：方法，行動和體系用來支持核心要求，也可能用來支持多重的核心要求。,,Be the Safety Benchmark 確定安全基準,People Involvement 人員參與,Health and Safety Priority 健康和安全第一,24 Hr. Incident follow up 24小時事故跟蹤,Green Cross 綠十字,,GMS Principle and Element GMS 原則與要素,,Each of the 5 GMS Principles is supported by key elements. There are 33 GM-GMS Elements.,GMS Principles,GMS Elements,Global Manufacturing Goals of Safety, People, Quality, Responsiveness & Cost are supported by the GMS Principles. There are 5 GMS Principles:,People Involvement 1. Vision/Mission 5. Team Concept 2. Values 6. People Involvement 3. Health & Safety Process 7. Open Communication 4. Qualified People 8. Shop Floor Management Standardization 9. Workplace Organization 10. Management By Takt Time 11. Standardized Work 12. Visual Management Built-In Quality 13. Product Quality Standards 17. Quality System Management 14. Manufacturing Process Validation 16. Quality Control & 15. In-Process Verification Feedback/Feedforward Short Lead Time 18. Simple Process Flow 23. Temporary Material 19. Small Lot Packaging Storage - CMA 20. Fixed Period Ordering 24. Pull Systems System/Order Parts 25. Level Vehicle Order Schedules 21. Controlled External Trans. 26. Supply Chain Management 22. Scheduled Shipping/Receiving Continuous Improvement 27. Problem Solving 31. Early DFM/DFA 28. Business Plan Deployment 32. Total Maintenance System 29. Andon Concept 33. Continuous Improvement 30. Lean Design of Facilities, Equipment, Tooling and Layout,People Involvement Elements人員參與原理 Vision，Value and Culture Priority 愿景，價值觀與企業(yè)文化 Mission 使命 Health & Safety Priority 健康與安全第一 Qualified People合格的人員,People Support System/Team Concept 人員支持體系/團隊精神 People Involvement人員參與 Open Communication Process開放式溝通流程 Shop Floor Management車間現(xiàn)場管理,Branches = Methods,Green cross Sheet,Manufacturing Safety Performance Wall,BPD- Group Information Board,Nerve Center - Group Leader Meeting Area BPD Visualization,Safety Lockout Procedure,Group Area,Open Office,Flexibility Chart,Standardization標準化 Definition: Standardization is a dynamic process by which we set standards of terminology, principles, methods, and processes within our organization. 定義：標準化是我們在自己的組織中建立術(shù)語、原則、方法和程序標準的動態(tài)的程序 Purpose: The purpose of standardization is to stabilize, so as to achieve a base from which to grow and improve. 目的：標準化的目的是為了達到穩(wěn)定以完成可以用來發(fā)展和改進的基礎(chǔ),,,,Standardization標準化,,World Class 世界級,,,Continuous Improvement 不斷改進,Change 改變,Standardization Elements標準化原理 Management by Takt Time時間管理 Workplace Organization工作現(xiàn)場管理 Standardized Work標準化作業(yè) Visual Management目視化管理,Safety Visualization,Visual Management- Air, water flow,Team member operation certification board,Workplace organization- 5S,Fixed Position Stop ( Marked On Shop Floor ) Trim Line,Final Process Area Code 1 Control Process,Built-In Quality Elements制造質(zhì)量原理 Product Quality Standards產(chǎn)品質(zhì)量標準 Manufacturing Process Validation 制造工藝驗證 In-Process Control & Verification 流程中控制和驗證 Quality Feedback/Feedforward質(zhì)量反饋/前饋 Quality System Management質(zhì)量體系管理,Built In Quality制造質(zhì)量 Definition: The methods by which quality is built into the manufacturing process, in a way that defects are prevented, detected, and countermeasures are implemented to prevent recurrence.定義：在制造過程中制造質(zhì)量、防止缺陷、檢測和實施防止問題再次發(fā)生的對策的方法 Purpose: To ensure that defects are not passed to the customer.3 目的：確保有缺陷的產(chǎn)品不會達到客戶手中,,Solve problems through teamwork! 通過團隊合作解決問題,Satisfy your Customer. . . 使客戶滿意,The Built-In-Quality Motto 制造質(zhì)量格言,In house stamping panel inspection,Boundary Sample - Visualization,CARE Line Quality Check,Error Proofing,QCOS Trend Control Sheet,ANDON-Quality Call,Final Process Area Code 1 Control Process,QCOS Sheet,Short Lead Time縮短制造周期 Definition: The movement of product or material in the right quantity, at the right time, to the right location, with the right equipment, using the shortest lead time and the lowest possible cost for both the supplier and the customer.定義：讓供應商和客戶在最短的制造周期內(nèi)用盡可能低的成本，在正確的地點使用正確的設(shè)備生產(chǎn)出正確的數(shù)量的產(chǎn)品或物料的運作 Purpose: To achieve customer enthusiasm by delivering the customer his/her product more quickly, while maintaining good quality. Ultimately, our Company benefits through cost reduction and increased customer loyalty. 目的：保證優(yōu)質(zhì)質(zhì)量的同時，通過更快傳遞客戶產(chǎn)品來獲得客戶熱誠。最終，我們的公司會受益于降低的成本和提升的客戶忠誠。,Short Lead Time Elements 縮短制造周期要素 Small Lot Packaging小包裝 Fixed Period Ordering System 固定周期訂單體系 Controlled External Transportation受到控制的外部交通 Simple Process Flow簡單的流程 Scheduled Shipping/Receiving有計劃的運送/接收,Temporary Material Storage臨時物料儲存 Internal Pull/Delivery內(nèi)部拉動/運送 Level Vehicle Order Schedules水平車輛訂單計劃 Supply Chain Management供應鏈管理,Material Andon Light Board,KANBAN Post,Kanban,Material ANDON,Continuous Improvement不斷改進 Definition: A process based on standardization, whereby improvement is made, through a series of small improvements.定義：一個基于標準化，通過一系列小的改進來達到改進的程序。 Purpose: To always advance ahead towards an ever more challenging target and make progress in Safety, People Involvement, Quality, Responsiveness, and Cost through the elimination of waste. 目的:不斷向前挑戰(zhàn)更多的目標并且通過減少浪費在安全、人員參與、質(zhì)量、響應和成本方面取得進步,Continuous Improvement Elements不斷改進要素 Problem Solving 問題解決 Business Plan Deployment 業(yè)務計劃部署 Andon Concept 暗燈原理 Lean Design of Facilities, Equipment, Tooling and Layout 設(shè)施、設(shè)備、工具和平面布置的精益設(shè)計 Early Manufacturing and Design Integration (DFM/DFA) 制造和設(shè)計的早期結(jié)合（制造能力設(shè)計、裝配設(shè)計） Total Maintenance System/Total Productive Maintenance 全員維護體系/全員生產(chǎn)性維修 Continuous Improvement Process 持續(xù)改進流程,The diagram above shows how each time an improvement is implemented, it creates temporary instability. There will be a short period of instability until new standards are set, and applied. Only once the situation is truly stable, can new improvements be implemented.上面這張圖表顯示出每次改進之后，都會帶來暫時的穩(wěn)定。而后會有一段短時間的不穩(wěn)定，直到建立并應用新的標準。只有當情況真正穩(wěn)定了，新的標準才能實施。,改進,改進,改進,標準化,標準化,標準化,標準化,ANDON Board,SGM Line Balance Wall,Pilot Area ( Building Line Balance Wall ),Creform Assembly Aid,GMS In SGM 全球制造體系在上海通用汽車,My Understanding of GMS Experience Share Q&A,Thanks!,上海通用汽車的宗旨,依靠一支訓練有素、富有使命感和團隊精神的員工隊伍，貫徹精益管理原則，注重不斷學習和積極創(chuàng)新。安全地為顧客提供高質(zhì)量的產(chǎn)品和服務，使上海通用汽車成為面向二十一世紀，國內(nèi)領(lǐng)先、在國際上有競爭力的汽車公司”。,上海通用汽車的宗旨中包含愿景、使命與方法： 愿景：使上海通用汽車成為面向二十一世紀，國內(nèi)領(lǐng)先、在國際上有競爭力的汽車公司 使命：安全地為顧客提供高質(zhì)量的產(chǎn)品和服務 方法：依靠一支訓練有素、富有使命感和團隊精神的員工隊伍，貫徹精益管理原則，注重不斷學習和積極創(chuàng)新。,Shanghai General Motor’s Core Values 上海通用汽車的核心價值,以客戶為中心 Customer Focus 以滿足客戶需求的程度作為衡量工作成效的標準 We will measure our performance by determining whether it has met customers’ satisfaction 安全 Safety 充分關(guān)注人的安全和健康以及環(huán)境安全 We will pay full attention to people’s safety and health as well as the safety of environment 充分授權(quán)的團隊合作 Empowered Teamwork 創(chuàng)造良好氛圍，積極發(fā)揮員工與合作伙伴特點、 長處 We will promote an environment in which the unique qualities of each employee and partner can be employed to win. 誠信正直 Integrity 成為值得信賴的公司和員工 We will be a trustworthy organization and employee 持續(xù)改進與創(chuàng)新 Continuous Improvement & Innovation 更好、更快、更有效，更多運用新思維 We will do things better, faster, more effective and implement more new ideas,People Involvement Elements 1,Corporate Vision, Values, & Cultural Priorities Definition: The Corporation’s desired state as well as attitudes, mindsets, beliefs, and behaviors each of which is critical to the success of the organization. Purpose: To guide individual behavior and organizational decisions, creating a process and results focused culture. Mission Definition: A local statement that conveys a mental image of the goal or desired state for a specific plant or function. Purpose: To motivate/inspire people to act and help the entire workforce visualize, understand, and relate to the organization’s competitive goals and objectives.,People Involvement Elements 2,Health and Safety Priority Definition: Implementation of behaviors, actions, policies, and practices that help our employees realize a healthy, injury free environment. Purpose: To ensure we protect the well being of our people through actions consistent with the belief that safety is our overriding priority and all accidents are preventable. Qualified People Definition: People at all levels of the organization that possess the required profile and skills to perform, thrive, and grow within a competitive manufacturing environment. Purpose: To ensure the best possible fit of people’s abilities with the expectations of the competitive manufacturing roles and responsibilities.,People Involvement Elements 3,People Support System / Team Concept Definition: Small groups of employees that are empowered to function as the owners and basic work unit who share common tasks, support each other, and achieve common goals through continuous improvement. Purpose: To involve employees in the work process to continuously improve performance, product quality, and working conditions through teamwork. To develop employee pride, job satisfaction, and personal growth. People Involvement Definition: Systems, procedures, practices, and programs that involve all employees as active participants in continuous improvement activities. Purpose: Create and maintain an environment which fosters a “spirit of pride.“,People Involvement Elements 4,Open Communication Process Definition: Behaviors and practices that create an environment that fosters a free and open flow of communication at all levels. Purpose: To exchange information that helps people at all levels make informed decisions and improve organizational performance. Shop Floor Management Definition: The behavior of management and support groups to go to where the work is performed, to understand, support, and manage the operations. Purpose: To ensure that decisions are made at the work site by utilizing relevant, factual, accurate, and first-hand information.,