production management.pdf

7/25/2019 Production Management.pdf

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1.1) ( SEIRI )

1. 2.

( )

3.

7-1

2

2 /

( -/-)

1.2) (Seiton)


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PPrroodduuccttiioonnMMaannaaggeemmeenntt

7 - 3

(visual control)

7-2

1.3) (Seiso) ( ) 5


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1.3.1) (Cleaning is Inspection)

5 (Ownership)

1.3.2) 3

1. 1. 2.

1. (Daily cleanliness)

2. (Cleanliness Inspection)

: :

:

:

:

3. (Cleanliness Maintenance)


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1. 2.

3.

5 5

5

5 5 5 5

(Big Cleaning Day) 4. 5 5

5.

6. 5 (Big Cleaning)

commitment

1.3.3) 1.

2. 360

3.

4.

/

5.


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1.4) (SEIKETSU)5 3

3

3

5

1. 2. 3. 4. 5. 6. 7. 8. 9.

10.

3 3

3


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1.4.1) 1. 1 ,

1 2.

3

3. 5

1.5) (Shitsuke) 5

1.5.1)

1.

2.

3.

5 4. 5.


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7-1 5.

5

55

Big Cleaning Day

5

- Visual Control

- Suggestion Scheme

- Internal Communication

5

5


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(2) (Just In Time : JIT)Just In Time () Toyota Motor

Corporation

(Wastes) (Non Value-AddedActivity) (Kaizen)

2.1) 7 (7 Wastes) 1. (Overproduction)

2. (Unnecessary Stock)

3. / (Transportation)

4. (Non effective Process)

Work inprocessqueues(banks)

Changeorders

Engineering designredundancie

s

Vendordelinquencies

Scrap

Designbacklog

s

Machinedowntime

Decisio

nbacklog

s

Inspectionbacklog

s

Paperworkbacklog

identify defects from a supplier

early in the process saves the

downstream work

identify defective work from

upstream stations, saves the

downstream work


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5. (Motion)//

6.

/ (Waiting / Idle / Delay) 7. (Defects / Rework)

7 JIT

3 Mu Muda , Mura , MuriMuda Mura ( )Muri

7-3

JIT

- Pull System

- Leveled Production

- Continuous-Flow

- Takt Time

Autonomation

Quality Build in Process

- Visual Control

- Poka-Yoke

- ANDON

Standardize work

KAIZEN

JIT Pull System ()

Leveled Production (/Heijunka) (Production Volume) (Production Sequence)


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Continuous-Flow Processing () Stock

(Inventory)

Takt Time ()

(Takt Time) =

Autonomation (/Jidoka)

Visual Control ()

Poka Yoke ()

ANDON

(Standardize Work)

Kaizen


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3) ( Total Productive Maintenance : TPM ) ( Total Productive Maintenance : TPM )

( Zero Failure ) ( Zero Defect ) ( Zero Accident )

3.1)

3.1.1)(Breakdown Maintenance; BM)

3.1.2) (Preventive Maintenance, PM)


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2 (Time Based Maintenance; TBM)

(Condition Based Maintenance; CBM)

3.1.3)(Corrective Maintenance, CM)

(Reliability)

(Maintainability)

3.1.4)(Maintenance Prevention, MP)

3.1.5)(Productive Maintenance) (Breakdown Maintenance)

(Preventive Maintenance) (Corrective Maintenance) (Maintenance Prevention)


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3.1.6) ( Total Productive Maintenance : TPM )

TPM 5 1. 2. 3. 4. 5. TPM

TPM

( Zero Accident )

( Zero Defect )

( Zero Failure ) TPM

TPM

3.2)TPMTPM TPM

TPM ( Overlapping Small Group )

( Two Ways Communication )


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7-2

TPM

3.3) (

)

3.3.1)16 (16 Major Losses) TPM

16 3 1 2

(Shutdown Losses)

(Production Adjustment Losses)2 6

(Breakdown Losses)

(Set up and Adjustment Losses)

(Minor Stoppage and Speed Losses)

TPM


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(Speed Losses)

(Defect) (Reprocesing)

3

5

(Management Losses)

(Motion Losses)

(Arrangement Losses)

(Losses resulting off automated systems)

(Monitoring and Adjustment losses)

4 3

(Yield Losses)

(Energy Losses) (Jig and Figure Losses)

3.3.2 )6 (6 Big Losses) 6

2 16 TPM

(OEE)

6

1. (Breakdown Losses)2. (Setup and Adjustment Losses)

3.

(Minor Stoppages and Speed Losses)4. (Speed Losses)5. (Defects and Rework)6. (Startup Losses)

1 2 (Availability)3 4 (Performance Rate) 5 6 (Quality Rate)

6 OEE


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1. (Breakdown Losses) 6

(Availability)

2

5-10 / 5

2. / / (Set up and Adjustment Losses) 6 (Availability)

A B A B

A B

A B

B


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3. (Minor Stoppagess and IdlingLosses) 6 (Performance Rate)

/

4. (Speed Losses) 6 (Performance

Rate)

1 1

120 60 0.5 / (60/120 /) 120 90 () 0.75 / (90/120 /) 0.25 /

2 / (120/60 /) 1.33 (120/90 /)


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5. (Defect and Rework Losses) 2 6

( )

(Quality Rate)

6. (Start Up Losses) 6

6 (Reprocessing Losses Rework Losses)

Recycle

3.3.3) (Overall Equipment Effectiveness,OEE) TPM

(Individual Improvement) OEE 6

(OEE) 3 1. (Availability)2. (Performance Rate)


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3. (Quality Rate)3 OEE

= X X X 100

(Availability)

= (+ ) x 100

= X 100

40 40 5 10 = (40 - (5+10)) x 100 / 40 = 25 X 100 /40 = 0.625 x 100 = 62.5%(World Class) 90%

(Performance Rate)

= (++) x 100

= X 100

= X

= (Standard Cycle Time)

(Actual Cycle Time)


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= X 25 1500 1

1.2 25 1,240

= (Standard Cycle Time)(Actual Cycle Time)

= 1.0 / = 0.8331.2 /

= X

= 1240 X 1.2 / = 1,488

= X = 0.833 X 1488 = 1239.5

= X 100

= 1239.5 X 100 = 82.63 %1500

(World Class) 95%

(Quality Rate)= (+ ) x 100

= X 100

1,240 40 200 = (1240 - (40+200)) x 100 / 1240 = 1000 X 100 / 1240 = 0.8064x100 = 80.64%

(World Class)

99%


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3 OEE

= X

X X 100= 0.625 X 0.8263 X 0.8064 X 100OEE. = 41.64 %

( Overall Plant Effectiveness: OPE)

(World Class) 85%

3.3.4)(Equipment Operating Rate,EOR) TPM

1 16 2

(Shutdown Losses)

(Production Adjustment Losses)

= (+) X 100

= X 100

48 ( 6 8 ) 48 1 2

48

6 2


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= 48 (6+2) = 40 (EOR) = 40 X 100 /48 = 83.33%

100%

6

OEE EOR OEE EOR

3.3.5) 5 (The Five Breakdown Measure)

1. ()

Nut Bolt

2.

( , , ) ( , , ) ( , , )

3. 1 2 ( )

4. 1 3

5.


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3. TPM ( TPM Implementation ) TPM

2

3

TPM 8

7-4 8

1. ( Individual Improvement )

2.

( Self Maintenance )

3. ( Planned Maintenance )

4. ( Education and Training )

5.

( Initial Phase Management )

6. ( Quality Maintenance )

7. ( Indirect Section Activity )

8. ( Safety and Environment Management )

:


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TPM 12 3 ( Preparation Step ) ( Implementation Step ) ( Stabilization Step )

7-5 12 TPM

4.

TPM

TPM

2. TPM TPM 3.

TPM4.

TPM5. TPM

6. TPM TPM

5.

7.1 7.2 7.3 7.4

7 6

8.

9. 10 10.

11.

12. TPM

PM Prize


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1. TPMTPM TPM

2.

TPM

TPM TPM

3.

TPM ( Overlapping Small Group )

TPM TPM TPM

TPM TPM

TPM

4. TPM


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TPM

2 % 1 % 1/10 85 %

5. TPMTPM

TPM TPM( PM Prize JIPM : Japan Institute of Plant Maintenance TPM

WWW.Jipm.Com ) TPM TPM TPM TPM8 TPM

6. TPM TPM

TPM

TPM TPM

7. ( 1-6 )

4


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(Individual Improvement)Focus Improvement Kobutsu Kaizen

1

16 PDCA 4-6

( Self Maintenance : SM )

TPM

TPM

7 1. ( Initial Cleaning )2. ( Eliminate Source of Contamination and

Difficult to Access Area )

3. ( Draw up Provisional Standard )4. ( General Inspection )5. ( Autonomous Inspection )

6. ( Standardize Procedure and WorkplaceSuits )

7. ( Continuous Improvement )

(Planned Maintenance)


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1.

2.

1-3

3.

4.

5.

6.

(Education and Training)

TPM On the job training

Operator 4

Bolt Nut

(Bearing) ( )


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8. ( Initial Phase Management )

/

( Life Cycle Cost : LCC ) ( Maintenance Prevention Design : MP Design )

LCC

9. ( Quality Maintenance )

( Quality Assurance ) (Equipment Management )

/ ( Defect-free Equipment ) /

/

/


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10. TPM ( TPM Activities of Administration and Support Department)

TPM

TPM TPM

/

TPM 5

1. (Individual Improvement)2. (Self Maintenance)3. (Education and Training)4. (Flexible Staffing)5. (Performance Measurement)

11. (Safety and Environment Management)

TPM TPM TPM

5


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12. ( Sustaining TPM Implementation and Raising Levels )

TPM

PMAward

3.5) ( Measuring TPM Effectiveness )

TPM 4. TPM ( 12 ) TPM ( TPM Basic Policy ) -

TPM TPM

3 6 TPM


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7-6

( Labor Productivity ) / ( Overall Plant Effectiveness )

* *

( Overall Equipment Effectiveness )

* *

/ /

*

/ ( MTBF ) / ( MTTR ) / M/C

( Quality )

/ /

( Cost )


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( Delivery )

( Safety ) /

( Morale )


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4) (Quality Control Circle:QCC)

4.1) Quality Control Circle (QCC)

QCC QCC QCC

4.2) QCC1 2

3 4 5 6 7 8

4.3) QCC1

QCC QCC

2

3

4

5

6

7


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4.4) QCC QCC

7-3QCC

:

: 1. , , QCC

2.QCC QCC

4.5)QCC

4.5.1) QCC QCC QCC

4.5.2) QCC

QCC

QCC

QCC

QCC

1

2

QCC 1

QCC 2

QCC 3

QCC 4


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/4.5.3) QCC

QCC

QCC / QCC , QCC QCC , QCC ,

, QCC

4.5.4) QCC

QCC

/QCC4.5.5) QCC

QCC

4.6) QCC 4.6.1)QCC

4.6.2)

QCC QCC / ( )


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QC

/

QCC QCC


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4.7) QCC

: 1 QCC 3-7 2.QCC

2.1 /2.2 2.3

QCC

QCC

&


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4.8) QCC

4.8.1) (Creative Thinking)

1. 2. 3. 4. 5.

6. 7.

8. 9.

1.

2. 3. 4. 5. 6.

4.8.2) (Brain Storming)

1. 2. 3. 4.


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1.

2. ( )3.

4. 5. 6. 7.

4.8.3)

(Team Working)Trust Endurance Accountability Management Willingness Orientation Respect Knowledge Intelligence Nuturance Generousity

1. 2. 3. 4. 5.

6. 7.

8.


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9. 10.

1. 2. 3. 5.

4.8.4) 1. 2.

3. 4. 5. 6. 7. 8.

1. 2. 3. 4. 5.

6.

7. 8. 9.

1. 2. 3.


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4. 5.

6. 7.

8.

1. (Leader)

2. (Trainer)

3.

(Coach)

4. (Consultant)

1. 2. 3.

4. 5.

1. 2.

3.

4. 5. 6. 7. 8. 9.

10.


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4.8.5)

1. 2. 3. 4. 5. 6. 7. 8.

1. 2. 5 W I H

* WHAT - * WHO - * WHERE - * WHY - * WHEN - * HOW -

1.

2.

3. 4. 5.

1.

2.

3.


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4. 5.

1. 2. 3. 4. 5.

1.

2. 3. 4. 5. 6.

7.

8. 9. 10.

1.

2.

3. 4. 5.

6. 7. 8.


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1. 2.

3.

4. 5. 1 6. 7.

4.8.6)

-

15 -

* Overhead Projector* Operate * * *

* *

4.9. QCC4.9.1)

QCC QCC

4.9.2) QCC QCC , QCC


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QCC QCC QCC

4.9.3) QCC

QCC , QCC QCC QCC QCC

QCC 10 QCC QCC 3

, - QCC QCC QCC

4.9.4) QCC QCC /

4.9.5) QCC

/ QCC QCC


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5) 7 (7 QC Tools)

5 1. 2. 3. 4. 5.

5.1) (Cause & Effect Diagram) ( ) ( )

4-8

5.1.1)


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5.2)

5.2.1) (Monitoring)

5.2.2)

......:

: 1525

...........

.

........

Check Sheet

42

62

17

11

26

3

5

7-4


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5.3) . 1897

80% 20% .

7-5

5.3.1)

X Y

5.3.2)


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5.4) (Graph)

5.4.1)

5.4.2)

Shipments of hazardous waste

7-6


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7-7

7-8


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100%

7-9

100 %

7-10


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5.5) (Scatter Diagram)

XX

Y X

7-11

5.5.1) 2 ( ) ( )

2

5.5.2) - - (x , y) (n = ?)

5.5.3) ( r) X Y

r = xy-nXY

( (x2- nX2) (y2- nY2)

X = X/n

Y = Y/n

r -1 1 r = 1 + r = -1 -

x

y


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r 0 r

5.5.4)

7-12

(Positive Correlation) X Y (Negative Correlation) X Y

(Non-Correlation) X Y

r =

1

r =

0.6

r =

-1

r =

0

r = -

0.8

r =

0.8


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5.6) (Variation)

7-13

5.6.1)

(Variable data)

5.6.3) 2


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7-14

(Bell-Shaped Distribution)

(Double Peaked Distribution)

2 2 2 (Specification) 2

(Plateau Distribution) (Mode)

(Comb Distribution)

(Skewed Distribution) (Mode)

(Truncated Distribution)

(Isolated-Peak Distribution)


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5.7) (Control Chart) (monitor)

(Common Cause Variation)

(Special Cause Variation) (Control Limits) (Trend) (Cycle)

5.7.1) (control limits)

(monitor)

(Stability) (process capability) Specification

5.7.2) pH

- ( X - R chart)

25 4 5 ( X ) (R) ( X ) ( R ) 3

(CL X ) = X (UCL X ) = X + Az R


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(LCL X ) = X - A z R

(CL ) = R

(UCL ) = D4 R

(LCL ) = D3R

A2 D

3D

4(n) 3-7

Observations

in

Sample, n A A2 A3 c4 1/c4 B3 B4 B5 B6 d2 1/d2 d3 D1 D2 D3 D4

2 2.121 1.880 2.659 0. 7979 1. 2533 0 3.267 0 2.606 1.128 0. 8865 0.853 0 3.686 0 3.267

3 1.732 1.023 1.954 0. 8862 1. 1284 0 2.568 0 2.276 1.693 0. 5907 0.888 0 4.358 0 2.574

4 1.500 0.729 1.628 0. 9213 1. 0854 0 2.266 0 2.088 2.059 0. 4857 0.880 0 4.698 0 2.282

5 1.342 0.577 1.427 0. 9400 1. 0638 0 2.089 0 1.964 2.326 0. 4299 0.864 0 4.918 0 2.114

6 1.225 0.483 1 .287 0. 9515 1. 0510 0.030 1 .970 0.029 1.874 2.534 0. 3946 0.848 0 5.078 0 2.004

7 1 .134 0 .419 1 .182 0. 9594 1. 0423 0 .118 1 .882 0 .113 1 .806 2 .704 0. 3698 0 .833 0 .204 5 .204 0 .076 1 .924

8 1 .061 0 .373 1 .099 0. 9650 1. 0363 0 .185 1 .815 0 .179 1 .751 2 .847 0. 3512 0 .820 0 .388 5 .306 0 .136 1 .864

9 1 .000 0 .337 1 .032 0. 9693 1. 0317 0 .239 1 .761 0 .232 1 .707 2 .970 0. 3367 0 .808 0 .547 5 .393 0 .184 1 .816

10 0 .949 0 .308 0 .975 0. 9727 1. 0281 0 .284 1 .716 0 .276 1 .669 3 .078 0. 3249 0 .797 0 .687 5 .469 0 .223 1 .777

11 0 .905 0 .285 0 .927 0. 9754 1. 0252 0 .321 1 .679 0 .313 1 .637 3 .173 0. 3152 0 .787 0 .811 5 .535 0 .256 1 .744

12 0 .866 0 .266 0 .886 0. 9776 1. 0229 0 .354 1 .646 0 .346 1 .610 3 .258 0. 3069 0 .778 0 .922 5 .594 0 .283 1 .717

13 0 .832 0 .249 0.85 0. 9794 1 .021 0 .382 1 .618 0 .374 1 .585 3 .336 0. 2998 0 .770 1 .025 5 .647 0 .307 1 .693

14 0 .802 0 .235 0 .817 0. 9810 1. 0194 0 .406 1 .594 0 .399 1 .563 3 .407 0. 2935 0 .763 1 .118 5 .696 0 .328 1 .672

15 0 .775 0 .223 0 .789 0. 9823 1. 0180 0 .428 1 .572 0 .421 1 .544 3 .472 0. 2880 0 .756 1 .203 5 .741 0 .347 1 .653

16 0 .750 0 .212 0 .763 0. 9835 1. 0168 0 .448 1 .552 0 .440 1 .526 3 .532 0. 2831 0 .750 1 .282 5 .782 0 .363 1 .637

17 0 .728 0 .203 0 .739 0. 9845 1. 0157 0 .466 1 .534 0 .458 1 .511 3 .588 0. 2787 0 .744 1 .356 5 .820 0 .378 1 .622

18 0 .707 0 .194 0 .718 0. 9854 1. 0148 0 .482 1 .518 0 .475 1 .496 3 .640 0. 2747 0 .739 1 .424 5 .856 0 .391 1 .608

19 0 .688 0 .187 0 .698 0. 9862 1. 0140 0 .497 1 .503 0 .490 1 .483 3 .689 0. 2711 0 .734 1 .487 5 .891 0 .403 1 .597

20 0 .671 0 .180 0 .680 0. 9869 1. 0133 0 .510 1. 49 0 .504 1 .470 3 .735 0. 2677 0 .729 1 .549 5 .921 0 .415 1 .585

21 0 .655 0 .173 0 .663 0. 9876 1. 0126 0 .523 1 .477 0 .516 1 .459 3 .778 0. 2647 0 .724 1 .605 5 .951 0 .425 1 .575

22 0.64 0 .167 0 .647 0. 9882 1. 0119 0 .534 1 .466 0 .528 1 .448 3 .819 0. 2618 0 .720 1 .659 5 .979 0 .434 1 .566

23 0 .626 0 .162 0 .633 0. 9887 1. 0114 0 .545 1 .455 0 .539 1 .438 3 .858 0. 2592 0 .716 1 .710 6 .006 0 .443 1 .557

24 0 .612 0 .157 0 .619 0. 9892 1. 0109 0 .555 1 .445 0 .549 1 .429 3 .895 0. 2567 0 .712 1 .759 6 .031 0 .451 1 .548

25 0 .600 0.153. 0 .606 0. 9896 1. 0105 0 .565 1 .435 0 .559 1 .420 3 .931 0. 2544 0 .708 1 .806 6 .056 0 .459 1 .541

S Charts

Factors for Control Limits

R Charts

Factors forFactors for Factors for

Central Line

Charts

Control Limits Central Line Factors For Control Limits

X

7-7

R

R

R


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x

105Subg roup 0

70

65

60

Sample

Mean

Mean= 65.36

UCL= 70. 12

LCL= 60. 59

20

10

0SampleRange

R= 8.267

UCL= 17. 48

LCL=0

Xbar/R Chart for Heights

7-15

- (Individual and Moving Range : X R I MR Chart) 1

1

2

(CL X ) = X

(UCL X ) = +

(LCL X ) = -

(CL ) = R (UCL

) = D

4R

(LCL ) = D3 R

2

3

d

R

2

3

d

Rx

R

R

R


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605040302010Subgr oup 0

80

70

60

50

Individua

lValue

Mean=65.36

UCL= 76. 98

LCL= 53. 74

15

10

5

0MovingRange

R= 4.369

UCL= 14. 28

LCL=0

I and MR Chart for Heights

7-15

- ( X - S Chart ) X -R

10 2

S = =

n =

x =

= (CL X ) =

(UCL X ) = + A 3S

(LCL X ) = - A 3S

(CL S ) = S

(UCL S ) = B 4 S

(LCL S ) = B 3 S

B 3-7

1

)(1

2

=

n

xxn

i

i

1

1

22

=

n

xnxn

i

i

x


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105Subgroup 0

70

65

60

SampleMean

Mean= 65.36

UCL= 70. 22

LCL= 60. 49

8

7

6

5

43

2

10

Sa

mpleStDev

S= 3.409

UCL= 7.122

LCL=0

Xbar/S Chart for Heights

7-16

- R ( S)

R - X ( X)

X ( X I)

: X ( X I) R(S) R ( S)


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(Cycles)

0

5

10

15

20

25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

7-16

(Trends)

0

5

10

15

20

25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

7-17

(Gradual Changes in Level) (Steady State)

UCL

LCL

CL

UCL

LCL

CL


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0

5

10

15

20

25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

7-18 (Mixtures)

0

5

10

15

20

25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

7-19

Stratification Stratification

UCL

LCL

CL

UCL

LCL

CL


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0

5

10

15

20

25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

7-20 Stratification

(Overadjustment)

0

5

10

15

20

25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

7-21

- (Fraction nonconforming , p Chart)

1

UCL

LCL

CL

UCL

LCL

CL


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Ford (1985) n p 5 (n) 50 ( n ) n 25% n 25%

p

25 (p) ( p )

(CLp) = p

(UCLp) = p

+ 3

(LCLp) = p - 3

7-22

nPP /)1(

nPP /)1(


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- (Number Nonconforming , np chart)np

np 25 (np) (n p )

(CL np) = n p

(UCL np) = n p + 3

(LCL np) = n p - 3

3020100

10

5

0

Sample Number

SampleCount

NP Chart for NonConf

NP=5.533

UCL=12.34

LCL=0

7-23

- (Nonconformities per unit , u chart)

(CL u) = u

(UCL u) = + 3 nu

(LCL u) = - 3 nu

)1( Ppn

)1( Ppn

u

u

u


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7 - 69

7-24

- (Number of Nonconformities , c chart)

(CL c) = c

(UCL c) = c + 3 c

(LCL c) = c

- 3 c

c


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7 - 70

20100

8

7

6

5

4

3

2

1

0

Sample Number

SampleCount

C Chart for RegLtn

C=2.636

UCL=7.507

LCL=0

7-25


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7 - 71

7-8

I-MR

(X-R)

1

-R ( 10)

,

(Quantitative

Data, Variable

Data) -S

( 10 )

1.2.

1.Specification2.

p

np

u

,

(Qualitative

Data,

Attribute

Data) c

1.2.

3.

1.2.

x

x


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7 - 72

7

1. 5 5

2.5

3. (Just In Time JIT) JIT

JIT

- Pull System

- Leveled Production

- Continuous-Flow

-

Tact Time

Autonomation

Quality Build in Process

- Visual Control

- Poka-Yoke

- ANDON

Standardize work

KAIZEN


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4. - 10

- 5

-

5 - 20 - 30 - 10

0.5 /

- 600

-

20 40 OEE 8 OEE

( , ) ( 6 Big Losses )

5. ( Self Maintenance ) ?

6. ( RX Chart)

production management.pdf

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