A identifica şi elimin
elimina toate formele de pierderi
(activităţi ce nu adaugă valoare) pentru a îmbunătăţi
satisfacţia clienţilor, făcând produsele şi serviciile mai
bune, mai rapide, mai ieftine
Tehnologii
Clasă
Îmbunătăţiri noi mondial
Instruire
şi
la scara
întregii
ă
Tradiţional
conştient Organizaţii
Producător izare (Rezultate)
în masă)
Key: Intro
9/97 (No 11)
Sistemul de comparaţie/
comparaţie/ Benchmarking
1 2 3 4 5
The Starting
Punctul Nivelul
World Class
Point
iniţial mondial
Diagramele de comparaţie/
comparaţie/ Benchmarking
Nivelul
4S in the 20 Keys programme is not
1 Sporirea productivităţii something imposed on you, but something
Cleaning
Diagrama nr. 1& Organising that helps you because these tools make
your job simple and easy. The first step
is to build company-wide common
20 de Chei permit
in order), tuturor
Seiso (Clean să conceapă
Seiri (Sort and order), Seiton (keep place
up), Selketsu
understanding and then to steadily climb
from level 1 to level 5. 4S is the basis of
productivity improvement as it links with
(Maintain cleanliness).
nivelul
• 4 S toactual al job
companiei,
the other Keys included in the
make your
Illustrated by
easier! •
Iwao Kobayashi,
programme. During the course of its
implementation, you may also see
Adachi Architects Ateller President PDI improvement in the other Keys. This is
Nivelul
2
în comparaţie cu alte companii din lume
Level
5
due to the linkage effect between all the
Keys, which in turn is an indication of
adequate spreading of 4S throughout the
workplace. 4S makes your work easier
Nivel Nivel
ul 3 ul 4
Fisă de evaluare:
evaluare: Cheia 1 – Curăţenia şi organizarea
No. Category Level Evaluation Criteria Judgement Calls /
1 Putting away 2 No unneeded items lying around. There are no cigarette butts, pieces of scrap paper, tools, files, machines, materials and parts that are not used
unneeded items for months or years.
2 Floor cleaning Cleaning equipment is stored neatly / everything has its place. Cleaning tools are stored near the shop floor. Brooms are hung properly so that the edges are not touching
the floor.
3 There is no garbage, dirt or paper on the floor. There is no danger of slipping and no trash in The floor is clean of iron scraps, water and oil so that the operators do not have to walk in the dirty areas.
floorwells. There is no danger of slipping.
4 Display boards No outdated, torn, or soiled announcements are displayed. Papers are straight and neat. There are no outdated, torn or soiled announcements on the display board. All announcements are clearly
There are no torn corners or tape marks left over from old displays. displayed.
5 Emergency access Nothing is obstructing the access to fire extinguishers and water hoses. Nothing is in front of Nothing obstructs access to fire extinguishers, water hoses, emergency exits, walkways and crossings. Fire
emergency exits or corridors. Location and use of switches and breakers are posted. Zebra extinguishers can be seen from 20 metres away. Use of switches and breakers are indicated. There are no
marks are painted on safety risk areas. foreign objects in electrical switchboards, ashtrays or garbage cans.
Direcţia viitoare
6 Items on the floor Work-;in-process and tools are not placed directly on the floor. Operators do not have to bend over to load up materials on the cart to go to the next operation. Large
materials are place on pallets.
7 Walkway maintenance 3 Nothing is placed on painted lines, and nothing extends over them. The layout of walkways Nothing is placed on or extends over painted lines. Walkways are used as arteries of physical distribution.
is satisfactory.
8 Walkways can be found at a glance and are aligned at right angles. The painted lines The painted lines are not chipped or soiled. Operators are satisfied with the walkways in the current plant
10
methods
„ce să facem” şi „încotro să mergem”
Storage and stacking
Cleaning of machines,
marking the walkways are not chipping off and not soiled.
Items are stored and stacked properly in containers, and they are not placed directly on the
floor.
The factory and equipment are painted. There are no places in the factory (less than 2
layout.
Cardboard boxes and plastic containers are stacked properly, and there is no danger in using and transporting.
The factory and equipment (less than 2 meters) is painted with a specific colour. There is no chipping of paint.
meters on vertical surfaces) that are not painted.
11
12
Structures & fixtures
devine clară pentru toţi
Machinery, platforms, carts, equipment and walls are not soiled.
Nothing leans against the walls, windows, pillars or equipment.
Machines, shelves, lockers, walls and equipment are not dirty with dust, rust or grime.
Nothing leans against the walls, windows, pillars or machines. Nothing is placed on and under the shelves and
lockers.
13 Perimeter area The department controls and cleans the area on the inside of the factory, fence for which it is The department cleans a one meter area outside of the assigned areas. Gutters around machines and the
cleanliness responsible. factory buildings and toilets are also clean.
14 Maintenance of work- Desks, carts and pallets are parked/laid straight. Empty and loaded carts and pallets are parked properly in the appointed areas.
in-process
15 4 Storage places are clearly indicated with sign panels. Inter-process coupling points (stores) are conveniently set up for customers (inventories are organised, stored
parallel and labelled clearly).
16 Arrangement of tools Storage places of tools are clearly indicated with sign panels. Tools are placed on panels near the machines and equipment for ease of use in placement and retrieval.
17 Necessary tools and jigs are placed in each shopfloor area. Necessary tools and jigs are conveniently arranged.
18 Organising desks and All shelves and desks are partitioned and labelled so that it is clear where items are and Tools, parts, gauges and papers are clearly organised in drawers according to their functions. All desks, work
shelves where things should be returned to. stations and stands comply with the requirements of model desks.
19 All shelves and desks are organised according to these partitions and labels. All shelves and desks are clearly labelled so that stored things can be found easily.
20 There are no unused files or documents on top of the desks or working surfaces. Top of the desks and working surfaces are clean from previous day’s work.
21 Eliminating causes of 5 Causes of dirt and disorder are eliminated. Special carts to hold work-in-process are utilised. Causes of dirt and disorder are eliminated. Special carts to hold work-in-process are utilised. All employees
dirt and disorder Each employee can do 4S by him/herself. do 4S by him/herself automatically.
22 Marking stock levels Quantities are marked clearly like a supermarket. Parts are systematically stored and there is an ordering process whereby parts are automatically ordered when
clearly necessary.
23 Establishing disciplines Earning over 100 points on the Key 1 checksheet even during surprise inspections. It is possible to earn over 100 points on the checksheet even during surprise inspections.
19 4 3
18 3 4
2
17 5
1
16 0 6
15 7
14 8
13 9
12 10
11
3 Yr Ideal March-01
G
r
o
u
p
A B C D E F G H I J K L
P
e
r
s
o
n
Cleaning and Organising 100 45.5 97.9 100 100 93.9 100 100 100 100 100 100 67/7 11/13 (84.6)
Rationalising the System 50 0 100 100 100 100 37.2 100 100 100 100 100 100 10/13 (76.9)
Small Group Activities 100 79 95 100 100 89.7 65.8 65.5 69 67 98 73 74 6/13 (46.2)
Reducing Work-in-Process
Quick Changeover Technology 48 0 91 100 100 77 60 60.2 60 67 100 100 100 6/13 (46.2)
Kaizen of Operations
Zero Monitor Manufact/Prod 56 75.9 10 100 100 55.6 100 100 22 100 100 100 82 9/13 (69.2)
Coupled Manufacturing/Prod
pentru toţi
81 50 100 100 100 100 100 100 100 100 100 40 100 11/13 (84.6)
Maint Machines & Equipm. 37 93.5 78 50 83 50 63 100 97.5 43 100 100 66 6/13 (46.2)
Quality Assurance 73 100 95 100 100 82.3 80 86 80 100 100 100 100 11/13 (84.6)
Developing your Suppliers 100 100 100 0 64 100 0 0 0 10 80 100 30 6/13 (46.2)
Eliminating Waste 100 0 93 93 23 100 64 100 100 86 100 100 100 10/13 (76.9)
Improvements
Training
Production Scheduling 100 79 95 100 100 89.7 65.8 65.5 69 67 98 73 74 6/13 (46.2)
Efficiency Control 100 60 100 33 100 5.4 100 67.4 0 33 100 85 39 6/13 (46.2)
Using Information Systems 48 0 91 100 100 77 60 60.2 60 67 100 100 100 6/13 (46.2)
Conserving Energy and Materials 100 63 100 85 100 0 89.5 100 72 92 100 85 99 10/13 (76.9)
Leading Technology/Site Techn. 56 75.9 10 100 100 55.6 100 100 22 100 100 100 82 9/13 (69.2)
5 9 1 1 1 6 6 6 6 4 0 3 5 53
Results
Red
Realizare între 50% şi 80%
: 49% and below 3 8 2 3 1 3 3 1 5 4 0 1 4 38
Rate of Green by Group 12/20 3/20 17/20 16/20 18/20 11/20 11/20 13/20 9/20 12/20 20/20 16/20 11/20 169/260
60 15.0 85.0 80.0 90.0 55.0 55.0 65.0 45.0 60.0 100 80.0 55.0 65
(%)
Realizare sub 50%
Agenda
Necesitatea afacerii
afacerii
Modul de abordare a transformării locului de
muncă şi scopul creării Programului 20 de Chei
Programul 20 de Chei
Beneficiile Programului 20 de Chei
Implementarea
Resursele necesare
Supravegherea echipelor implicate
Investiţiile preconizate
Concluzii
Beneficiile Programului 20 de Chei
3300
3041
2921
3000
2751
2629
2700
2448
2400 2225
2042
2100 1892
1780
1800
1690
1567
1500
1388
1202
1200 1027
820
900 689
600 439
224
300
0 25 60
0
Beneficiile Programului 20 de Chei
eldim 2
Rezultatele obţinute pe
parcursul a 3,5 ani,
implementând 20 de Chei
(producător de piese
pentru motoarele reactive,
Olanda)
Apreciat ca cel mai bun furnizor pentru “Rolls Royc
Royce” şi “Pratt &
Whitney””
Whitney
Lichidarea defectelor la un milion de piese, de la 5800 până la 1050
(înainte de corectarea rebutului) – 82%
Reducerea timpului total de la 6 săptămâni la mai puţin de o săptămână
(+80%)
A sporit semnificativ productivitatea şi a redus cheltuielile (m
(mai Ieftin
eftin))
Beneficiile Programului 20 de Chei
Înlesnirea procesului de lucru prin curăţenie şi organizare
Beneficiile Programului 20 de Chei
Amplasarea orientată spre mişcarea utilajului
eldim 2
Beneficiile Programului 20 de Chei
Schimbare momentană a
eldim 2
tehnologiei < 120 sec.
Beneficiile Programului 20 de Chei
Aspectul practic
1. Orientaţi şi etalonaţi,
implicând toţi lucrătorii 2. Analizaţi
1
20 2
5
19 3
4
18 4
3
2
17 5
3. Planificaţi
1
16 6
15 7
14 8
13 9
12 10
11
4. Instruiţi şi
5. Analizaţi modul derulării implementaţi cheile
prioritare
Reuşita implementării
Rolul supraveghetorului
Rolul supraveghetorilor
Rolul supraveghetorilor
Date de contact:
Str. Mateevici 75, Chişinău, R. Moldova
Tel. + 373 22 850620, Fax: + 373 22 85 0621
E-mail: info@proera.md Site: www.proera.md
Agenda
Necesitatea afacerii
afacerii
Modul de abordare a transformării locului de
muncă şi scopul creării Programului 20 de Chei
Programul 20 de Chei
Beneficiile Programului 20 de Chei
Implementarea
Resursele necesare
Supravegherea echipelor implicate
Investiţiile preconizate
Concluzii
Concluzii