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Programul 20 de Chei este fundamentul
transformării locului de muncă
În mod holistic, el se concentrează asupra
elementelor unei asemenea transformări
Fiecare este implicat în instruirea vizând
concepţiile şi implementarea
Modul de abordare a transformării
locului de muncă
Implementarea Programului 20 de Chei este
susţinută de către Programul de instruire în domeniul
supravegherii echipelor de lucru implicate
Şefii de echipe (supraveghetorii) joacă un rol
important în transformarea eficientă a locului
de muncă
Tehnologii Clasă
Îmbunătăţiri noi mondial
la scara
Instruire
şi întregii
ă
Tradiţional conştient Organizaţii
Producător izare (Rezultate)
în masă)
Key: Intro
9/97 (No 11)
Sistemul de comparaţie/ Benchmarking
1 2 3 4 5
ThePunctulStarting Nivelul
iniţial World Class
Point mondial
Diagramele de comparaţie/ Benchmarking
Nivelul
4S in the 20 Keys programme is not
1 Sporirea productivităţii something imposed on you, but something
that helps you because these tools make
DiagramaCleaningnr. 1& Organising your job simple and easy. The first step
is to build company-wide common
Seiri (Sort and order), Seiton (keep pla e
in order), Seiso (Clean up), Selketsu
20 de Chei permit tuturor să conceapă
u derstanding and then to steadily climb
Adachi Architects Ateller President PDI implementation, you may also see
în comparaţie cu alte companii din lume
improvement in the other Keys. This is
Level ue to the linkage effect between all the
Nivelul 5 Keys, which in turn is an indication of
adequate spreading of 4S throughout the
2 workplace. 4S makes your work easier
prin evaluarea sub formă
Nivel Nivel
ul 3 ul 4
Fisă de 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4 Display boards No outdated, torn, or soiled announcements are displayed.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
7 Walkway maintenance 3 Nothing
and Direcţia
is placed on painted lines,
nothingextendsovrthem.Thelay
outofwalkways
marks are painted on safety risk areas. foreign objects in electrical switchboards, ashtrays or garbage cans.
viitoare Nothngispla cedonorextendsovr pain ted lines. Walkways are used as arteries of physic al dis tribution.
6 Items on the floor Work-;in-process and tools are not placed directly on the floor. Opera ors do n t h ve to bend over to load up materials on the cart to go to the next operation. Large
materials are place on pallets.
is satisfactory.
8 methods „ce
Walkways can be found at a glance and are aligned at right angles. The painted lines
să facem” şi „încotro să mergem”
The painted lines are not chipped or soiled. Operators are satisfied with the walkways in the current plant
marking the walkw ys re not chipping off and not soiled. lay ut.
9 Storage and stacking Items are stored nd sta ked prop rly in containers, and they are not placed directly on the Cardboard boxes and plastic containers are stacked prop rly, and there is no danger in using and transporting.
floor.
10 Cleaning of machines, The factory and equipment are painted. There are no places in the factory (less than 2 The factory and equipment (less than 2 meters) is painted with a specific colour. There is no chipping of paint.
meters on vertical surfac s) that are not pai ted.
devine clară pentru toţi
11 Structures & fixtures Machinery, platforms, carts, quipment a d walls are not soiled. Machines, shelves, locke s, walls and equipment are not dirty with dust, rust or grime.
12 Nothing leans against the walls, windows, pillars or quipment. Nothing lea s against the walls, windows, pillars or mach nes. 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.
5 Fully meets requirements
= 0 Needs improvement
=
Score 0 1-15 16-30 31-50 51-70 71-85 86-100 101-110
All items
20 Key Level 1 1,5 2 2,5 3 3,5 4 4,5 5
Referențialul/Benchmarking
Pentru a compara, a mobiliza şi a motiva oamenii,
se apelează la exemple reale
20 de Chei. Diagrama radar
1
5
20 2
19 4 3
18 3 4
17 2 5
1
16 0 6
15 7
14 8
13 9
12 10
11
3 Yr Ideal March-01
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)
6/13 (46.2)
Quick Changeover Technology 48 0 91 100 100 77 60 60.2 60 67 100 100 100
Kaizen of Operations
100 63 100 85 100 0 89.5 100 72 92 100 85 99
respective pentru a fi vizualizată 10/13 (76.9)
9/13 (69.2)
Zero Monitor Manufact/Prod 56 75.9 10 100 100 55.6 100 100 22 100 100 100 82
Coupled Manufacturing/Prod
81 50 100 100 100 100 100 100 100 100 100 40 100
pentru toţi 11/13 (84.6)
6/13 (46.2)
Maint Machines & Equipm. 37 93.5 78 50 83 50 63 100 97.5 43 100 100 66
Workplace Discipline 10/13 (76.9)
100 33 81 100 87 100 100 80 80 83 100 50 10
Quality Assurance 11/13 (84.6)
73 100 95 100 100 82.3 80 86 80 100 100 100 100
Developing your Suppliers 6/13 (46.2)
100 100 100 0 64 100 0 0 0 10 80 100 30
Eliminating Waste 10/13 (76.9)
100 0 93 93 23 100 64 100 100 86 100 100 100
Empowering Employees to make 11/13 (84.6)
100 45.5 97.9 100 100 93.9 100 100 100 100 100 100 67/7
Improvements
Skill Versatility and Cross 50 0 100 100 100 100 37.2 100 100 100 100 100 100
10/13 (76.9)
Training
Production Scheduling 100 79 95 100 100 89.7 65.8 65.5 69 67 98 73 74
6/13 (46.2)
Results
Red : 49%
Realizare
and below
între 50% şi 80% 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
(%)
Agenda
Necesitatea 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
3000 2921
2751
2700 2629
2448
2400 2225
2042
2100 1892
1780
1690
1800
1567
1500 1388
1202
1200 1027
900 820
689
600 439
300 224
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 Royce” şi “Pratt &
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 (mai Ieftin)
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
Rebutul s-a redus cu 80%
Societatea pe acţiuni (mai Bune)
„Moldagrotehnica” şi-a dublat Productivitatea s-a dublat
(mai Ieftin)
vânzările la fiecare 3 ani
E considerată ca una din cele
mai bune fabrici în „Lumea
Parmalat” (32 de ţări)
Beneficiile Programului 20 de Chei
Idea numărul 4271 la “Seiko”, Singapore
Conservarea materialelor şi implementarea ideii de
economisire a materialelor
Beneficiile Programului 20 de Chei
Aspectul practic
1. Orientaţi şi etalonaţi,
implicând toţi lucrătorii
20
2. Analizaţi
5 1 2
19 4 3
18 3 4
17 2 5
1 3. Planificaţi
16 6
15 7
14 8
13 9
12 10
11
4. Instruiţi şi
5. Analizaţi modul derulării implementaţi
cheile
prioritare
Reuşita implementării
Instruiţi şi antrenaţi primul nivel de conducători
(manageri)
Asiguraţi-vă că toate nivelele organizatorice îşi
înţeleg rolurile şi responsabilităţile
Agenda
Necesitatea 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
Resursele necesare
La o companie cu 500 de angajaţi este necesară o persoană
devotată şi respectată în calitate de Manager al
Proiectului (nivelul managerial)
Pentru alţi manageri şi supraveghetori 20 de Chei
trebuie să devină o parte a activităţii lor (acest lucru
nu este ceva separat de activitatea reală)
Timpul de instruire constituie circa 2%, iar timpul total al
unui angajat variază de la 1% până la 6%
Rolul supraveghetorului
Rolul supraveghetorilor
Cea mai
mare parte a
activităţii,
care în mod
direct aduce
valoare, este
efectuată aici
Supravegherea SuperEchipelor
Rolul supraveghetorilor – Vechea mentalitate
Selectarea şi instruirea “ad hoc”
Asigurarea procesului continuu de
producţie
Spaţiu larg pentru control
Responsabilitatea redusă pentru
angajaţi
Statutul redus al autorităţii
(remuneraţiei)
Sfârşitul carierei
Comunicare evitată
Persoană de legătură la negocieri
Supravegherea SuperEchipelor
Rolul supraveghetorilor
Manager al micului business
Şef de echipă
Instructorul echipei
Manager resurse umane
Creator de relaţii la locul de muncă
Comunicator eficient
Agenda
Necesitatea 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
Investiţii
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
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