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未來計劃 Future Plan
自主研 Jishuken NPS 台新企管
改 善 基 本 技 巧
Kaizen Basic Rules . 掌握 NPS 新生產技術三原則 Follow 3 Articles of NPS (1) 一個流程 One Piece Fiow (2) 依據產距時間生產 Work To TT (3) 後拉式生產 Pull production . 三無思想 3-Mu Philosophy (1) 無馱Muda (2) 無理 Muri (3) 無穩 Mura . 改善動作之步驟 Steps of Kaizen (1) 要決定 TT Determine TT (2) 先做作業合理化，消除無馱 Rationalize opration to eliminate Muda (3) 將每一作業員的工作時間安排等於 TT，消除無理 Assign wworks of TT to each operator to eliminate Muri (4) 建立穩定的作業環境，消除無穩 Stablize operation to eliminate Mura
自主研 Jishuken NPS 台新企管 步驟 Step 名 稱 Dbscription
改 善 八 大 步 驟 Kaizen 8 Steps
參 考 文 件 /要 點 . Reference / * key Points
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主題選定 . NPS自主研究會登記表 Theme Selected . NPS Kaizen Registration Sheet
自主研 Jishuken NPS 台新企管
縮 短 交 期 技 巧 Shorten Throughput Time Rules
(1) 基本要領：實施一個流流線生產方式 Basic Rule : To implement One-Piece-Flow Line. (2) 實施平準化生產，減少換模批量，縮短換模時間 Introduce Leveling production，reduce changeover batch size and reduce changeover time. (3) 消除離島作業，朝同步化生產努力 Eliminate isolated work station，try to synchronize production. (4) 設定“最大-最小”在制量管理系統，剔除多餘在製品 Set the “Max-Min” WIP Control System，to eliminate extra WIP. (5) 建立“順序號碼”達成“先進先出” Design “ Sequence Code ” to control “ First In First O備或連續式設備 Prefer to using samll.continue machine i.s.o. big machine. (7) 掌握“品質三不原則”，提升良品率 Keep production line in the way of “ Fresh ”,“ Fast ”, and “ United ” to increase yield. (8) 改善瓶頸工程，提升全線生產速度 Kaizen bottleneck process to increase line output speed. (9) 嘗詴一個流生產，縮短加工時間 Try to introduce one-piece-flow，to reduce Process Time. (10) 實施全員生產保全，設備保有預防保養時間 Implement TPM，to let M / C have time to be preventive maintenance.
自主研 Jishuken NPS 台新企管
減 少 不 良 技 巧 Defect Reduction Rules
(1) 掌握“五現主義” Follow 5-Gen Principles 1. 走入“現場” Go to Gemba ( Shopfloor ) 2. 觀察“現物” OBSERVE Gembutsu ( Objects ) 3. 了解“現實” Realize Genjitsu ( Facts ) 4. 立即“現作” Immediate gentsuku ( Actions ) 5. 成果“現查” Results Gensa ( Confirmation ) (2) 運用“要因分析七手法” Make use of “ cause Analysis 7 tools ” 1. 做出柏拉圖，先從佔70% ~ 80% A類不良項目下手改善 Analyze by Pareto Chart，Start with A Category ( 70% ~ 80% of Defects ) to do Kaizen. 2. 掌握行成不良之因果關係圖 ( 魚骨圖 )，考慮 5 MIE ( 人員、機器、物料、方法、量測及環境 ) 之原因 Work out the cause-effect (Fishbone)diagram. Consider the factors of Man，Machine，Materials，Method， Measurement and Environment. 3. 運用五五法要問五次為什麼，找出不良之真因(確實造成不良之特定要因) Ask why five times 5WIH to find out root cause of defection. 4. 運用比較法，比較最好與最差之狀況，協助找出真因 Compare the best with the worst to find out root cause. 5. 運用放大法，放大不良品來觀察 Enlarge the defect to observe the fact. 6. 不良品解剖法，了解不良品之內涵 Dissect the defect，to realize the defective factors. 7. 利用潛水法，直到找到問題真因為止 Dive until find out the root cause. (3) 遵照十二字真言：“保持新鮮、迅速確實、三國統一” Keep production operation in the way of :“Fresh，Fast and United”. (4) 徹底以“防錯”技巧，根絕不良之來源 Use foolproof method to eliminate defects. (5) 重要觀念：自主全數檢查，自己做的產品自己檢查、自己修理。要做情報檢查，不要做判別檢查 Implement Self-100% inspection. Operator is in charge of production，inspection and rework the product. Do information inspection i.s.o. screen inspection. (6) 要做出不增加工時的自主全數檢查之技巧。例如自動檢查、塊規(Gauge)檢查、可/不可(Go/No Go)檢查等 Develop no man-hours added Self-100% inspection system by such as : Automatic inspection，gauge inspection，Go / No Go inspection etc...
目標設定 Target Setting . NPS自主研究會登記表 . NPS Kaizen Registration Sheet
* 產距時間 * Take Time
* 數量化 * Quantify
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現況調查 . 流程圖 Process Flow Chart . 作業配分表 Process Time Chart Current Situation . 標準作業票 Standard Work Sheet . 標準作業組合票 Standard Work Combination Sheet . 製程別加工能力表 Process Capability sheet . 時間觀測表 Time Measurement Sheet . 改善成果表 kaizen Result Record * 五現主義“ 5 gen Principles ” : 現場 Gemba , 現物 Genbutsu , 現實 Genjitsu , 現作 Gentsuku , 現查 Gensa 要因分析 Cause Analysis . 改善快報 Kaizen News * 三無思想 “ 3-Mu phiosophy ” : 無馱Muda , 無理 Muns , 無穩 Mura * 五現主義 5 Gen Principles * 要因分析七手法 Cause Analysis 7tools : - 柏拉圖 Pareto Chart - 五五法 5x5WIH - 魚骨圖 Fishbone Chart - 比較法 Comparison - 放大法 Enlargement - 解剖法 Dissection - 潛水法 Dive
自主研 Jishuken NPS 台新企管
作 業 合 理 化 原 則 Principles of Operation Rationalization
(1) 作業員在同一邊工作，逆時針順序排列，盡量靠攏，一般為80公分 Operators work at the same side by counterclockwise process sequence，and work as closer as possible. Normal station pitch is 80 cm. (2) 不要搖頭，不要彎腰 No turn head，No bend body (A) 物料、工具要放在作業者正前方，且在正常工作範圍 Tool and parts should be located in front of operator and in the normal working area. * 料盒要設計成 Part container should be : 1 正面窄、縱深長 Narrow front side and longer length. 2 雙盒式置料 One part with twin containers 3 少量多回供應 Supply parts by less quantity but more frequent. (B) 物料、工具要定位且預放。工具要能懸掛起來 Tools and parts should be pre-positioned in a definite location，and hang up the tools. (3) 不要插秧，利用夾具使雙手能同時對稱反向動作 Utilize fixtures to let two hands no idle or hold time (4) 利用重力滑道及道具 Utilizze gravity chute and special designed tools (5) 作業區域保持乾淨，在製品不要堆積，保持一個流 Keep good housekeeping in work statio，follow one piece flow and no stack wip. (6) 水蜘蛛要能從另一側定時定量供料給作業員 Water spider should periodically provide fixed quantity of parts to operator from the opposite side of opposite. (7) 盡可能將前後工程連線起來 Connect processes as more as possible to flow line. 考詳細資料：工作改善(IE)七大手法：許文治著 Detailed reference:IE 7 Tools (Chinese version),by Arthur Hsu.