A3报告A3reporttool.ppt

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1、成本 Cost健康, 安全及环境 EHS改进改进Improved前置期LeadTime质量QualityEBS变革模式变革模式 Change model稳定 Stabilize&改进 Improve目标目标: 企业改进企业改进Target: Business improvements定义的作业定义的作业Defined Task执行执行Execution测量测量Measurements纠正措施纠正措施Correctiveactions标准化标准化Standardization改进改进Improvement潜力潜力Potential偏差偏差DeviationA3是一强有效的工具是一强有效的工具;

2、正确地运用它能促进企业的改进正确地运用它能促进企业的改进并并提高对事物的了解提高对事物的了解The A3 can be a powerful tool; Used well it produces both Business improvements and increased insightA 3格式报告法在格式报告法在 -需要改善员工的安全问题需要改善员工的安全问题 健康健康, 安全及环境安全及环境 Need to improve safety issues for employees - EHS-需要提高内部的效率需要提高内部的效率 成本成本 Need for internal effi

3、ciency - Cost Need to meet customer demands - Time/QualityA 3问题问题ProblemA3 以解决问题的科学方法为基础以解决问题的科学方法为基础 A3 - Is built upon the scientific method of problem solvingA 3A3 连接连接:The A3 connects the:原因原因Cause可能的可能的解决方案解决方案Possible solution实验实验 Experiment测量测量Measure审核审核 Verify!12543A3 - 是一种系统的思考方式是一种系统的思考方式

4、 它的形式简化了解决过程它的形式简化了解决过程A3 - Is a way of thinking systematically, - The Format simplifies the solution process. 业务案例业务案例(问题/挑战)Business Case(Problem/challenge)1目前情形目前情形 (原因分析)Current condition(cause analysis)2目标情形目标情形(假设)Target situation(Hypothesis)3行动计划行动计划(实验)Action plan(Experiment)4测量测量 (审核)Measur

5、ements (Verify)5A 3业务案例业务案例 Business Case阐释必须实现改进的地方和原因阐释必须实现改进的地方和原因 (策划这个业务案例的原因) Describe where and why improvements must be implemented(The reasons for working on this BC) 正确的案例定义正确的案例定义(问题) Accurate definition of the BC (problem)目前和目标的成效目前和目标的成效Current and target results 指定时限指定时限 Specify the ti

6、meline2006目标成效 Target result这是为审核A3是否解决业务案例的必要 This is necessary in order to verify wether the A3 solved the BC 2007目前成效 Current result目前情形 是一项原因分析 Current Condition is a cause analysis全面彻底地分析有关业务案例的目前流程与问题Thorough analysis of the current process and problems linked to the BC关键问题 Key question:“我们目前为

7、何没能达到业务案例的要求我们目前为何没能达到业务案例的要求?” ”Why do we not meet the BC requirement currently?”描述目前的情形. 涉及的人员. 绘制流程的实际运作 (亲临现场查看 - “实地,实物”) Describe the situation. Involve people. Map the process the way it really works (go out and see for your self, on site,- “ the actual part, the actual place”)生产, 物料和信息流程 Pro

8、cess, material and information flow对工作的组织 How work is organised相关资料 Relevant data 重要的是得查明根本原因重要的是得查明根本原因它们存在何处它们存在何处, 以及为解决业务案例而必须改变的事项以及为解决业务案例而必须改变的事项Important to find the root causes. Where they are, and what must be changed in order to meet the BC 绘制流程绘制流程 达成共识达成共识Draw the process -Secure a comm

9、on understanding客户客户 Customer客户客户 Customer生产计划生产计划 ProductionPlanningIIIIIIIIIIIIIVIVPakking &Skiping包装 Packing &递送 Shipping前置期前置期 Lead Time指导员Supervisor若你无法绘出目前的流程若你无法绘出目前的流程 那么你对它并不了解那么你对它并不了解If you are not capable of drawing your current process, -you do not understand it描述在解决了目前识别的原因之后我们所期望的流程运作

10、情形 Describes the way we expect the process to work after eliminating the causes identified from the current condition 它最好是一张描述改进后的新流程要素的绘图 It should preferably be a drawing describing the important elements in the new improved process 它是一个假设, -”我们相信通过解决目前情形中的识别原因从而解决这个业务案例” It is a hypothesis, -”we

11、believe that the BC can be met by eliminating the causes for the problems identified in the “current condition” 它阐释了行动措施将能否确认这个假设 It describes the countermeasures that will confirm or fail to confirm the hypothesis 目标目标 (未来未来) 情形情形 是解决方案的建议是解决方案的建议 Target (future) situation -is the solution proposal

12、Produksjons-生产计划生产计划 Production planning客户客户 Customer7天的冻结计划天的冻结计划7 days frozen scheduleIIIIIIIIIIII-IVPakking &Skiping包装 Packing&运送 Shipping前置期前置期 Lead time帮助链Help Chain氯化塔Chloride ColumnNo 1到备用塔To back upcolumn到酸罐1To Acid tank No 1到酸罐2 To Acid tank No 2由酸泵4 From Acid pump 4酸泵2 Acid pump 2FI氯化塔Chlo

13、ride columnNo 1到主反应堆To main reactor酸泵2Acid pump 2FI目前目前Current目标目标Target来自挪威埃肯Bremanger微硅工厂的氯化车间 (3线)From the Chloride factory, Silgrain Facility at Elkem Bremanger in Norway (3 lines) 一共减少了16个阀门并改进了维修过程 (第一线及预防) Total reduction of 16 valves and improved maintenance process(1st line and preventative

14、) 每年通常需要更换阀门两次 The valves normally would have to be replaced twice a year. 预计降低维修成本 150 000 - 200 000 NOK/年 Expected maintenance cost reduction 150 000 - 200 000 NOK/year流程图的流程图的式样式样选择必须以问题的类型为基础选择必须以问题的类型为基础 -你可能要用若干种的式样以便确切地描述流程 The type of flow diagram must be chosen based on the type of problem,

15、 -you might need several types to describe the process properly到主反应堆To main reactor到酸罐1To Acid tank No 1行动计划行动计划告诉我们什么是必须执行的事项告诉我们什么是必须执行的事项, 负责事项的人员及完成事项的时间负责事项的人员及完成事项的时间!Action plan tells us what needs to be done, who is responsible for doing it and when it will be done!什么什么 What 30 60 90 谁谁 WhoA

16、 3什么什么 What 30 60 90 谁谁 Who系统系统 System工作培训工作培训 Work Training若无一个系统一致的行动计划的后续追踪若无一个系统一致的行动计划的后续追踪, 通过通过A3分析完成的工作将无法带来期望的成效分析完成的工作将无法带来期望的成效Without a systematic and consistent follow up of the Action plan the Work done with the A3 analysis will not give the expected results. 跟进必须保证发展跟进必须保证发展, 区分优先事项区分

17、优先事项, 资源调配资源调配, 必要的调整以及在贯彻计划过程中的不断学习必要的调整以及在贯彻计划过程中的不断学习The Follow up must secure Progress, priorities, allocation of resources, necessary adjustments and continued learning during the plan deployment明确地定义必须执行的事项明确地定义必须执行的事项, - 期限及负责人员期限及负责人员, 执行执行“目标情形目标情形”下下描述描述的每个行动对策的每个行动对策Clearly define What mu

18、st be done, -when and by whom, to implement each of the countermeasures described under ”Target Situation”业务案例业务案例不明确或不完整不明确或不完整? Unclear or incomplete business case? 我们未正确地定义问题我们未正确地定义问题? We did not define the problem correctly?我们未找到问题的根本原因我们未找到问题的根本原因? We did not find the root cause of the problem

19、? 错误理解目前的情况? (misunderstood current condition?)未涉及到相关的人员? (did not involve the right people?)我们的目标未能解决我们的问题我们的目标未能解决我们的问题? Our target did not solve our problem?错误的假设? (Hypothesis was wrong?)我们的行动计划不切实际我们的行动计划不切实际? Our action plan was unrealistic? 我们在着手工作前的等待过长? (we waited too long before starting th

20、e work?)忽视了培训的需要? (neglected the need for training?)我们未对测量追踪到底我们未对测量追踪到底? We did not follow up on our measurements?有时我们没能达到期望的成效有时我们没能达到期望的成效, - 为什么为什么?Sometimes we dont get what we expected, - Why? A 3BC工厂工厂/分公司分公司 A3 Plant/ BU A3BCBC部门部门 A3Department A3BCBCBCBC部门管辖范围部门管辖范围 A3Department AreaA3上一级上一

21、级A3中的某个行动点中的某个行动点, 可作为下一级可作为下一级A3内的一个业务案例内的一个业务案例 One of the action points from a superior A3, Could be a business case for a second level A3.A 3BCBCBCBCBCBCBC管理层的挑战管理层的挑战: 阐明问题阐明问题, 设定期望设定期望, 亲身参与及追踪改进行动亲身参与及追踪改进行动 Managements Challenge: Clarify, Set expectations, Self involvement and Follow-up imp

22、rovement activities.策略计划策略计划Strategic Plan分公司 Business Unit部门 Department 指导方针指导方针Road map公司 Division部门管辖范围 Area必须发起并管理变革 Change must be sponsored and managed;? . 定义作业定义作业 Defined Task执行执行Execution测量测量Measurements纠正措施纠正措施Corrective actions需要一个变革管理的控制环 There is a need for a change management control l

23、oop变革管理系统的目的变革管理系统的目的The Purpose of the Change Management system系统应该系统应该 The System should 是一个实际有效的管理系统是一个实际有效的管理系统 Be a practical management system 确保改进的实现确保改进的实现 Secure the realization of improvements 监控所有改进行动的进展监控所有改进行动的进展Monitor the progress of all improvement activities 在初期在初期揭露问题并使它们能被目视揭露问题并使

24、它们能被目视Uncover and visualise problems early stage 针对要点采取纠正行动针对要点采取纠正行动Handle corrective actions towards the IP 协调行动协调行动 Coordinate activities 区分行动的优先次序区分行动的优先次序 Prioritize activities系统不应该系统不应该 System should not 作为一个项目计划作为一个项目计划 Work as a “Project plan” 限制改进行动限制改进行动Control the Improvement activities 监

25、控关键的流程监控关键的流程Monitor Critical Processes 监控生产操作监控生产操作 Monitor operation activities 是错综复杂且资源密集的是错综复杂且资源密集的Be complicated and resource intensive 视觉化的系统视觉化的系统; 设计给工厂的领导队伍设计给工厂的领导队伍; 提供提供给组织的其余人员给组织的其余人员The System should be visual;Designed for the Plant lead team; available to the rest of the organizatio

26、nAktivitet Prio Ansv Dato原材料原材料 物流物流Raw material - logisticsAktivitet Prio Ansv Dato生产生产 ProductionAktivitet Prio Ansv DatoCSPCSP Aktivitet Prio Ansv Dato维修维修Maintenance改进队伍 Improvement teamS每周的追踪进度计划每周的追踪进度计划 A3/主要行动主要行动Weekly follow-up Schedule A3s/main initiativesSPAEBS Resource32 33 34 35 36 37

27、38 39 40 41 42 43 Annual One timeXXXXXXXXXXXX16XXXXXXX1,610XXXX5-10XX2*XXXXXXXXXFinishedXXX2XXX12Spas fill in financial potentialsA3/ActivityFinancial potential - $306090Follow up plan Maintenance Maintenance MaintenanceRaw material - logisticsProductionCSP Maintenance CSP A3 CSP A3维修维修 A3 Maintenan

28、ce A3A3 分公司分公司A3 UNITBusinessCaseCurrentTargetMaininitiatives原材料原材料 Raw materialBusinessCaseChange activitiesCurrentTargetBusinessCaseChange activitiesCurrentTargetBusinessCaseChange activitiesCurrentTarget生产生产 A3 Production A3sBusinessCaseChange activitiesCurrentTarget领导队伍领导队伍Lead teamS应用原则应用原则Rule

29、s in UseTools & MeasuresTEAM BASED ORGANIZATIONStabilize work place and equipment5 SMeasurement & feedbackVisual ProductionPreventive MaintenanceMIBCritical Process ManagementTEAM ORGANIZATIONSimplify, Standardize, TrainEBS的工具的工具 EBS ToolsEBS在于改进在于改进. 探索研究原理探索研究原理, 应用原则及应用原则及A3格式报告法格式报告法的效能的效能. 花时间去

30、亲自体会这个系统花时间去亲自体会这个系统 EBS - is about improvement. Explore the power of the Principles, RIU and the A3 method.Invest time to get a feeling for the system for your self. 策略过程Strategy ProcessLEVERANDRKUNDE问题 PROBLEM 问题 Problem 原因分析 Cause analysis解决方案Solution 执行 Implementation 追踪 Follow up 转移机会? Transfer

31、 opertunities?根本原因根本原因ROOTCAUSERegel 1- Arbeidet til en personRegel 2 - koplinger mellom”leverandrer” og “kunder”Regel 3 - FlytruterRegel 4 - ForbedringerRIUBehovResponsStrekfigurmodell med idealsituasjon系统受工具和方法的支持系统受工具和方法的支持System supported by tools and methodsBusiness Case我们的需求Our NeedCurrent ConditionTarget Condition现况是SituationNow Is.情形将会是SituationWill Be.We believe that if., then.Improvement ActivitiesScheduleMetrics Shdsjeeis laldlflroo Fhfhfruekd fhjsje Jkieopsmm gkgy mnbCurrent Future Actual 25 5边做边学Learning by doing结束结束