康明斯目视管理法
Cummins Visible Controls
1Cummins 目视管理 Visible Controls
目的 Objectives
n 阐述目视管理: 目标，定义，和标准
Describe Visible Controls: goal, definition,
and criteria
n 了解如何运用 Understand how to use them
n 讲解4种做法
Define the 4 categories
n 展示与持续改进的联系
Show connection to
Continuous Improvement Process
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与CPS*的联系 CPS Connection
n 隐藏问题，不能使问题受到重视并得到解决。我们
必须能够很快地标识问题，并立即做出反应。问题
点必须可以一目了然。
— CPS 员工手册 1991，24页
*CPS-康明斯生产系统
n “Hidden problems will not get attention and will not
be fixed. We must be able to identify problems
quickly and respond to them immediately. Trouble
spots must be obvious at a glance.”
— CPS Employee Manual, 1991, pg. 24
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.
n 下面两种方法对于信息运用管理可能会有很大的区别：
How information is organized is perhaps the most
distinguishing feature between…
信息共享 目视交流
Information Sharing Visible Communication
4Cummins 目视管理 Visible Controls
目视管理目标
Visible Controls Goal
1. CPS 质量目标是：
“使过程成效指标和问题均目视化”
A CPS quality objective is to “make performance
to processes and problems visible.”
2. 持续改进是我们的生存之道
Continuos Improvement is a way of life
3. 建立发展一个部门区域间交互责任的体系
Developing a system of overlapping
responsibilities between functional area
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目视管理
VISIBLE CONTROL DEFINITION
目视管理就是信息展示，全面直观地、方便地
能看见，以便对其做出反应，进行调整控制。
A visible control is defined as a display of information
devised to be in full view or readily seen in order to allow
reaction or regulation to the source or cause of
information.
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基本准则 Essential Criteria
使重要的信息以最快的速度方便地传递到决策和措
施制定的地方
They are used to facilitate the transfer of important
information as quickly as possible at the point where
decision and action can be made.
1、简洁陈述 Simplicity of presentation
2、可视测评 Visibility of measurements
F情况目视通报到每位员工
situation are visible to everyone
F目标和责任目视通报到每位员工
goal and rules are visible to everyone
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基本准则 Essential Criteria
3、每位员工进行参与
Everyone’s involvement
4、基础信息数据的真实收集
Undistorted collection of primary information
5、重要数据的直接测评（至关重要的几个）
The straightforward measurement of what’s
important (The Vital Few)
6、对紧急情况有全面的了解掌握
Achieve an overall feel of urgency
7、针对变异有完善计划和受训练的反映
Planned and disciplined response to abnormalities
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行GO
停
STOP
我该如何做？？
What should I do???
9Cummins 目视管理 Visible Controls
出口Exit 96
目视信息-不好
Visible Information
-Bad Example
10Cummins 目视管理 Visible Controls
目视信息-好
Visible Information
-Good Example
.
出口Exit 96
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共同负责 Shared Responsibility
工厂质量水平
Plant Level
公司目标
Company Goals:
*世界级 World class
*CPS
*通告Inform visitors
班组板块区
Team’s Territory
班组目标Group Goal:
*用户/供应商
customer/supplier
*成本/质量/发运
cost/quality/delivery
*问题 problem
独立工作站
Individual Workstation
工序说明 Operation Specific:
*工艺文件 Process doc.
*标准工作图示 Std work charts
*维护 Maintenance
*环境管理 Housekeeping
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工厂质量水平 Plant Level
团队班组
板块区
Team’s
Territory
用户Customer
支持 Support
方法 Methods
规范 Specification
用户 Customer
工厂测评 Plant measure
过程测评 Process measures
供应商
Supplier
维护 Maintenance
安全 Safety
独立工作站 Individual Workstation
供应商 Supplier
计划 Plans
安全Safety
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目视管理准则
The Rule of Visible Controls
班组必须审核和认可目视管理
The team has to review and approve any visible
control
“…提交目视管理文件进行公开评议—使员工获
得认知，提供员工发表建设性意见的机会”
“…submitting a visible control document to a
process of public scrutiny --result in better
ownership of the knowledge and opportunities for
constructive criticism.”
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公开式传达信息
Openness of Communication
问题状况的明确展示使每位员
工知道目前过程的状态
“Visible display of problem status lets
everyone know the current status of the
process.”
度假,
一周后返回
On vacation
Return in 1week
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生产计划展示 例1 Handout Solution for Situation 1
-Production Schedule for Plant B, Example #1
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生产计划展示例2 Handout Solution for Situation 1
-Production Schedule for Plant B, Example #2
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人力计划举例 Handout Solution for Situation 1
-Workforce Planing
A工厂 Plant A
B工厂 Plant B
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四种展示 The Four Categories
n 目视生产控制
Visible Production Control
n 目视质量控制
Visible quality control
n 过程指示
Process indicators
n 进程显示
Making Progress Visible
改进 Improvement ：
节拍 cycle time
实际 Actual:
min reduction
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生产管理 Production Control
(…过程状态一目了然 understanding the process at a glance.)
n 看板或拉料卡显示材料状态
Chanson or Pull Cards showing material status
n 工作标准化 Standardized work charts
n 瓶颈工序标识出
Bottleneck operations identified
n 工序流程图 Process flow charts
n 预先确定场所
Predetermined locations
u整洁、工装和设备定置摆放
clear, designated tool& equipment locations
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生产管理 Production Control
u材料存储标识完善
well marked material storage
u材料过量堆积 overflow areas
n 警示灯显示问题或异常情况
Andon displays to indicate problems or
abnormal situations
n 生产量计数 Production count status
n 发交状况 Delivery status
n 料箱（架）限制零件装载量
Containers limiting the amount of parts
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料架满装指示举例
Example of Production Control
Instructions for filling a container
错误 No 正确 Yes
满装线
Fill line
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警示灯板
Andon (a lighting panel)
n 发生故障传送信息的装置
Which is an “information transfer
device for trouble occurrence”.
u同时可指示停止或故障解除警示
uAlso reference to as stop alarms,
uptime lights
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生产管理警示板
Production Control Board
-Andon Board
目标 345
Target
实际 345
Actual
时间损失 8min
Loss time
最新消息：工作站 3材料短缺，
工作站 6有质量问题
Status update:Station 3 has a material
shortage, Station 6 has a quality problem
6 7 8 9 10
1 2 3 4 5
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生产警示灯有如下表示：
Example of Production: Andon Lights
-红色 Red : 生产线停止Line Stop
-黄色Yellow: 请求支持援助
Worker has called for help
-绿色Green: 正常正常 Normal
operation
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警示灯有如下表示：
Example : Andon Lights
-红色Red: 设备故障 Machine trouble
-白色White: 生产终止 end of production run
-绿色Green: 材料短缺停产
no work shortage of mat.
-兰色Blue: 有问题 defective unit
-黄色Yellow: 要求调整 set-up required
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过程指示 Process Indicators
(…用于监控工作进程的设施 devices for monitoring work
progress)
n 设备机油消耗 Machine oil consumption
n 班组培训矩阵表(技能水平/培训项目)
Team training matrix (skill level/training)
n 安全成效 Safety results
n 内部环境管理维护成效 Housekeeping
results
n 库存周转 Inventory turns
n 色彩编码任务 时间安排卡片
Color coded job scheduling cards
n 在制品 Line side storage
n 节拍 Tat time, cycle time
n 调整时间 Set-up Time
n SPC 图 SPC charts 27Cummins 目视管理 Visible Controls
过程标示举例: 发动机挂旗
Example of process indicators:
Engine Flags
n 红色 - 发动机质量问题要拆检
Red - Engine Quality Teardown
n 黄色 - 缺“自制”件
Yellow - Shortage of “made in works” part
n 兰色 - 缺“外协”件
Blue -Shortage of “bought out finished “ part
n 绿色 - 发动机准备做试验
Green -Engine ready for test
n 白色 - 等待检查 White -Awaiting inspection
28Cummins 目视管理 Visible Controls
质量管理 Quality Control
(…质量状况一目了然 understand quality status at a glance)
n 用户质量水平 Customer Quality Levels
n 工序控制纪录 Process Control Records
u SPC图 SPC charts
u CPC情况 CPC status (CPC triangles)
n 量检具检定状况 Gauge calibration status
n 接受/不可接受标样 Boundary Samples referencing
acceptable/non-acceptable quality
n 供应商质量成效 Supplier results
n 规定明确的不合格品区 Clearly defined non-conforming area
n 工艺文件 Process Documentation
u 检查计划 Inspection plans
29Cummins 目视管理 Visible Controls
工作场地一目了然
A VISIBLE WORKPLACE
产品陈列
Product
display
用户反馈
Customer
Feedback
成效展示
Results
displayed
30Cummins 目视管理 Visible Controls
工作场地一目了然
A VISIBLE WORKPLACE
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工作场地一目了然 A VISIBLE WORKPLACE
n 谈论视觉图像信息却不用图片，似乎有些似是而非。这就是展示
车间目视管理图片的原因。
It would be somewhat paradox to speak of visual
communication without relying on an image. This is the reason
for presenting a visual workplace.
n 上张图示不是固定不变的逐条要遵循的实际例子，每个工厂有各
自不同的实际操作运行情况。没有理由完全按照图示中每个项目
去实施。其他内容或展示可能更适合具体的情况。这里主要是提
供目视交流、管理的一种思路。
n The workplace depicted is not a practical example to be followed
literally. Each firm has its own constraints and operating
structure. There is no reason automatically to include everything
appearing in this sketch. Conversely, other elements--or other
forms of presentation--maybe more suitable for certain situation.
In this portrayal, the intent is to present significant visual
communication themes.
43Cummins 目视管理 Visible Controls
工作场地一目了然 A VISIBLE WORKPLACE
n 班组板块 The Team’s Territory
1.板块标识 Identify territory
2.标识活动、资源和产品
Identify activities, resource,& product.
3.班组园地 Identify the team
4.地面标记 Marking floor
5.标识工装和工位器具 Marking of tools and racks
6.技术区域 Technical area
7.交流和休息区域 Communication & rest area
8.信息和指示 Info. & instruction
9.清扫工具 Neatness (broom)
n 目视文件 Visual Doc.
10.生产指导和技术程序
Manufacture Instruction & tech. procedure
44Cummins 目视管理 Visible Controls
工作场地一目了然 A VISIBLE WORKPLACE
n 目视生产管理 Visual production control
11.计算机终端 Computer terminal
12.生产计划 Production schedule
13.维修计划 Maintenance schedule
14.零标识 Identification of components
n 目视质量管理 Visual quality control
15.设备监控信号 Machine monitor signals
17.记录
n 指标展示 Display Indicators
18.目标、结果和差距Objectives, results, and differences
n 进展 Rendering Progress Visible
19.改进活动 Improvement activities
20.公司方针、计划和任务
Company policy, project & mission
45Cummins 目视管理 Visible Controls
实施改进 Making Improvements
（目视板可使每个员工追踪改进工作的进展）
(Display so that anyone can follow improvement work as it progresses)
n 用户满意 Customer satisfaction
n 用户/供应商合作协议Customer/supplier working agreements
n 项目和状况 Projects and status
n 改进活动 Improvement activities
u 之前/之后 Before/After
n 培训计划 Training matrices
n 改进板 Improvement boards
n 问题解决过程 Problem solving process status
n 库存降低腾空场地
Floor space freed up due to inventory reduction
n 预防性维护计划 Preventative maintenance schedule
46Cummins 目视管理 Visible Controls
合适的搬运摆放作业指导
Instructions for Proper Stacking Procedure
不在正确 No 正确Yes
47Cummins 目视管理 Visible Controls
预防问题重新设计
Re-design for prevention
of problem
目视管理的实施
Levels of Visible Controls Implementation
•工艺文件 Process documentation
•环境维护管理 Housekeeping duties
•图表-发交 ,员工培训计划
Charts - parts shipped, - operator training matrices
•检查计划 Inspection plans
•不合格品报告 Reject reports
•色斑材料区
Color striped material zones
•SPC 图 SPC charts
•控制限 Boundary samples
•发动机试验 Engine test
•活塞环颜色码 piston ring color code
•特殊力矩复检
specialized torque overchecks
预防 PREVENTION
发现 DETECTION
•停线 灯machine down lights
•装配红灯 assembly red lights
•2预通道无线系统
2-way radio system
最初展示运行状态
Initial display of
operational status
质量信息和规范
Quality information &
specification
工作环境探测异常
Work environment for
abnormality detection
问题可视或可见警示
Visual or audible alerts
to problem
防错 Failsafing
自动
Automation
48Cummins 目视管理 Visible Controls
“标准是一个参照点, 提供给班组追随的目标,
同时也提供了出发的起点.”
“A standard is a point reference that simultaneously
provides the group with a point to adhere to and a
point of departure.”
通过信息展示, 建立了工作和改进有据可依的“标记牌
”
By visibly displaying information we establish a “sign
post” that can be worked to and improved upon. 49Cummins 目视管理 Visible Controls
评价和改进
Evaluate and Improve
实施改进
Implement Improvements
确定改进区域
Define improved
system
建立改进目标
Establish
improvement goal
目视交流
Visual Communication
可见结果 成效
Visibility of results
文件易于 阅读
Easy to read documents
50Cummins 目视管理 Visible Controls
说明 Description
n 建立改进目标--班组共所周知的
Establish Improvement Goals = Know as a group
u 交付的承诺 Delivery commitments
u 目标和时间进度计划 Goals and schedules
u 责任 Roles
n 实施改进--班组有目共睹的
Implement Improvement = Seeing as a group
u 延迟 Delays
u 库存状态 Inventory levels
n 评价和改善--集体实施
Evaluate and Improve = Action as a group
u 共同的责任和目标 Consensus on rules and objectives
u 参与实施改进 Participation in making improvements
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n 为了提供一个反馈到工序的自控环境, 目视管理应该:
In order to provide an environment of self control
feedback to the operations should:
u 一目了然 Read at a glance
u 关注至关重要的几件事项
Deal with the Vital few
u 关注操作人员可控制的事项 (或缺陷)
Deal with operator controllable items (or defects)
u 提供提示作用
Provide prompt signals
u 提供纠正措施指南
Guide Corrective Action
目视管理 Visible Controls
单行道 ONE WAY
52Cummins 目视管理 Visible Controls
谢 谢
!
THANK
YOU!
53Cummins 目视管理 Visible Controls
