识别浪费,Time Line Reduction 缩短时间线,The Toyota Way,The Heart of the TPS: Eliminating waste. 丰田生产体系的核心：消除浪费.,Lean 精益,We should not focus on results and then rally a team to fix the problem. This is a reaction based approach.我们不应该遇到问题后，就组织一个团队去解决，这是应急措施的方法 By building a strong foundation from bottom up, focusing on the tools provided, automatically positive results will be a byproduct. 如果我们从基层到高层建立一只强大坚实的基础，在关注我们精益方法的应用，好的结果会自动出现。,Improving performance 提升绩效,Lean production is aimed at the elimination of waste in every area of production 精益生产就是瞄准生产区域的浪费的消除 Its goal is to incorporate 它的目标包含 less human effort, 最少的人员消耗 less inventory, 最少的库存 Less scrap 最少的报废 less time and 最短的周期 less space 最少的设备 To become quicker to respond to customers changes in demand while making top quality products in the most efficient way possible.以最快的速度响应客户的需求同时以最有效的方法提供高质量的产品,The 7 Wastes 7大浪费,T = Transport 搬运,I = Inventory 库存,M = Motion 动作,W = Waiting 等待,O = Overproduction 过量生产,O = Over processing 过度加工,D = Defects 缺陷,Typically the following is the break up VA / NVA in the manufacture of a part.增值/非增值活动所占比例 Value added = 5% 增值Necessary NVA = 45%. 必须的不增值NVA (Waste) = 50% 浪费,LEAN = ELIMINATION OF WASTE,What is Hidden Waste?什么是隐藏的浪费,Work that does not add value but is required under the current operating conditions 不增加价值但不得不做的工作 tool changeover 换模 Inspection 检查 parts handling 手持部件 transporting parts 搬运部件 unwrapping of purchased parts 外购件拆包 Paperwork 文字工作 Decanting 转移容器 progress chasing 追赶进度 storage space 储存空间 Meetings 会议 managing inventory库存管理,1. Transportation 搬运,Customers do not pay to have goods moved around, so any movement of material in a factory is a waste. 客户不会为工厂内无效的搬运付钱，所以搬运是浪费 Materials stored a long way from point of use 存储地相距使用点太远 Unnecessary moving or handling of parts 不必要的搬运 Handling equipment moving without any parts being moved搬运设备的空移动 Feedback on quality is inversely related to transport length 长距离搬运导致质量的隐患 increases the likelihood of damage!增加损坏的可能性,1. Transportation 搬运,Cellular Manufacturing provides 细胞化生产方式提供 short distances, short lead-times, small batches 颈段距离，周期时间，更小批量 Low WIP, low cost, Good problem solving & team spirit 低库存，成本，号的问题解决精神,1025 feet 30 Days,200 feet 1 Day,1. Transportation,The traditional Approach; 传统方法 Specialist departments 独立的分工,Long distances 长距离 long lead-times长周期 big batches大批量 high wip 高在制品 high cost高成本 poor problem solving 差的问题解决能力,2. Inventory 库存,Large stocks 大量库存 Stock pile of finished goods大量的成品库存 High WIP 高的在制品 High raw materials原材料 Excessive racking 多余的货架 Excessive warehouse space 多余的仓库面积 Excessive handling equipment 多余的搬运设备 Extra management 额外的管理 Obsolescence报废 Poor layout不合理的布局 Restrictive layout 限制的布局 Excessive transportation多余的搬运 Unnecessary searching and moving of materials 不必要的寻找,2. Inventory,The main causes for inventory are 库存的主要原因是 Process unreliability (to cover downtime) 不稳定的工艺（弥补损失时间） Poor process responsiveness (to cover changeovers) 较慢的相应流程（来弥补长的换型时间） Push systems of manufacture 差的制造系统 Inventory increases the manufacturing lead time, this leads to:库存增加制造周期，导致：slower introduction of engineering changes and process improvements 更慢的工程更高相应 increased quality risk 质量风险增加 increased risk of obsolescence 报废增加,It leads to 导致 Concealed problems 隐藏的问题 Increased lead times 加长的周期时间 Prevents rapid identification of problems 阻碍快速识别问题 Increases space requirements 增加额外的空间需求 And thereby discourages communication因此导致沟通不畅 Inventory deliberately hides problems 隐藏问题 Quality concerns are not considered important if extra parts can be used in place of defective parts由于可以多生产，导致忽略质量问题 Conceals imbalance in processes 掩盖生产不平衡的问题The true cost of inventory is the money tied up in it 库存的成本是资金的积压,Inventory is EVIL库存有罪,3. Motion 动作,Unnecessary movement of operators and machines as they carry out cycles of work 不必要的人员和设备动作 double handling 二次搬运 triple handling 三次搬运 Reaching 伸手 Bending 弯腰 Stretching伸长 Walking 走动 Twisting 踮脚 more than two turns to loosen bolts 松螺丝超过2圈 unduly exerting themselves in any way 任何形式的不当的用力,3. Motion,MOVE does not necessarily equal WORK.动作不等于工作An operator may be kept “busy” for hours looking for tools without adding any value for the customer 操作员可能很忙的花1小时在找寻工具，但不是增值的活动,4. Waiting等待,The waste of waiting occurs whenever time is not being used effectively.等待浪费是时间没有真正有效的利用起来 Waiting for material 等料 Waiting for maintenance等维修 Waiting for tool change/setter等工具 Waiting for quality check 等质量检查 Waiting for next station等下一个工序 Operators slower than line动作慢导致等待 An imbalance in the line不平衡 Materials waiting for machine changeovers 材料等机器还型 A bottleneck process short of work 瓶颈工序引起的 Operators watching machines to complete cycles操作员看作设备操作，等待下料,Waiting is the enemy of smooth flow,5. Waiting,When operators are waiting for work or waiting for something to do, it is waste. Can the time not be better spent on another operation ?有等待就有浪费，不管是在等料还是其它 Training 培训 Cleaning 清扫 5S maintaining equipment设备维护 checking (machinery and quality)检查 practising a changeover 换型 improvement activities 改善活动What is your best use of time?,