What Are the Best Tips for Lean Manufacturing Implementation?

Lean Production (LP) is a praise from several experts from the Massachusetts Institute of Technology (IMVP) for the "Just In Time" production method in Japan.

Lean Production Technology

Right!

Refined, that is, less and refined, does not invest in excess production factors, but only produces the necessary amount of market-required products (or products needed in the next process) at the appropriate time; benefits, that is, all business activities must be beneficial and effective, economical . Lean production is the best production organization system and method in the industry.

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Compared with mass production methods, the advantages of lean production methods adopted in Japan are mainly reflected in the following aspects:

1. Whether the required human resources are in product development, production systems, or other parts of the factory, compared with factories in mass production, the minimum can be reduced to 1/2;

2 New product development cycleminimum can be reduced to 1/2 or 2/3;

3 In-process product inventory in the production process-can be reduced to a minimum of 1/10 of the general level under mass production methods;

4 Factory occupied spaceminimum can be reduced to 1/2 in the case of mass production;

5 Finished product inventoryminimum can be reduced to 1/4 of the average inventory level under mass production methods;

6 product quality-can be greatly improved;

Lean production is a production technology and management technology that thoroughly pursues the rationality and efficiency of production and can flexibly produce high-quality products that meet various needs. Its basic principles and many methods have positive significance for the manufacturing industry. The core of lean production, that is, the basic ideas about production planning and control and inventory management, also plays an important role in enriching and developing modern production management theories.

Lean production, as a new management idea from environment to management goals, has achieved success in practice. It is not a simple application of one or two new management methods, but a set highly related to the corporate environment, culture and management methods. Integrated management system, so lean production itself is an autonomous system.

1. The basis for implementing lean production-5S activities to improve the level of on-site management.

2. Just-in-time productionJIT production system

When the customer needs it, provide the required product according to the amount required by the customer. A series of tools are used to enable enterprises to achieve just-in-time production. The main tools are:

Takt Time == Cycle Time

Continuous Improvement KAIZEN (Continuous Improvement)

One flow productionOne Piece Flow

Cell Production U-shaped layout

Value Stream Analysis VA / VE

Methodology IE

Pull Production and Kanban PULL & KANBAN

Visual management

Reduced production cycles-reduced LEADTIME

Total Production Maintenance (TPM)

Quick mold change (SMED)

3. 6 quality management principles should be implemented throughout the entire product development and production process. mainly include:

Operator's quality responsibility

Work concept of operator actively stopping the line

Error proofing system technology

Standard Operation SO & Operation Standard OS

FIFO control FIFO

Finding the root cause (5 whys) 5WHY

4. Give play to the subjective initiative of the workforce Emphasize that "playing the subjective initiative of the team is the basic way of running a lean enterprise." It is necessary to encourage teamwork and push down the walls between the various departments of the enterprise.

5. Visual management. Not only managers but also all employees at a glance at the status of the company. The best way to fully communicate information is to put all the processes on the desktop and visualize them instead of operating in the dark.

6. Continuous pursuit of perfection. The concept of business management and the thinking of employees are very critical. Even if the ideal perfection can never be achieved, we must continue to move forward, even if the waste is trivial, progress is little by little!

"Zero waste" is the ultimate goal of lean production, which is specifically manifested in seven aspects of PICQMDS. The goals are detailed as follows:

(1) "Zero" waste of man-hours for conversion (Products? Multi-variety mixed production)

Reduce the waste of time for the variety switching of the processing operations and the production line of the assembly line to "zero" or close to "zero".

(2) "Zero" inventory (Inventory? Reduce inventory)

Connect processing and assembly to streamline, eliminate intermediate inventory, change the estimated production of the market to simultaneous production of orders, and reduce product inventory to zero.

(3) "zero" waste (Cost? Comprehensive cost control)

Eliminate waste from redundant manufacturing, handling, and waiting to achieve zero waste.

(4) "Zero" bad (Quality?)

Defects are not detected in the inspection position, but should be eliminated at the source of the occurrence, and zero defects should be pursued.

(5) "Zero" failure (Maintenance? Increase operating rate)

Eliminate the breakdown of machinery and equipment to achieve zero failures.

(6). "Zero" stagnation (Delivery? Fast response, short delivery time)

Minimize Lead Time. To this end, it is necessary to eliminate intermediate stagnation and achieve "zero" stagnation.

(7). "Zero" Disaster (Safety? Safety First)

Comprehensive safety prevention inspections of people, factories and products, and SF inspection system implemented.

Lean production is the best production organization system and method in the industry. IE is the engineering foundation to complete the lean production method, and IE is an important part of lean production.

Industrial Engineering IE (Industrial Engineering) is a discipline that designs and improves integrated systems composed of people, materials, equipment, energy, and information.

When Japanese companies implement lean production, they use a large number of operational research, motion research, and time analysis techniques in basic IE to make lean production always stand on a scientific basis, so they are vibrant and fruitful. Japanese companies have great creativity in the use of IE. Lean production has not only brought about a qualitative change in the production organization method, but also brought a series of fundamental corporate organizations such as product development, quality control, internal and external collaborative management, and user relations Major changes in the system and management system and major changes in corporate operating values, the most affected of which include the corporate culture of Japanese companies. According to Nakayama Kiyomizu, director of Toyota Motor Corporation's production survey department, the Toyota Production Method (JIT) is the application of IE in enterprises. Japan introduced IE from the United States, and after half a century of development, it has formed an IE with Japanese characteristics, that is, IE is closely integrated with management practices, emphasizing on-site management optimization. In the process of implementing lean production, Chinese enterprises should combine field IE and start with the popularization and promotion of basic IE, so as to realize pull-on-time production.

Many of us believe that "lean" is just-in-time production JIT. The most popular and popular saying abroad is: Lean is to eliminate all waste. Others have used terms such as "simultaneous manufacturing SM" and "mobile manufacturing FM". The goal of lean thinking is to "create the perfect value for the user with the process of perfection." These statements make sense, and they all try to describe this revolutionary idea in the leanest language. "Lean thinking is the integration of people, processes and technology" is a more comprehensive and serious understanding

According to the viewpoint of "integration of process, people and technology", a comprehensive understanding of lean thinking will help enterprises grasp the main points of building a lean enterprise, which has better operability. For traditional production enterprises or large-scale production enterprises to change to lean production, lean production has the following forms:

1. Kanban is information that indicates jobs

This is the most basic function of Kanban. Information such as what to pick, how much to pick, when and where to pick it up and how to handle it, etc., these information are clearly indicated on the Kanban board. As long as the workers in each process see the kanban, their production quantity, time, method, sequence, transportation time, and transportation objects will be completely clear. Therefore, the kanban is like a nerve on the production line, transmitting fetch and production instructions, and controlling overproduction and overstocking. Kanban plays a significant role in accelerating capital turnover and reducing costs.

2. Kanban is a "visual management" tool

Since the kanban must be moved with the physical object at any time, it can control over-production, indicate the production sequence and simplify on-site management procedures. This persistence makes visual management possible. For example, the name, output, production time and method, delivery location and quantity of the parts are specified on the Kanban board, so that the production site personnel can independently judge and deal with problems at a glance. At the same time, it is also convenient for management personnel to grasp the production capacity, inventory status and personnel arrangement of the process, and improve the level of business management.

3 Kanban is a means to improve management

In the case of using Kanban, if a certain process equipment fails and a defective product is produced, according to one of the operating rules of Kanban: "Cannot send defective products to the subsequent process". If the requirements of the subsequent process are not met, then It will cause a complete shutdown of the line, which can immediately expose the problem, so that prompt improvement measures can be taken to solve the problem. In this way, not only has the problem been solved, but the "physical constitution" of the production line has been continuously enhanced, which has brought about an increase in productivity. The goal of the lean production approach is to eventually achieve "zero inventory", and Kanban provides a tool to move in this direction.