What is Lean production
To lean production is not only a production mode with the main goal of minimizing the resources occupied by enterprise production and reducing enterprise management and operation costs, but also an idea and a culture.The implementation of lean production is a process of determination to pursue perfection and excellence. It is a spiritual force that supports the life of individuals and enterprises, as well as a realm of self-satisfaction in the endless to learning process.Its goal is perfection, perfection, and the never-ending pursuit of the seven zeros.
Ii. Four characteristics of Lean production
Most of the enterprises have already realized the lean production to the enterprise a importance of lean production management enterprise is the same, of course, lean production to a certain extent can make the production efficiency of the enterprise, at the same time can also be in a certain extent, the enhancement enterprise's own ability to compete, but although a lot of companies want to implement lean management, but did not really understand a characteristics of lean production, so what is the distinguishing feature of lean production management?
1. Eliminate all waste and pursue excellence
Lean production is characterized by the elimination of all waste, the pursuit of excellence and continuous improvement.To get rid of all the useless things in the production link, the principle of the arrangement of each worker and his post is that the value must be increased, and eliminate all the posts that do not add value.Streamlining is its core, streamlining all non-value-added work in product development, design, production and management, aiming to respond to market demand with the best quality, the lowest cost and the highest efficiency.
2. Emphasize the role of people and give full play to their potential
Lean production largely transfers tasks and responsibilities to workers who directly add value to the product.And the task is assigned to a group, by the cooperation of the workers within the group.To this end, workers are required to master a variety of jobs, reduce workers who do not add value directly, and increase workers' autonomy in production.When the production line breaks down, the workers have the right to decide to stop, find out the reason and make the decision.Teamwork expands the scope of workers' work, stimulates workers' interest in work and innovative spirit, and is more conducive to the implementation of lean production.
3. Zero waste
Inventories are the bane: high inventories are one of the hallmarks of mass production.Due to the instability of equipment operation, unreasonable process arrangement, high rejection rate and unbalanced production, supply is often not timely. Inventory is regarded as an essential "buffer".But lean production is that inventory is the "scourge" of the enterprise, the main reason is: (1) inventory increases the cost of operation;Inventories mask the problems of the business.
Both ineffective labor in production and excess labor in advance of inventory are wastes.To eliminate this waste, lean production requires ruthlessly removing links and jobs that do not directly add value to the product.
4, The pursuit of perfection, never satisfied
Lean production takes "the endless pursuit of perfection" as its business goal and pursues continuous improvement in product quality, cost and service.This idea is an important characteristic which is different from mass production mode, and it is also the spiritual power for lean production to be successful.Just-in-time production (JIT) and continuous improvement process (CIP) are the embodiment of the pursuit of perfection in lean production.
Lean production mode strives for the rationality and efficiency of production, and pursues the production technology and management technology that can flexibly and flexibly produce high-quality products to meet various demands. Its basic principles and many methods are of positive significance to the manufacturing industry.
Three, six advantages of lean production
In view of the above characteristics and compared with mass production, the advantages of lean production are mainly reflected in the following aspects:
1. Whether in product development, production system or other departments of the enterprise, compared with enterprises under the mass production mode, the human resources required can be reduced by half;
2. New product development cycle can be reduced by more than half;
3. Wip inventory in the production process can be reduced to one-tenth of the general level under mass production mode;
4. The space occupied by enterprises can be reduced to half that of enterprises adopting mass production;
5. The inventory of finished products can be reduced to one quarter of the average inventory level of mass production enterprises;
6. Product quality can be improved three times.
Four, the ten tools of lean production
1. Just-in-time production (JIT)
Just-in-time production (JIT) originated in Japan, and its basic idea is to "produce what is needed only when it is needed and in the quantity needed".The core of this mode of production is the pursuit of a production system without inventory, or the production system to minimize inventory.When we are in production, we should operate in strict accordance with the standard requirements. We should produce according to the demand and send as many materials as needed on site to prevent abnormal inventory.
2. 5S and visual management
5S (sorting, rectification, cleaning, cleaning and accomplishment) is an effective tool for visual management on site, as well as an effective tool for the improvement of staff's accomplishment.The key to the success of 5S is standardization, the most detailed site standards and clear responsibilities, so that employees should first maintain the cleanliness of the site, and at the same time expose the site to solve the problems of the site and equipment, and then gradually develop the standard and regular professional habits and good professional accomplishment.
3. Kanban Management
Kanban can be used as a means to exchange information on in-plant production management.Kanban cards contain considerable information and can be used over and over again.There are two common types of Kanban: production kanban and delivery Kanban.Kanban is more direct, visible and easy to manage.
4. Standardized Operation (SOP)
Standardization is the most effective management tool for production efficiency and high quality.After value flow analysis, the production process forms the textual standard according to the scientific technological process and operation procedure. The standard is not only the basis for product quality judgment, but also the basis for training employees to operate in a standardized way.These standards include visual field standards, equipment management standards, product production standards and product quality standards.Lean production requires "everything to be standardized."
5. Overall production maintenance (TPM)
With the participation of the whole staff, to create a well-designed equipment system, improve the utilization of existing equipment, achieve safety and high quality, prevent the occurrence of failures, so that the enterprise to reduce costs and improve the overall production efficiency.Not only 5S, but also work safety analysis and production safety management.
6. Use value Stream Map to identify waste (VSM)
The production process is full of amazing waste phenomenon. Value Stream Mapping is the foundation and key point of implementing lean system and eliminating process waste:
• Identify where waste occurs in the process and identify lean improvement opportunities;
• Understand the components and importance of the value stream;
• The ability to actually draw a value stream map;
• Recognize the use of data in value stream diagrams, and ** the sequence of data quantification improvement opportunities.
7. Balanced design of production line
Because of the unreasonable layout of the assembly line, the production workers move unnecessarily, thus reducing the production efficiency;Because the action arrangement is unreasonable, the process route is unreasonable, causes the worker repeatedly to pick up or put down the work piece.Assessment is important now, and so is site planning.Save time and effort.Twice the result with half the effort.
8. PULL production (PULL)
The so-called pull production is based on Kanban management. "Take out" means that the later process produces according to the needs of the "market". Take the same amount of work-in-process shortage of this process from the previous process, thus forming a whole-process pull control system, never producing one more product.JIT needs to be based on pull production, and pull system operation is a typical feature of lean production.Lean pursuit of zero inventory, the main ** pull system operating mode to achieve.
9. Quick Switch (SMED)
The theoretical basis for rapid switching is operational research and concurrent engineering, which aims to reduce the equipment downtime as much as possible with teamwork.When changing product line and adjusting equipment, the lead time can be compressed to a large extent, and the effect of quick switch is very obvious.
In order to reduce the idle wait waste to ** less, the process of shortening the setup time is the process of gradually removing and reducing all non-value-added jobs and converting them to non-stop time.Lean production is realized by constantly eliminating waste, reducing inventory, reducing defects, shortening manufacturing cycle time and other specific requirements. Reducing setting time is one of the key techniques to help us achieve this goal.
10. Continuous Improvement (Kaizen)
Miracles begin when value is precisely identified, value streams are identified, steps that create value for a particular product are continuously flowing, and customers are pulling value from the enterprise.