Waste Identification 4t 7大浪費識別 - 日本專家

識別浪費TimeLineReduction縮短時間線TheToyotaWayTheHeartoftheTPS:Eliminatingwaste.豐田生產(chǎn)體系的核心：消除浪費.Lean精益Weshouldnotfocusonresultsandthenrallyateamtofixtheproblem.Thisisareactionbasedapproach.我們不應該遇到問題后，就組織一個團隊去解決，這是應急措施的方法Bybuildingastrongfoundationfrombottomup,focusingonthetoolsprovided,automaticallypositiveresultswillbeabyproduct.如果我們從基層到高層建立一只強大堅實的基礎，在關注我們精益方法的應用，好的結果會自動出現(xiàn)。Improvingperformance提升績效Leanproductionisaimedattheeliminationof

waste

ineveryareaofproduction精益生產(chǎn)就是瞄準生產(chǎn)區(qū)域的浪費的消除Itsgoalistoincorporate

它的目標包含lesshumaneffort,最少的人員消耗lessinventory,最少的庫存Lessscrap最少的報廢lesstimeand最短的周期lessspace最少的設備Tobecomequickertorespondtocustomerschangesindemandwhilemakingtopqualityproductsinthemostefficientwaypossible.以最快的速度響應客戶的需求同時以最有效的方法提供高質量的產(chǎn)品The7Wastes7大浪費

T=Transport搬運

I=Inventory庫存

M=Motion動作

W=Waiting等待O=Overproduction過量生產(chǎn)O=Overprocessing過度加工D=Defects缺陷TypicallythefollowingisthebreakupVA/NVAinthemanufactureofapart.增值/非增值活動所占比例Valueadded=5%增值NecessaryNVA=45%.必須的不增值NVA(Waste)=50%浪費Typically95%ofTotalLeadTimeisNon-ValueAdded!!!95%的活動都是不增值的Valueadded增值5%Non-valueadded不增值LEAN=ELIMINATIONOFWASTEWhatisHiddenWaste?什么是隱藏的浪費Workthatdoesnotaddvaluebutisrequiredunderthecurrentoperatingconditions不增加價值但不得不做的工作toolchangeover換模Inspection檢查partshandling手持部件transportingparts搬運部件unwrappingofpurchasedparts外購件拆包Paperwork文字工作Decanting轉移容器progresschasing追趕進度storagespace儲存空間Meetings會議managinginventory庫存管理……..

1.Transportation搬運Customersdonotpaytohavegoodsmovedaround,soanymovementofmaterialinafactoryisawaste.客戶不會為工廠內無效的搬運付錢，所以搬運是浪費Materialsstoredalongwayfrompointofuse存儲地相距使用點太遠Unnecessarymovingorhandlingofparts不必要的搬運Handlingequipmentmovingwithoutanypartsbeingmoved搬運設備的空移動Feedbackonqualityisinverselyrelatedtotransportlength長距離搬運導致質量的隱患increasesthelikelihoodofdamage!增加損壞的可能性1.Transportation搬運CellularManufacturingprovides細胞化生產(chǎn)方式提供shortdistances,shortlead-times,smallbatches頸段距離，周期時間，更小批量LowWIP,lowcost,Goodproblemsolving&teamspirit低庫存，成本，號的問題解決精神PressPlatingWeldingShippingAssyPackingPolishing1025feet30Days200feet1Day1.TransportationThetraditionalApproach;傳統(tǒng)方法Specialistdepartments獨立的分工PressPlatingWeldingShippingAssyPackingPolishingLongdistances長距離longlead-times長周期bigbatches大批量highwip高在制品highcost高成本poorproblemsolving

差的問題解決能力2.Inventory庫存Largestocks大量庫存Stockpileoffinishedgoods大量的成品庫存HighWIP高的在制品Highrawmaterials原材料Excessiveracking多余的貨架Excessivewarehousespace多余的倉庫面積Excessivehandlingequipment多余的搬運設備Extramanagement額外的管理Obsolescence報廢Poorlayout不合理的布局Restrictivelayout限制的布局Excessivetransportation多余的搬運Unnecessarysearchingandmovingofmaterials不必要的尋找2.InventoryThemaincausesforinventoryare庫存的主要原因是Processunreliability(tocoverdowntime)不穩(wěn)定的工藝（彌補損失時間）Poorprocessresponsiveness(tocoverchangeovers)較慢的相應流程（來彌補長的換型時間）Pushsystemsofmanufacture差的制造系統(tǒng)Inventoryincreasesthemanufacturingleadtime,thisleadsto:庫存增加制造周期，導致：－slowerintroductionofengineeringchangesandprocessimprovements更慢的工程更高相應increasedqualityrisk質量風險增加increasedriskofobsolescence報廢增加Itleadsto導致Concealedproblems隱藏的問題Increasedleadtimes加長的周期時間Preventsrapididentificationofproblems阻礙快速識別問題Increasesspacerequirements增加額外的空間需求Andtherebydiscouragescommunication因此導致溝通不暢Inventorydeliberatelyhidesproblems隱藏問題Qualityconcernsarenotconsideredimportantifextrapartscanbeusedinplaceofdefectiveparts由于可以多生產(chǎn)，導致忽略質量問題Concealsimbalanceinprocesses掩蓋生產(chǎn)不平衡的問題Thetruecostofinventoryisthemoneytiedupinit庫存的成本是資金的積壓InventoryisEVIL庫存有罪3.Motion動作Unnecessarymovementofoperatorsandmachinesastheycarryoutcyclesofwork不必要的人員和設備動作doublehandling二次搬運triplehandling三次搬運Reaching伸手Bending彎腰Stretching伸長Walking走動Twisting踮腳morethantwoturnstoloosenbolts松螺絲超過2圈undulyexertingthemselvesinanyway任何形式的不當?shù)挠昧?.MotionMOVEdoesnotnecessarilyequalWORK.動作不等于工作Anoperatormaybekept“busy”forhourslookingfortoolswithoutaddinganyvalueforthecustomer操作員可能很忙的花1小時在找尋工具，但不是增值的活動4.Waiting等待Thewasteofwaitingoccurswhenevertimeisnotbeingusedeffectively.等待浪費是時間沒有真正有效的利用起來Waitingformaterial等料Waitingformaintenance等維修Waitingfortoolchange/setter等工具Waitingforqualitycheck等質量檢查Waitingfornextstation等下一個工序Operatorsslowerthanline動作慢導致等待Animbalanceintheline不平衡Materialswaitingformachinechangeovers材料等機器還型Abottleneckprocessshortofwork瓶頸工序引起的Operatorswatchingmachinestocompletecycles操作員看作設備操作，等待下料Waitingistheenemyofsmoothflow5.WaitingWhenoperatorsarewaitingforworkorwaitingforsomethingtodo,itiswaste.Canthetimenotbebetterspentonanotheroperation?有等待就有浪費，不管是在等料還是其它Training培訓Cleaning清掃5Smaintainingequipment設備維護checking(machineryandquality)檢查practisingachangeover換型improvementactivities改善活動Whatisyourbestuseoftime?5.OverProduction過量生產(chǎn)5.OverProductionOverproductionoccurswhen當如下情況發(fā)生Buildplansaregeneratedbasedonaforecastwhich“guesses”thedemandandpushesinventoryup.按照預測生產(chǎn)建庫存Processesarenotlinkedtogether工藝間銜接不好Bonussystemsencourageoutputthatisnotneeded不合理的激勵措施，如計件制Performancemeasuresencouragehighmachineutilisationwhenproductionisnotrequired當產(chǎn)量不高時，一味的強調用足設備資源Inappropriateequipment(longchangeovers,producingfasterthantakt,poorprocesscapability)不合適的設備條件（長換型時間，比節(jié)拍時間做的更快，不穩(wěn)定的流程）5.OverProductionOverproductionisaproblembecause:過量生產(chǎn)將導致Usesresourceunnecessarily(People,MaterialandMachines)浪費人機料資源Createscashflowproblemsbylockingincash現(xiàn)金流問題Leadstoextendedleadtimesbycreatingwaitingtimealongthewholeprocess加長整個流程等待時間CreatesunnecessaryInventory(requiringextraspace,extratransportation,extraequipment,andextraresource)制造不必要的庫存等一系列的問題Increasesscrapcostsandcanleadtoobsolescence導致報廢MachineMaintenanceandImprovementactivitiescannottakeplacewhilstMachinesandPeopleareOverproducing沒有時間做設備保養(yǎng)UltimatelypreventstheFLOWofmaterials阻礙物料流動6.OverProcessing過度加工Unnecessaryactionsorinappropriateprocesses不必要的動作或不適合的流程Wrongchoiceofequipment選錯設備Baddefinitionofcustomers’needs對客戶需求的錯誤定義Unnecessaryoperations不必要的操作Excessiveinspections過度的檢查Unnecessaryinspections不必要的檢查Complexmachinery復雜化的設備duetopoorSupplierquality供應商的質量問題Bottlenecks瓶頸Unbalancedprocess不平衡的流程Additionalworknecessarytobeabletocompleteajob

超過完成一項工作的必須的步驟.Producingtoahigherspecificationthannecessary

按照過高的標準來生產(chǎn)6.OverProcessing過度加工“Usingahammertocrackanut”.Thinkingonebigmachineratherthanseveralsmallerones.“殺雞用牛刀”leadtopressuretorunmachineasoftenaspossible頻繁的使用設備encouragesgeneralpurpose,morecomplexmachines更復雜的設備poorlayout&extratransportation不合理的布局和額外的搬運

Usethesmallest,simplestmachine,capableofproducingtherequiredquality,attherightspeedandcanbepositionedatthepointofuse使用最小巧,簡單的設備以合適的速度來生產(chǎn)需要的數(shù)量,且放置在使用點.7.Defects缺陷LessthanperfectpartsScrap報廢Trimming修理Rejects不合格品Sorting分類排查Rework返工Quarantine隔離Waitingfordecisions等待決議Delayduetodefects由于缺陷延遲Transportationduetodefects缺陷搬運Re-inspecting&sorting重新檢查Reworkarea/linesinproductionprocess返工區(qū)域Overtimetocatchbackdemand加班7.Defects缺陷Typesofmistakes錯誤的分類Negligence疏忽Misunderstanding誤解Wrongidentification錯誤的識別Lackofexperience缺少經(jīng)驗LackofStandardOperations缺少標準流程NotfollowingStandards沒有指示標準Wronginformation錯誤信息Lackofknowledge缺少知識Carelessness粗心Doh!Toavoidmistakes:避免錯誤Inventerrorproofingdevices開發(fā)防錯設備Checklists檢查清單Dowelpinsandlocationpins定位銷Errorandalarmdetectors錯誤報警探測器limitortouchswitches限位接觸開關Detectors,readers探測器，讀數(shù)proximitydetec