精益生产教材(第一讲).ppt

MM4LMALeanManufacturing 10CreditsLevel4 AssessedbyendofSpringSemester LeanManufacturing Operations ProcessThinking LeanManufacturing Operations LeanThinkingHistory EliWhitneyisbelievedtohavestartedtheideaofLeanManufacturing In1799heperfectedtheconceptofinterchangeableparts HeacceptedacontractfromtheNorthAmericangovernmentfor10 000musketsat 13 40each Upuntilthistime musketpartswerenotinterchangeable Ifonesmallpartwasdamaged thewholeweaponwasthrownaway LeanManufacturing Operations LeanThinkingHistory 1900 FrankGilbrethinventedprocesschartingtorecogniseandunderstandnon valueaddedwastetoeliminateitfromtheprocess 1910 HenryFordcreatedacontinuousflowsystem 1924 WalterShewhartinventedtheprocesscontrolchart 1835 SamuelColtremovedthewastefromreloadingaswellasinterchangeableparts 940 JamesEdwardDemingappliedQualitycontrolmethodstotheUSnationalcensus LeanManufacturing Operations LeanThinkingHistory 1948 TaichiOhnoandhishelperShigeoShigostarttoredesigntheFordManufacturingSystem 1948 WithinfluencefromGen DouglasMcArthurDeminglecturesinJapanonwaste 1950 TheycreatedtoolssuchasSMED SingleMinuteExchangeofDies 1960 Inventedpullsystems KanBan 1973 Coinedthephrase JustInTimeManufacturing 1980 NBCtransmitsdocumentary IfJapancan Whycan twe 1950 JamesEdwardDemingtaughtQualitycontrolmethodstotheJapanese400topindustrialists LeanManufacturing Operations ProcessThinking DefinitionofLeanManufacturing IsaManufacturingphilosophywhichshortensthetimelinebetweenthecustomerorderandtheshipmentByeliminatingwaste Givethecustomerwhattheywantwhentheywantit anddon twasteanything Leanproductioncombinesthebestfeaturesofcraftproduction high quality individualized custom madeproducts andmassproduction manufacturingatgreatquantitiestosatisfybroadconsumerneedsatlowerprices Leanprincipleshavebeenappliedsuccessfullyworldwideintheautoindustryandarebeingincreasinglyemployedinmanyotherindustrialsectors Chiefbenefitsofleanproductionincludetheuseoffewerresources rapidandefficientproductdevelopmentcycle higherqualityatlowercost andgreaterflexibility LeanManufacturing Operations ProcessThinking LeanManufacturing Operations ProcessThinking LeanManufacturing Operations ProcessThinking LeanManufacturing Operations ProcessThinking Paradigmsarelikefiltersforourbrainsthathelpustoevaluateandorganizenewinformation Theydeterminethewayweseetheworldandthefuture Unfortunately paradigmscanalsobesodeeplyrootedinourmindstheybecomebarriersthatkeepinnovativeideasandnewopportunitiesfromreachingtheplacewhereinventivethinkingdevelops Movingforwardinthebusinessworldgoeshandinhandwithforward thinking Itisthereforenecessaryforsuccessfulorganizationstobeopentoopportunitiesandsolutionsthatdon tnecessarilyfitintothemouldthatsomeparadigmscreate JoelBarker Visionary LeanManufacturing Operations ProcessThinking LeanManufacturing Operations ProcessThinking A System isanetworkofinterdependentcomponentsthatworktogethertotrytoaccomplishtheaimofthesystemW E Deming LeanManufacturing Operations ProcessThinking LeanManufacturing Operations ProcessThinking LeanManufacturing Operations ProcessThinking LeanManufacturing Operations ProcessThinking Exercise Forapprox 5minutes Listpotentialbarrierstochange Whatmightyoudotoovercomethesebarriers LeanManufacturing Operations ProcessThinking 3thingsthatneedtobeinplaceforchangetotakeplace1 Theconceptissound2 Politicalwill3 Socialmotivation LeanManufacturing Operations ProcessThinking Process LeanManufacturing Operations ProcessThinking Exercise LeanManufacturing Operations ProcessThinking Process Inputs Outputs Transformation ProductorService Activity Leanmanufacturingisastrategyforremainingcompetitivethroughtheendlesspursuitofwasteelimination 1 Focusonthecustomer Whoaretheexternalcustomers Whatisaninternalcustomer Whatisvaluetothecustomer 2 Eliminatethe7wastesofproduction Whatarethe7wastes Whatcauseswaste Howdoweeliminatewaste 3 Domorewithless Howcanweincreasevalue Howtowastelessresources Howcanwedoboth LeanManufacturing Operations ProcessThinking LeanManufacturing Operations ProcessThinking Process Specifyvalue Fromtheperspectiveoftheultimatecustomer intermsofaspecificproductwithspecificcapabilitiesofferedataspecificpriceandtime i e QCDrequirements IdentifytheValueStream Developamodelofthecurrentandfuturevaluestreamsthatdeliversthespecifiedvalueandeliminatesobviousnonvalueprocessesandactivities Flow Implementthedesiredvaluestreamthatmakestheremainingvalueaddedstepsflowbytheeliminationofwastes Pull Anyupstreamprocesswillonlyproduceproductwhenthedownstreamprocessasksforit Note Onlywhentheprocessiscapableandincontrolshouldapullsystembeimplemented Perfection Continuallyidentifywaysto 1 increasecustomervalue 2 reducethecostsofnon valueaddingbutnecessaryactivities and 3 removesuccessivelayersofwaste astheyareuncoveredinexistingactivities Improvementsareundertakencontinuously systematicallyandgobeyondwastereductioneffortstoenhancevaluethroughinnovativechanges improvements Dr Demingbelievedthatinordertomanagethesystemsweworkin weneedtohave profoundknowledge ofthesystemsweworkin Often wearesolostinthewaywework thatweforgetaboutthesystemweworkin Weassociateourworkwithourtitlesandforgetwhatourpurposeofourworkis Inordertomanagebetterweneedtoknowwhyourorganisations systems exist ForthatweneedtofirstBELIEVEthatourorganisationsareindeedcomposedof networksofinterdependentcomponentsthatworktogethertoachievetheaimsofthesystem Dr Deming sowndefinitionofaSystem Wemustunderstandthatallthecomponentsarenotalikehoweveraliketheymayappeartobe Forthisweneedtounderstand Variation Weneedtounderstandthe why oftheinteractionsbetweenthecomponentsandhowtheinteractionsaffecttheultimateperformanceoftheSystemwithrespecttotheAimoftheSystem Understandthe theoryofKnowledge thewaywelearnandgrowmentally Finally weneedtounderstandthattheonlylivingpartsofsystems organisations arehumans Thegrowthofasystemdependsonthegrowthoftheindividualsinthesystem Weneedtounderstandtheindividualsaswellastheresultsofinteractionsbetweenindividuals ThisisunderstandingPsychology Ihavebeenveryconciseandverycryptic Youmaylearnmorebyreadingafewtextsonthesubject ThegreatthingabouttheDemingPhilosophyisthatyoucanneverbe finished withit TheSystemofProfoundKnowledgecanbeappliedtoanysystemincludingyourownlife Leanisallaboutgettingtherightthingstotherightplaceattherighttimethefirsttimewhileminimizingwasteandbeingopentochange FromthebookTheMachineThatChangedTheWorld weknowthatleanpracticeshaveledtosignificantimprovementsintheautomobileindustryintermsofcost quality andproductivity Asaresult leanisbecomingmoreprevalentinotherindustrialsectorsaswell Leancombinesthebestofcraftproductionwithmassproduction Sure leancanmeanlessofmanythings lesswaste lessdesigntime fewerorganizationallayers andfewersuppliers Butleancanalsomeanmore moreemployeeempowerment moreflexibilityandcapability moreproductivity morecustomersatisfactionandwithoutadoubt morelong termcompe