Waste Identification 4t 7大浪费识别 - 日本专家

1、识别浪费 Time Line Reduction 缩短时间线 The Toyota WayThe Toyota Way The Heart of the TPS: Eliminating waste. 丰田生产体系的核心：消除浪费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

2、 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 i

3、s 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 T = Transpor

4、t 搬运搬运 I = Inventory 库存库存 M = Motion 动作动作 W = Waiting 等待等待 O = Overproduction 过量生产过量生产 O = Over processing 过度加工过度加工 D = Defects 缺陷缺陷 Typically the following is the break up VA / NVA in the manufacture of a part.增值增值/非增值活动所占比例非增值活动所占比例 Value added = 5% 增值增值 Necessary NVA = 45%. 必须的不增值必须的不增值 NVA (Wast

5、e) = 50% 浪费浪费 Typically 95% of Total Lead Time is Non-Value Added! 95%的活动都 是不增值的 Value added 增值增值 5% Non-value added 不增值不增值 LEAN = ELIMINATION OF WASTE Types of Activities 活动的分类 Value Added Work 增值工作 The part of the job the customer wants to pay for 客户愿意付钱的活动 Hidden Waste 隐藏的浪费 Work that doesnt add

6、value but is required under the current operating conditions 不得不做的工作，但不增值 Obvious Waste 明显的浪费 Work that does not add value and is not necessary 不必须也不增 值的活动 WASTE What is Value Added Work?什么是增值工作？ Work which increases the value of a part. i.e. that which the customer is willing to pay for增加部件的价值，哪些客户

7、愿意付钱的的部分 e.g.如 Press冲压 Polish抛光 Assemble 组装Forge成形 Heat treat 热处理Plate电镀 Bend折弯Cut剪切 Drill钻孔Cast压铸 Weld电焊Paint油漆. 5% 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 tr

8、ansporting 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

9、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

10、 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 传统方法 Specialist departments 独立的分工 Press Plating WeldingShipping Assy Packing Polishing Long distances 长距离 long lead-times长周期 big bat

11、ches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 Obsolescen

12、ce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

13、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 pro

14、blems 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 plac

15、e 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 tripl

16、e 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.动作不等于工作动作不等于工作 An operator may be kept “busy” for hours looking for tools without add

17、ing any value for the customer 操作员可操作员可 能很忙的花能很忙的花1小时在找寻工具，但不是小时在找寻工具，但不是 增值的活动增值的活动 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

18、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 5. Waiting When operators are waiting for work

19、 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? 5. Ove

20、r Production 过量生产 Making in excess of customer demand or in advance of customer demand超过客户需求或提前完成客户需求 Making too much 做多了 Making too early 做的太早了 Making “just-in-case” 保险起见多做 Making large batches 大批量做 Making quicker than demand 比需求更快的做 Making quicker because of unstable process 由于不稳定的原因更快的做 Making mo

21、re because of inappropriate machinery 由于不恰当的设备做多 了 Our aim should be to make exactly what is required, no more and no less, just-in-time and with perfect quality 我们的目标是做客 户需要的，不多不少，时间正好，质量上乘 5. Over Production Overproduction occurs when 当如下情况发生 Build plans are generated based on a forecast which “gu

22、esses” the demand and pushes inventory up.按照预测生 产建库存 Processes are not linked together工艺间衔接不好 Bonus systems encourage output that is not needed不合理 的激励措施，如计件制 Performance measures encourage high machine utilisation when production is not required当产量不高时，一味的强调用足 设备资源 Inappropriate equipment (long chang

23、eovers, producing faster than takt, poor process capability) 不合适的设备条件（ 长换型时间，比节拍时间做的更快，不稳定的流程） 5. Over Production Overproduction is a problem because:过量生产将导致 Uses resource unnecessarily (People, Material and Machines) 浪费人机料资源 Creates cash flow problems by locking in cash 现金流问题 Leads to extended lead

24、 times by creating waiting time along the whole process加长整个流程等待时间 Creates unnecessary Inventory (requiring extra space, extra transportation, extra equipment, and extra resource) 制造不必要的库存等一系列的问题 Increases scrap costs and can lead to obsolescence 导致报废 Machine Maintenance and Improvement activities ca

25、nnot take place whilst Machines and People are Overproducing没有时间做设备保养 Ultimately prevents the FLOW of materials 阻碍物料流动 6. Over Processing 过度加工 Unnecessary actions or inappropriate processes 不必要的动作或不 适合的流程 Wrong choice of equipment 选错设备 Bad definition of customers needs 对客户需求的错误定义 Unnecessary operati

26、ons 不必要的操作 Excessive inspections 过度的检查 Unnecessary inspections 不必要的检查 Complex machinery 复杂化的设备 due to poor Supplier quality 供应商的质量问题 Bottlenecks 瓶颈 Unbalanced process 不平衡的流程 Additional work necessary to be able to complete a job 超过完成一项工作的必须的步骤. Producing to a higher specification than necessary 按照过高

27、的标准来生产 6. Over Processing 过度加工 “Using a hammer to crack a nut”. Thinking one big machine rather than several smaller ones. “杀鸡用牛刀” lead to pressure to run machine as often as possible 频繁的使用设备 encourages general purpose, more complex machines 更复杂的设备 poor layout & extra transportation 不合理的布局和额外的搬运 Use

28、 the smallest, simplest machine, capable of producing the required quality, at the right speed and can be positioned at the point of use 使用最小巧,简单的设备以合适的速度来生产需要 的数量,且放置在使用点. 7. Defects缺陷 Less than perfect parts Scrap 报废 Trimming 修理 Rejects 不合格品 Sorting分类排查 Rework返工 Quarantine隔离 Waiting for decisions等

29、待决议 Delay due to defects由于缺陷延迟 Transportation due to defects缺陷搬运 Re-inspecting & sorting重新检查 Rework area/lines in production process返工区域 Overtime to catchback demand加班 7. Defects缺陷 Types of mistakes 错误的分类 Negligence 疏忽 Misunderstanding 误解 Wrong identification错误的识别 Lack of experience缺少经验 Lack of Standard Operations缺少标准流程 Not following Standards没有指示标准 Wrong information错误信息 Lack of knowledge缺少知识 Carelessness粗心 Doh! To avoid mistakes:避免错误 Invent error proofing devices 开发防错设备 Checklists 检查清单 Dowel pins and location pins定位销 Error and alarm detec