第7讲精益运营lean operations

精益运营

Synonyms

continuousflowmanufacturehighvalue-addedmanufacturestocklessproduction

low-inventoryproduction

fast-throughputmanufacturingleanmanufacturing

Toyotaproductionsystemshortcycletimemanufacturing

浪费(muda)

Activities:

operation

movement

inspection

delay

storage

Whichofthesesymbolssignifynon-valueaddingactivities?

Typesofwaste:

overproduction

waitingtimetransportprocessinventorymotiondefectivegoods

influencingthethroughputefficiency

ElementsofLean

Just-in-time

Jidoka(自働化)

Heijunka(平准化)

Kanban

Nagare(流)

‘Valuestream’mapping

‘Valuestream’mappingfocusesonvalue-addingactivitiesanddistinguishesbetweenvalue-addingandnon-value-addingactivities.

Invoicestatus

Cashmanagement

T/T=Tasktime

TTT=TotalthroughputtimeV-AT=Value-addedtimeC/T=Cycletime

Valuestreammapforanindustrialairconditioninginstallationservice

Forecasts

Salesoffice

Operationsplanning

Jobtrackingconfirmations

Completionconfirmation

Survey

T/T=0.5

Avail=100%

C/T=30

Waitinbranch

Order

T/T=0.5

Avail=100%

C/T=10

Waitforassembly

Assemble

T/T=5.0

Avail=100%

C/T=12.5

T/T=0.75

Avail=100%

C/T=17

Shiptobranchandwait

Frame

Install

T/T=0.75

Avail=100%

C/T=35

Waitforinstallers

30 mins 58hrs 30 mins 96hrs 5hrs

48hrs

60

mins

48hrs

60mins

TTT=258

hrsV-AT=8

hrs

FigureValuestreammapforanindustrialair-conditioninginstallationservice

JITMainconcepts

Quality

Throughputtime

Cost

2016/6/27 8

Quality

Cleardefinitionofquality

PokaYoke(foolproof)

Everybodyisaqualityinspector

Andon

Continuousimprovementphilosophy

Solve(nothide)problems

Workinimprovementteams

Throughputtime

Smallbatches

Separateproductionbatchfromtransportationbatch

Setuptimereduction

Smoothschedule

Synchronizeoperations

Kanbans

CONWIP(constantworkinprocess)

U-shapedlines

Cost

Balancecapacitywithdemand

Linebalancing

U-shapedlines

Saturateworkers,notmachines

Multifunctionalworkers

Eliminatewaste–valuestreaming

Leanservice

Intermsofoperationsandimprovements,theserviceindustriesingeneralarealongwaybehindmanufacturing.

Notallleanmanufacturingideastranslatefromfactoryfloortoofficecubicle.

Adoptingleanoperationsprinciplesaltersthewayacompanylearnsthrough