Lean-Manufacturing-Overview(精益生产)

IfThisSoundsLikeYourCompany……MaybeNOWIsaGoodTimeToLookAt‘LeanManufacturing’Herearesomeofthebasictruthsof‘Lean’andmanyofthetoolsyouwillfindessentialtoimplementit.WhetheryouareinManufacturing,HealthService,FinancialServices,PublicSectororANYotherindustry–‘Lean’CANhelpYOU!Clickforenlightenment…..OrdersCompletedYesterdayMoreouttheDoorYourPayYourBreaksEndtoBackchatYourTimeAnsweringbackCooperationHardWorkSENSEOFURGENCYFLEXIBILITYSoundFamiliar?………..withinaLeanCompanyBasicLeanPhilosophy……..DescriptionofaLeanCompany•LeaniscompletelyaboutCULTURE,orthe“ThinkingWay”.•Leanisnotapartofwhatwedo,itisineverythingthatwedo,itisourwayofthinking.•Itisanembeddedcultureofunderstandingthecustomer’sneeds,continuallystrivingtoreducewasteandoptimisingtheperformanceofprocess,peopleandinfrastructure.•Atalllevelsthereisastrongdesiretobebetter.•AcultureofLeanisvisiblyprioritisedandpractisedfromthetoptothebottomoftheworkforce.•Thekeyisunderstandingthecustomeranddeliveringhisrequirements.Lean….•Improvesbusinessperformanceusingsimple,practicaltoolsandtechniquestoenhancequality,cost,deliveryandpeoplecontribution.•Exposesthewastesinthesystem•Peoplehavetochangetheirlongstandingworkpracticesandideas•Seniormanagementwillhavetodriveleanprinciplesforwardwithtotalcommitmenttoitssuccess•Nota“bolton”technique,moreawayoflifeleadingtoatotalchangeincultureTypesofWork–IdentifyingWasteValueAdding(VA):AnyactivitythatdirectlyaddsvaluetotheproductNon-ValueAdding,butunavoidablewithcurrenttechnologyormethods.AnyworkcarriedoutthatdoesnotincreaseproductvalueIncidentalWork(NVA),butunavoidablewithcurrenttechnologyormethods.AnyworkcarriedoutthatdoesnotincreaseproductvalueWasteAnactivitythatdoesnotaddvaluetotheproductandhencesomethingthatyoudon’twanttobedoing,hence‘Waste’.WasteEliminationNon-ValueAdding,butunavoidablewithcurrenttechnologyormethods.AnyworkcarriedoutthatdoesnotincreaseproductvalueValueAddWasteTraditionalFocus•WorkLonger-Harder-Faster•AddPeopleorEquipmentLeanManufacturing•ImprovetheValueStreamtoEliminateWasteLEADTIMEIncidentalWork(NVA)E.g.InspectionNon-ValueAdding,butunavoidablewithcurrenttechnologyormethods.AnyworkcarriedoutthatdoesnotincreaseproductvalueQUALITYPRODUCTSDefectsshouldneverbepassedontothefollowingprocessTheideathatdefectsaretheresponsibilityofinspectionspecialistsattheendofthelinedoesnotexistValueAdded(VA)E.g.GoodThinking….….GoodProductsEmployeesarenotexpectedtosimplyroutinelydotheirjobbutareexpectedtocontributetotheimprovementoftheirownworkoperations,utilisingtheirownpersonalexperience,knowledgeandcreativity.Ontheremainingslidesarebriefoverviewsofsomeofthe‘Lean’ToolsMIFA-Material&InformationFlowAnalysisComponent/Sub-AssemblyforecastsFinishedGoodsForecastsOrdersRawMaterialsComponentsSub-AssembliesFinalAssemblySupplierCustomerCompanyProcessAProcessBProcessCProcessDDespatchGoodsInwardsProductionControlForecastOrdersFaxForecastWeeklyScheduleIIIIProductionLeadTimeProcessingTimeHrsHrsHrsHrsDaysDaysDaysDaysDaysContinuousFlowProcessingWIPbuildsupProcessAProcessBProcessCBATCHMANUFACTUREBatchmanufacturingisoftenorganisedbygroupingprocesses,howeverthiscaninhibitmaterialflowProcessABCXONEPIECEFLOWInventoryiseliminatedbetweenprocessesallowingtheproducttoflowthroughthevaluestreamPROCESS123456789(Timeinhrs)123DELAYDELAYPARTSWAITUNTILPREVIOUSPARTSAREPROCESSEDLEADTIME=7HOURSPROCESS123456789(Timeinhrs)123REDUCEDLEADTIME=3HOURSPARTSWAITUNTILPREVIOUSPARTSAREPROCESSEDeg:ifthestockbetweenprocessesisthreeunitsthefollowingsituationwouldoccurTheintroductionofcontinuousflowsignificantlyreducesLeadTimeBenefitsofCFPare:ReducedworkinprogressReducedLeadTimeReducedtransportationFloorspacesavingImprovedcommunicationPeopleandOrganisationStage1.InformationStage3DirectionStage2.SupportStage4EncouragementDenialFrustrationIrritationAngerConfusionExploringAcceptanceCommitmentTimeConfidence,Morale&EffectivenessLookingtothepastLookingtothefutureHiddenbehaviourOpenbehaviourTheChangeCurveLeanTransformation:-Ismorethanjustanewwayofmanufacturing.Itisgoingtochallenge&changethewholeorganisation.Successdependsonthepeopleintheorganisationandtheiracceptanceandcommitment.LeanwilltoucheveryoneClearandconsistentcommunicationsChangethewayyoudothings,bedifferent-bethebest!GoodQualityProductOntimeeverytimeSharedBenefitsCustomerServiceBuildaPartnershipLessfirefightingImprovedrelationshipsInvestinjobcreationCreatealongtermfutureProvideeverythingforthejobCreateachangeenvironmentEncourageinnovationWorktogetherforacommongoalGivepeoplemoreskillsProvidethetoolstobethebestCreateasafer&cleanerenvironmentHavetheskillsforthejobInvolvedinproblemsolvingWorksmarternotharderRaise&solveproblemsCreatesustainableimprovementLessfrustrationOwnershipofcelltargetsTeamworkingInnovativecultureLeadershipChangeTheWILLtoimproveInspiretheBELIEFProvidetheTOOLSDOit!ManagementQualityproductsHighproductivityFlexibilityJobsecurityGoodworkingenvironmentReasonablesalary&benefitsExpectsExpectsWorkforceYou’renotafailureifyoudon’tmakeit.You’reasuccessbecauseyoutry.“IfwealwaysdowhatwealwaysdidthenWe’llalwaysgetwhatwealwa