7大浪费经典介绍(中英文版)

WasteElimination消除浪费2Whychangeandimprove?我们需要改善吗3TopMgtMiddleMgtFrontLineAssociateBreakthroughDailyManagementSupervisorKaizenHowShouldYouSpendYourTime?工作角色与时间分配4ChangeIsNotEasy求变并非易事ChangeandImprovementDoNotComeEasy改变和改进来之不易Basicpremise基本前提Physicstellsus物理原理告诉我们Humannature人类本性Why?为什么？Therefore因此Thegreatertheresistance阻力越大Toimprovewemustcontinuouslychange要提高就必须不断改进Foreveryaction(change)thereisanequal&oppositereaction每一次用力（改变）都会有相应的反作用力Peopleresistchange(i.e.lookforexcuses,waitandsee,etc.)人们抗拒变化（如：寻找借口，等待，坐视旁观等等）Becausechangetakespeopleoutsidetheircomfortzones因为变化会使他们脱离舒适的环境Themoreyouchangethegreatertheresistance变化越大阻力也越大Themoredifficultitistoimprove改进就越难5PurposeofTraining培训目的•Introducetheconceptsofthe7kindsofwaste介绍7种浪费的概念•Defineanddiscussvalueaddedandnon-valueadded定义和讨论“增值”与“非增值”•Identifyanddiscusswaystoeliminatewaste辨认和探讨消除浪费的方法6Input输入•Energy能源•People人力•Capital资本•Water水•Materials材料•Tools工具Output输出•Products产品•Services服务Waste浪费ValueAdded增值Focusoftraditionalimprovementprograms传统方式侧重于•Worklonger增加工作时间•Workharder增加工作强度•Addpeople增加人手•Addequipment增加设备•Fastercycletimes加快周转时间Focusofleanproduction精益焦点•Eliminatewaste消除浪费IdentificationofWaste浪费的识别7增值–客户愿意为何付费?增值–客户愿意付费的将原材料或信息转换成产品或服务的步骤或活动ThatChangeARawMaterialOrInformationIntoAProductOrServiceForWhichTheCustomerIsWillingToPay当确定价值时我们必须从客户的观点出发WeMustThinkFromTheCustomer’sPerspectiveWhenDeterminingValue!不增值-不需要的步骤或活动,增加的流程时间和成本多于价值Non-ValueAdded–NonessentialStepsOrActivitiesThatIncreaseProcessTimeAndAddCostsRatherThanValue8IsitValueAdded(VA)orNon-ValueAdded(NVA)?请判断是否增值？VA增值NVA不增值Cuttingoperation切削工序ValueAdded–Examples增值案例9IsitValueAdded(VA)orNon-ValueAdded(NVA)?请判断是否增值？VA增值NVA不增值Cuttingoperation切削工序ValueAdded–Examples增值案例10IsitValueAdded(VA)orNon-ValueAdded(NVA)?请判断是否增值？VA增值NVA不增值Cuttingoperation切削工序Grindingoperation磨削工序ValueAdded–Examples增值案例11IsitValueAdded(VA)orNon-ValueAdded(NVA)?请判断是否增值？VA增值NVA不增值Cuttingoperation切削工序Grindingoperation磨削工序ValueAdded–Examples增值案例12IsitValueAdded(VA)orNon-ValueAdded(NVA)?请判断是否增值？VA增值NVA不增值Cuttingoperation切削工序Grindingoperation磨削工序HeatTreatment热处理ValueAdded–Examples增值案例13IsitValueAdded(VA)orNon-ValueAdded(NVA)?请判断是否增值？VA增值NVA不增值Cuttingoperation切削工序Grindingoperation磨削工序HeatTreatment热处理ValueAdded–Examples增值案例14IsitValueAdded(VA)orNon-ValueAdded(NVA)?请判断是否增值？VA增值NVA不增值Cuttingoperation切削工序Grindingoperation磨削工序HeatTreatment热处理MovingMaterial搬运ValueAdded–Examples增值案例15IsitValueAdded(VA)orNon-ValueAdded(NVA)?请判断是否增值？VA增值NVA不增值Cuttingoperation切削工序Grindingoperation磨削工序HeatTreatment热处理MovingMaterial搬运ValueAdded–Examples增值案例16IsitValueAdded(VA)orNon-ValueAdded(NVA)?请判断是否增值？VA增值NVA不增值Cuttingoperation切削工序Grindingoperation磨削工序HeatTreatment热处理MovingMaterial搬运Inspection检查ValueAdded–Examples增值案例17IsitValueAdded(VA)orNon-ValueAdded(NVA)?请判断是否增值？VA增值NVA不增值Cuttingoperation切削工序Grindingoperation磨削工序HeatTreatment热处理MovingMaterial搬运Inspection检查ValueAdded–Examples增值案例18ofallmanufacturingtimeisnon-valueadded!95%的生产时间是不能增值的95%Non-ValueAdded非增值19增值vs.非-增值增值非增值必要不必要通过KAIZEN持续提高如果可能消除,如果不可能Kaizen如果可能消除,如果不可能Kaizen立即消除20•Inventory库存•Motion多余动作•Transportation搬运•Waiting等待•Overproduction过量生产•Processing过程不当•Correction返工•Unusedtalent/skills•NonergonomicsworkstationIdentifyandEliminate9WastesI’MTWOPC+UN21Anysupplyinexcessofprocessrequirementsnecessarytoproducegoods任何超过加工必须的物料供应WasteofInventory库存浪费22InventoryHidesProblems!!库存会隐藏问题！！InventoryHidesWaste!!库存会隐藏浪费！！Water=Inventory水=库存ROCKS=PROBLEMS暗礁=问题LongChangeovers换模时间过长Variation变更EquipmentDowntime设备停机时间InventoryLevel库存量LargeLotSizes过大的批量SupplierQuality供应商的质量Poorlayout糟糕的厂区布局InventoryHidesProblems过多的库存会隐藏问题23LowDownInventoryToExposeProblem通过降库存暴露问题交货问题质量问题效率问题维修问题库存水平24Anymovementwhichdoesnotcontributevaluetotheproductorservice任何不增加产品或服务价值的人员和设备的动作WasteofMotion多余动作25Anymovementofmaterialthatdoesnotsupportaleansystem不符合精益生产的一切物料搬运活动WasteofMaterialTransportation物料搬运26IdleTimeThatIsProducedWhenTwoDependentVariablesAreNotFullySynchronized当两个关联要素间未能完全同步时所产生的空闲时间WasteofWaiting等待27WasteofOverproduction过量生产•生产多于下游客户所需MakingMoreThanNeeded•生产快于下游客户所求MakingFasterThanNeeded劳模？28OverproductionWaste生产过剩Overproductionisconsideredtheworstwaste!生产过剩被认为是最严重的浪费！Why?为什么？29Overproductionspinsoffallothertypesofwaste生产过剩超过了其他所有的浪费形式•Overproduction生产过剩•Needmoreboxes需要更多箱子•Needmanypallets需要更多托盘•Needforklift需要叉车•Needforkliftdrivers需要叉车司机•Needadditionalfloorspace需要额外的地面空间•Needwarehouse需要仓库•Needwarehouseoperators需要库房管理员•Manypartsgetrusty许多零件生锈•Needsortingoperator需要分类管理员•Needrework需要返工•Makescrap产生废料OverproductionWaste生产过剩30Effortwhichaddsnovaluetoaproductorservice对最终产品或服务不增加价值的过程WasteofProcessing过程不当/过多的工艺31ReworkofaProductorServicetoMeetCustomerRequirements为了满足顾客的要求而对产品或服务进行返工WasteofInspection/Correction/Rework检验/校正/返工32TheApproach方式TheMeans/Tools工具TheStrategy策略ELIMINATIONOFWASTE消除浪费COSTSLEADTIME生产周期COSTS成本QUALITYTHEFIRSTTIME一次交验的质量WORKPLACEORGANIZATION车间组织及布局5S/VISUALCONTROLS5S/目视化管理QUICKCHANGEOVER快速换模KANBAN看板DEDICATEDLINESONEPIECEFLOW特定单件流动生产线ONEPIECEFLOW单件流水生产STANDARDWORK标准化作业QUALITY有效的质量管控LeanManufacturing精益制造ContinuousImprovementbytheEliminati