大浪費經(jīng)典介紹(中英文版)

1、Waste Elimination消除浪費消除浪費2Why change and improve? 我們需要改善嗎我們需要改善嗎3Top MgtMiddle MgtFront LineAssociateBreakthrough Daily ManagementSupervisorKaizenHow Should You Spend Your Time?工作角色與時間分配工作角色與時間分配4Change Is Not Easy求變并非易事求變并非易事Change and Improvement Do Not Come Easy改變和改進(jìn)來之不易Basic premise基本前提基本前提Physi

2、cs tells us物理原理告訴我們物理原理告訴我們Human nature人類本性人類本性Why?為什么？為什么？Therefore因此因此The greater the resistance阻力越大阻力越大To improve we must continuously change要提高就必須不斷改進(jìn)For every action (change) there is an equal & opposite reaction每一次用力（改變）都會有相應(yīng)的反作用力People resist change (i.e. look for excuses, wait and see, e

3、tc.)人們抗拒變化 （如：尋找借口，等待，坐視旁觀等等）Because change takes people outside their comfort zones因為變化會使他們脫離舒適的環(huán)境The more you change the greater the resistance變化越大阻力也越大The more difficult it is to improve改進(jìn)就越難5Purpose of Training培訓(xùn)目的培訓(xùn)目的Introduce the concepts of the 7 kinds of waste介紹7種浪費的概念Define and discuss valu

4、e added and non-value added定義和討論“增值”與“非增值”Identify and discuss ways to eliminate waste辨認(rèn)和探討消除浪費的方法6Input輸入輸入 Energy 能源 People 人力 Capital 資本 Water 水 Materials 材料 Tools 工具Output 輸出輸出 Products 產(chǎn)品 Services 服務(wù)Waste 浪費浪費Value Added增增 值值Focus of traditionalimprovement programs傳統(tǒng)方式側(cè)重于傳統(tǒng)方式側(cè)重于 Work longer 增加工

5、作時間 Work harder 增加工作強度 Add people 增加人手 Add equipment 增加設(shè)備 Faster cycle times 加快周轉(zhuǎn)時間Focus of lean production精益焦點精益焦點 Eliminate waste 消除浪費Identification of Waste 浪費的識別浪費的識別7增值增值 客戶愿意為何付費客戶愿意為何付費? 增值增值 客戶愿意付費的將原材料或信息轉(zhuǎn)換成產(chǎn)品或服務(wù)的步驟或活動客戶愿意付費的將原材料或信息轉(zhuǎn)換成產(chǎn)品或服務(wù)的步驟或活動That Change A Raw Material Or Information Int

6、o A Product Or Service For Which The Customer Is Willing To Pay當(dāng)確定價值時我們必須從客戶的觀點出發(fā)當(dāng)確定價值時我們必須從客戶的觀點出發(fā)We Must Think From The CustomersPerspective When Determining Value! 不增值不增值- 不需要的步驟或活動不需要的步驟或活動, 增加的流程時間和成本多于價值增加的流程時間和成本多于價值 Non-Value Added Nonessential Steps Or Activities That Increase Process Time

7、And Add Costs Rather Than Value8Is it Value Added (VA) or Non-Value Added (NVA)?請判斷是否增值？VA增值NVA不增值Cutting operation切削工序Value Added Examples增值案例增值案例9Is it Value Added (VA) or Non-Value Added (NVA)?請判斷是否增值？VA增值NVA不增值Cutting operation切削工序Value Added Examples增值案例增值案例10Is it Value Added (VA) or Non-Value

8、 Added (NVA)?請判斷是否增值？VA增值NVA不增值Cutting operation切削工序Grinding operation磨削工序Value Added Examples增值案例增值案例11Is it Value Added (VA) or Non-Value Added (NVA)?請判斷是否增值？VA增值NVA不增值Cutting operation切削工序Grinding operation磨削工序Value Added Examples增值案例增值案例12Is it Value Added (VA) or Non-Value Added (NVA)?請判斷是否增值？V

9、A增值NVA不增值Cutting operation切削工序Grinding operation磨削工序Heat Treatment熱處理Value Added Examples增值案例增值案例13Is it Value Added (VA) or Non-Value Added (NVA)?請判斷是否增值？VA增值NVA不增值Cutting operation切削工序Grinding operation磨削工序Heat Treatment熱處理Value Added Examples增值案例增值案例14Is it Value Added (VA) or Non-Value Added (NV

10、A)?請判斷是否增值？VA增值NVA不增值Cutting operation切削工序Grinding operation磨削工序Heat Treatment熱處理Moving Material搬運Value Added Examples增值案例增值案例15Is it Value Added (VA) or Non-Value Added (NVA)?請判斷是否增值？VA增值NVA不增值Cutting operation切削工序Grinding operation磨削工序Heat Treatment熱處理Moving Material搬運Value Added Examples增值案例增值案例1

11、6Is it Value Added (VA) or Non-Value Added (NVA)?請判斷是否增值？VA增值NVA不增值Cutting operation切削工序Grinding operation磨削工序Heat Treatment熱處理Moving Material搬運Inspection檢查Value Added Examples增值案例增值案例17Is it Value Added (VA) or Non-Value Added (NVA)?請判斷是否增值？VA增值NVA不增值Cutting operation切削工序Grinding operation磨削工序Heat

12、Treatment熱處理Moving Material搬運Inspection檢查Value Added Examples增值案例增值案例18of allmanufacturing time is non-value added!95%的生產(chǎn)時間是的生產(chǎn)時間是不能增值的不能增值的95%Non-Value Added 非增值非增值19增值增值 vs. 非非-增值增值增值增值非增值非增值必要必要不必要不必要 通過通過KAIZEN持續(xù)提高持續(xù)提高如果可能消除如果可能消除, 如果不可能如果不可能Kaizen 如果可能消如果可能消除除, 如果不可如果不可能能Kaizen 立即消除立即消除20Invent

13、ory 庫存庫存Motion 多余動作多余動作Transportation 搬運搬運Waiting 等待等待Overproduction 過量生產(chǎn)過量生產(chǎn)Processing 過程不當(dāng)過程不當(dāng)Correction 返工返工Unused talent/skillsNon ergonomics workstationIdentify and Eliminate 9 WastesIM TWO PC +UN21Any supply in excess of process requirements necessary toproduce goods任何超過加工必須的物料供應(yīng)Waste of Inven

14、tory 庫存浪費庫存浪費22Inventory Hides Problems !庫存會隱藏庫存會隱藏問題問題 ！Inventory Hides Waste !庫存會隱藏浪費！庫存會隱藏浪費！Water = Inventory水水=庫存庫存ROCKS = PROBLEMS 暗礁暗礁=問題問題LongChangeovers換模時間過長Variation 變更Equipment Downtime設(shè)備停機時間Inventory Level 庫存量Large Lot Sizes過大的批量Supplier Quality供應(yīng)商的質(zhì)量 Poor layout糟糕的廠區(qū)布局Inventory Hides P

15、roblems過多的庫存會隱藏問題過多的庫存會隱藏問題23Low Down Inventory To Expose Problem通過降庫存暴露問題通過降庫存暴露問題交貨問題交貨問題質(zhì)量問題質(zhì)量問題效率問題效率問題維修問題維修問題庫存水平庫存水平24Any movement which does not contribute value to the product or service 任何不增加產(chǎn)品或服務(wù)價值的人員和設(shè)備的動作Waste of Motion 多余動作多余動作25Any movement of material that does not support a lean sys

16、tem不符合精益生產(chǎn)的一切物料搬運活動Waste of Material Transportation物料搬運物料搬運26Idle Time That Is Produced When Two Dependent Variables Are Not Fully Synchronized當(dāng)兩個關(guān)聯(lián)要素間未能完全同步時所產(chǎn)生的空閑時間Waste of Waiting 等待等待27Waste of Overproduction 過量生產(chǎn)過量生產(chǎn)勞模？勞模？28Overproduction Waste生產(chǎn)過剩生產(chǎn)過剩Overproduction is considered the worst wast

17、e!生產(chǎn)過剩被認(rèn)為是最嚴(yán)重的浪費！Why?為什么？29Overproduction spins off allother types of waste生產(chǎn)過剩生產(chǎn)過剩超過了超過了其他所有的其他所有的浪費形式浪費形式 Overproduction生產(chǎn)過剩生產(chǎn)過剩 Need more boxes 需要更多箱子需要更多箱子 Need many pallets 需要更多托盤需要更多托盤 Need fork lift 需要叉車需要叉車 Need fork lift drivers 需要叉車需要叉車司機司機 Need additional floor space需要額外的地面空間需要額外的地面空間 Nee

18、d warehouse 需要倉庫需要倉庫 Need warehouse operators 需要庫房管理員需要庫房管理員 Many parts get rusty 許多零件許多零件生銹生銹 Need sorting operator 需要分類需要分類管理員管理員 Need rework 需要返工需要返工 Make scrap 產(chǎn)生廢料產(chǎn)生廢料Overproduction Waste生產(chǎn)過剩生產(chǎn)過剩30Effort which adds no valueto a product or service對最終產(chǎn)品或服務(wù)不增加價值的過程 Waste of Processing過程不當(dāng)過程不當(dāng)/過多的工

19、藝過多的工藝31Rework of a Productor Service to Meet Customer Requirements為了滿足顧客的要求而對產(chǎn)品或服務(wù)進(jìn)行返工Waste of Inspection/Correction/Rework 檢驗檢驗/校正校正 / 返工返工32 The Approach 方式方式 The Means/Tools 工具工具 The Strategy 策略策略ELIMINATION OF WASTE消除浪費消除浪費COSTSLEADTIME生產(chǎn)周期生產(chǎn)周期COSTS成本成本QUALITY THEFIRST TIME一次交驗的一次交驗的質(zhì)量質(zhì)量WORKPLA

20、CE ORGANIZATION車間組織車間組織及布局及布局5S/VISUAL CONTROLS5S/目視化管理目視化管理QUICK CHANGEOVER快速換?？焖贀Q模KANBAN 看板看板DEDICATED LINESONE PIECE FLOW特定單件流動生產(chǎn)線特定單件流動生產(chǎn)線ONE PIECE FLOW 單件流水生產(chǎn)單件流水生產(chǎn)STANDARD WORK標(biāo)準(zhǔn)化作業(yè)標(biāo)準(zhǔn)化作業(yè)QUALITY 有效的質(zhì)量管控有效的質(zhì)量管控Lean Manufacturing精益制造精益制造Continuous Improvement by the Elimination of Waste通過消除浪費而不斷改

21、善通過消除浪費而不斷改善33觀念轉(zhuǎn)變，觀念轉(zhuǎn)變，價值流管理，團(tuán)隊精神及，價值流管理，團(tuán)隊精神及5S，持續(xù)改進(jìn)持續(xù)改進(jìn)設(shè)備總有效性設(shè)備總有效性自動化及防錯自動化及防錯作業(yè)快速轉(zhuǎn)換作業(yè)快速轉(zhuǎn)換流動生產(chǎn)流動生產(chǎn)設(shè)備布局設(shè)備布局多技能員工多技能員工小批量生產(chǎn)小批量生產(chǎn)縮短生產(chǎn)周期縮短生產(chǎn)周期均衡混流生產(chǎn)均衡混流生產(chǎn)看板拉動看板拉動準(zhǔn)時化生產(chǎn)準(zhǔn)時化生產(chǎn)庫存降低庫存降低消除浪費降低成本消除浪費降低成本全面質(zhì)量管理全面質(zhì)量管理全面生產(chǎn)維護(hù)全面生產(chǎn)維護(hù)精益企業(yè)精益企業(yè)Lean Enterprise精益企業(yè)之屋精益企業(yè)之屋3434!I HearI ForgetI SeeI RememberI DoI Understand357 Kinds of Waste 七大浪費七大浪費庫存多余動作運輸?shù)却^量生產(chǎn)多余流程質(zhì)量缺陷變化變化/未使用的創(chuàng)造力未使用的創(chuàng)造力 (the 8th Waste)36“Growing Eyes