THE8WASTESMASTER

1、THE 8 WASTESISSUE 018大浪費大浪費2Identification and Elimination of WasteIdentification and Elimination of Waste Is Essential For Business Improvement識別并消除浪費對業(yè)務增長而言是必要的Successful Implementation Requires That All Employees Must be Trained to Identify and Eliminate Waste from Their Work成功的實現(xiàn)需要所有員工從他們的工作訓練中學

2、會識別并消除浪費Do you think that Waste exists in all areas of our business both Shop Floor and Office?你認為浪費存在于我們公司所有領域么，包括車間和辦公室？Examples?舉例？識別并消除浪費3The 8 Wastes8大浪費4Waste of Overproduction 生產過剩的浪費生產過剩的浪費Definition:定義Producing More Than Needed 生產超過需求Producing Faster Than Needed 生產快于需求5Waste of Overproducti

3、on 生產過剩的浪費生產過剩的浪費Inventory stockpiles 庫存Extra copies of documents 額外的副本文件High level of floor space used for storage 存儲占地面積過高Extra labour 額外的勞動力Excessive capacity 過度的產能Obsolete material 過時材料Extra storage / duplicate files 附加/重復存儲What Would You See? 看到什么？看到什么？6Waste of Overproduction 生產過剩的浪費生產過剩的浪費Rew

4、ard systems based on quantity produced基于生產數(shù)量的獎勵機制Lack of communication 缺乏交流Long changeover 長轉換Unbalanced flow 不平衡流Low uptimes / insufficient maintenance無故障運行時間低或維修不足Too much equipment / oversized equipment 太多設備Focus on expectation (forecast) rather than customer demand (consumption) 關注預期而不是消費者需求What

5、 Could Be The Cause?原因是什么？原因是什么？7Waste of Bad Quality 不良品質的浪費不良品質的浪費Definition:Repair or Re-Do of a Product or Service to Fulfill Customer Requirements修理或重訂產品或服務來滿足客戶需求8Waste of Bad Quality 不良品質的浪費不良品質的浪費Repair and rework areas 維修或返工區(qū)域Parts in scrap bins 部分廢料箱Quarantine areas 檢疫隔離地帶Extra people need

6、ed to check work 額外的人需要檢查工作A high level of inspection 高水平的檢查Missed commitments / deadlines 違背承諾或錯過最后期限Premium freight Used 使用超額運費Expediting replacement items 加快更換零件目錄What Would You See? 看見什么？看見什么？9Waste of Bad Quality 不良品質的浪費不良品質的浪費Incapable processes 無法處理No Standard Work 不符合標準Excessive variation 過分

7、變動Incapable suppliers 不能勝任的供應商Insufficient training 訓練不足Inadequate tools / equipment 工具或設備不足Poor layouts / excess handling布局欠佳/過度處理High inventory levels 高庫存水平Poor communications 缺乏溝通What Could Be The Cause? 什么原因？什么原因？10Waste of Transportation 搬運造成的浪費搬運造成的浪費Definition: 定義Any Excessive Movement of Mat

8、erial or Information材料或信息的過度流動Information Generated信息創(chuàng)建信息創(chuàng)建Entered輸入輸入Filed 歸檔歸檔Sent to the Plant工廠傳送工廠傳送Verified驗證驗證Filed歸檔歸檔Approved批準批準Entered輸入輸入Returned返回返回11Waste of Transportation 搬運造成的浪費搬運造成的浪費 Excessive use of fork truck 過度使用叉車Multiple storage locations 多個存儲位置Complex inventory management 負責

9、的存貨管理Large warehouse / storage areas 大型倉庫/存儲區(qū)域Material handlers have unbalanced work schedules材料處理程序有不平衡的工作安排Heavy duty barriers and protection devices重稅壁壘和防護設備Conveyor systems 輸送機系統(tǒng)Tracking or expediting information 跟蹤或加速信息What Would You See? 看見什么？看見什么？12Waste of Transportation 搬運造成的浪費搬運造成的浪費Large

10、lot processing 很多加工Inconsistent schedules 前后矛盾的日程安排Lack of Work Place Organization 缺乏車間組織Poor facility / area layou t設備貧乏/區(qū)域布局不好Large buffer stocks 大的緩沖庫存Complex information management systems復雜的信息管理系統(tǒng)What Could Be The Cause? 什么原因？什么原因？13Waste of Overprocessing 過度加工的浪費過度加工的浪費Definition: 定義Effort Whi

11、ch Adds No Value to a Product / Service. 努力增加沒有價值的產品/服務Enhancements Which are Transparent to the End User, or Work That Could be Combined with Another Purpose.增強功能使其對最終用戶而言是易懂的，或者能結合其他用途工作EngineeringChanges14Waste of Overprocessing 過度加工的浪費過度加工的浪費Double-Handling of parts 雙重處理部分Endless Refinement when

12、 the customer specification has not changed 當訂貨規(guī)格沒有改變時無盡的細化Extra Copies / Excessive Information額外的副本/過多信息Reports / documents that include unneeded information 包括不需要的報告或文件Excessive distribution / CC lists 過度分配Multiple process operations (e.g. 2 passes on a bar to achieve the required diameter) 多個流程操作

13、Exceeding the customer requirements (e.g. achieving a mirror finish when not necessary) 超過客戶需求What Would You See? 看見什么？看見什么？15Waste of Overprocessing 過度加工的浪費過度加工的浪費Technology used Inappropriately 技術使用不當Decision making at inappropriate Levels 在不適當?shù)乃絻茸龀鰶Q策Not understanding customer requirements 不理解客戶需

14、求Purchasing policy for materials (cost versus fitness for purpose) 材料采購政策（成本與適用性相對）Unclear business processes 不清楚的企業(yè)流程Lack of Boundary Samples or Clear Customer Specifications缺乏過界樣品或明確的客戶規(guī)范What Could Be The Cause? 什么原因？什么原因？16Waste of Inventory 庫存造成的浪費庫存造成的浪費Definition: 定義Any Supply in Excess of Cus

15、tomer Requirements Necessary to Produce Goods or Services Just in Time所有超過客戶需求的貨物或服務供應必須及時生產17Waste of Inventory 庫存造成的浪費庫存造成的浪費Stagnated Material Flow 停止不前的物料流FISH instead of FIFO 熒光原位雜交代替先進先出Large Rework Campaigns When Problems Surface當問題出現(xiàn)時大的重做活動Slow response to change in customer demands緩慢響應客戶需求的

16、變化Additional Material Handling Resources (People, Equipment, Racks, Storage, Space / Systems)額外的材料處理資源（人，設備，貨架，存儲，空間/系統(tǒng)）Low Inventory Turns 低庫存周轉率Stock Between Processes 庫存之間的流程Stock of items of the wrong kind needed 庫存所需的類型不對Producing just in case 以防意外的生產What Would You See? 看見什么？看見什么？18Incapable pr

17、ocesses / equipment 不能勝任的進程/設備Push instead of Pull 推動代替拉動Inappropriate goal setting (e.g. measured on throughput rather than achieving customer demand)不適當?shù)哪繕嗽O定（例如，測量生產量而不是實現(xiàn)客戶需求）Incapable suppliers 不能勝任的供應商Long changeover times 轉換時間長Management decisions 管理決策Inaccurate forecasting of requirements 不準確

18、的需求預測Inaccurate tracking systems 不精確的追蹤系統(tǒng)Waste of Inventory 庫存造成的浪費庫存造成的浪費What Could Be The Cause? 什么原因？什么原因？19Waste of Waiting 等待造成的浪費等待造成的浪費 Definition: 定義Idle Time That is Produced When Two Dependent Activities or Events are Not Fully Synchronized由于兩個相互依賴的活動或事件不同步而產生的閑置時間20Waste of Waiting Time 等

19、待造成的浪費等待造成的浪費People waiting for machine 人等機器Machine waiting for people 機器等人People waiting for parts 人等零件People waiting for information 人等信息People waiting for people 人等人Unbalanced flow of work 不平衡的工作流程What Would You See? 看見什么？看見什么？21Waste of Waiting Time 等待造成的浪費等待造成的浪費 Processes not synchronized 工作流程

20、不同步Poor machine / people effectiveness 設備/人的工作效率不好Poor supply chain 供應鏈欠佳Unplanned equipment downtime 計劃外的設備停機No Standard Work 不符合標準的工作What Could Be The Cause? 什么原因？什么原因？22Waste of Operator Motion 操作員動作的浪費操作員動作的浪費Definition: 定義Any Movement by People Which Does Not Add Value to the Product or Service

21、人為的活動卻不增加產品或服務價值23Waste of Operator Motion 操作員動作的浪費操作員動作的浪費Looking for tools or equipment 尋找工具或設備Looking for information 尋找信息Looking for materials or supplies 尋找材料或物資Excessive Reaching / Bending 過度彎曲Machines / Material too Far Apart (Walk Time)機器或材料太遠（行走時間）Confusing Motion during Work 工作期間的混亂運動Poor

22、machine / operator effectiveness機器或操作員效率不好What Would You See? 看見什么？看見什么？24Waste of Operator Motion 操作員動作的浪費操作員動作的浪費Poor layout 規(guī)劃不好Lack of work place organization 缺乏車間組織No Standard Work 不符合標準的工作Interdependent functions not co-located相互依賴的功能沒有同地協(xié)作What Could Be The Cause? 什么原因？什么原因？25Failing To Utilis

23、e Employees Creativity未能利用員工的創(chuàng)造力未能利用員工的創(chuàng)造力Definition: 定義Not engaging people in the process未指定人員參與過程26No Primary Visual Display 沒有主要的直觀顯示No action plans 沒有活動計劃No meetings 沒有會議No efforts to improve the work area or processes沒有努力提升工作區(qū)域或過程Team members not asked for their opinions or ideas沒有詢問團隊成員的意見或想法T

24、eam members not participating in improvement activities團隊成員不參與改進活動 Poor Problem Solving / Root Cause Analysis解決問題或根本原因分析能力不好What Would You See? 看見什么？看見什么？Failing To Utilise Employees Creativity未能利用員工的創(chuàng)造力未能利用員工的創(chuàng)造力27Employee Involvement not seen as important員工參與不被認為是重要的Leaders are expected to decide

25、what actions need to be taken領導人將決定需要采取什么行動Failing To Utilise Employees Creativity未能利用員工的創(chuàng)造力未能利用員工的創(chuàng)造力What Could Be The Cause? 什么原因什么原因28Types of Waste:浪費的種類浪費的種類Overproduction 生產過剩生產過剩Bad Quality 不良品質不良品質Transportation 運輸運輸Overprocessing 過度加工過度加工Inventory 庫存庫存Waiting Time 時間等待時間等待Operator Motion 操作員動作操作員動作Failing To Utilise Employees Creativity 未能利用員工的創(chuàng)造力Identification and Elimination of Waste識別并消除浪費識別并消除浪費A Contributor To Waste:浪費的原因浪費的原因 Overburden負擔過重負擔過重29Overburden 負擔過重負擔過重Definition: 定義Occurs When People or Machines are Pushed Beyond Their Natu