THE8WASTESMASTER

1、THE 8 WASTESISSUE 018大浪費(fèi)大浪費(fèi)2Identification and Elimination of WasteIdentification and Elimination of Waste Is Essential For Business Improvement識(shí)別并消除浪費(fèi)對(duì)業(yè)務(wù)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(shí)現(xiàn)需要所有員工從他們的工作訓(xùn)練中學(xué)

2、會(huì)識(shí)別并消除浪費(fèi)Do you think that Waste exists in all areas of our business both Shop Floor and Office?你認(rèn)為浪費(fèi)存在于我們公司所有領(lǐng)域么，包括車間和辦公室？Examples?舉例？識(shí)別并消除浪費(fèi)3The 8 Wastes8大浪費(fèi)4Waste of Overproduction 生產(chǎn)過剩的浪費(fèi)生產(chǎn)過剩的浪費(fèi)Definition:定義Producing More Than Needed 生產(chǎn)超過需求Producing Faster Than Needed 生產(chǎn)快于需求5Waste of Overproducti

3、on 生產(chǎn)過剩的浪費(fèi)生產(chǎn)過剩的浪費(fèi)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(chǔ)占地面積過高Extra labour 額外的勞動(dòng)力Excessive capacity 過度的產(chǎn)能Obsolete material 過時(shí)材料Extra storage / duplicate files 附加/重復(fù)存儲(chǔ)What Would You See? 看到什么？看到什么？6Waste of Overproduction 生產(chǎn)過剩的浪費(fèi)生產(chǎn)過剩的浪費(fèi)Rew

4、ard systems based on quantity produced基于生產(chǎn)數(shù)量的獎(jiǎng)勵(lì)機(jī)制Lack of communication 缺乏交流Long changeover 長轉(zhuǎn)換Unbalanced flow 不平衡流Low uptimes / insufficient maintenance無故障運(yùn)行時(shí)間低或維修不足Too much equipment / oversized equipment 太多設(shè)備Focus on expectation (forecast) rather than customer demand (consumption) 關(guān)注預(yù)期而不是消費(fèi)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(zhì)的浪費(fèi)不良品質(zhì)的浪費(fèi)Definition:Repair or Re-Do of a Product or Service to Fulfill Customer Requirements修理或重訂產(chǎn)品或服務(wù)來滿足客戶需求8Waste of Bad Quality 不良品質(zhì)的浪費(fèi)不良品質(zhì)的浪費(fèi)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(cuò)過最后期限Premium freight Used 使用超額運(yùn)費(fèi)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(zhì)的浪費(fèi)不良品質(zhì)的浪費(fèi)Incapable processes 無法處理No Standard Work 不符合標(biāo)準(zhǔn)Excessive variation 過分

7、變動(dòng)Incapable suppliers 不能勝任的供應(yīng)商Insufficient training 訓(xùn)練不足Inadequate tools / equipment 工具或設(shè)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(yùn)造成的浪費(fèi)搬運(yùn)造成的浪費(fèi)Definition: 定義Any Excessive Movement of Mat

8、erial or Information材料或信息的過度流動(dòng)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(yàn)證驗(yàn)證Filed歸檔歸檔Approved批準(zhǔn)批準(zhǔn)Entered輸入輸入Returned返回返回11Waste of Transportation 搬運(yùn)造成的浪費(fèi)搬運(yùn)造成的浪費(fèi) Excessive use of fork truck 過度使用叉車Multiple storage locations 多個(gè)存儲(chǔ)位置Complex inventory management 負(fù)責(zé)

9、的存貨管理Large warehouse / storage areas 大型倉庫/存儲(chǔ)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(hù)設(shè)備Conveyor systems 輸送機(jī)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(yùn)造成的浪費(fèi)搬運(yùn)造成的浪費(fèi)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(shè)備貧乏/區(qū)域布局不好Large buffer stocks 大的緩沖庫存Complex information management systems復(fù)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(fèi)過度加工的浪費(fèi)Definition: 定義Effort Whi

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

12、 the customer specification has not changed 當(dāng)訂貨規(guī)格沒有改變時(shí)無盡的細(xì)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(bào)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(gè)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(fèi)過度加工的浪費(fèi)Technology used Inappropriately 技術(shù)使用不當(dāng)Decision making at inappropriate Levels 在不適當(dāng)?shù)乃絻?nèi)做出決策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(duì)）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(fèi)庫存造成的浪費(fèi)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(wù)供應(yīng)必須及時(shí)生產(chǎn)17Waste of Inventory 庫存造成的浪費(fèi)庫存造成的浪費(fèi)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(jìn)先出Large Rework Campaigns When Problems Surface當(dāng)問題出現(xiàn)時(shí)大的重做活動(dòng)Slow response to change in customer demands緩慢響應(yīng)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(shè)備，貨架，存儲(chǔ)，空間/系統(tǒng)）Low Inventory Turns 低庫存周轉(zhuǎn)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(duì)Producing just in case 以防意外的生產(chǎn)What Would You See? 看見什么？看見什么？18Incapable pr

17、ocesses / equipment 不能勝任的進(jìn)程/設(shè)備Push instead of Pull 推動(dòng)代替拉動(dòng)Inappropriate goal setting (e.g. measured on throughput rather than achieving customer demand)不適當(dāng)?shù)哪繕?biāo)設(shè)定（例如，測量生產(chǎn)量而不是實(shí)現(xiàn)客戶需求）Incapable suppliers 不能勝任的供應(yīng)商Long changeover times 轉(zhuǎn)換時(shí)間長Management decisions 管理決策Inaccurate forecasting of requirements 不準(zhǔn)確

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

19、待造成的浪費(fèi)等待造成的浪費(fèi)People waiting for machine 人等機(jī)器Machine waiting for people 機(jī)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(fèi)等待造成的浪費(fèi) Processes not synchronized 工作流程

20、不同步Poor machine / people effectiveness 設(shè)備/人的工作效率不好Poor supply chain 供應(yīng)鏈欠佳Unplanned equipment downtime 計(jì)劃外的設(shè)備停機(jī)No Standard Work 不符合標(biāo)準(zhǔn)的工作What Could Be The Cause? 什么原因？什么原因？22Waste of Operator Motion 操作員動(dòng)作的浪費(fèi)操作員動(dòng)作的浪費(fèi)Definition: 定義Any Movement by People Which Does Not Add Value to the Product or Service

21、人為的活動(dòng)卻不增加產(chǎn)品或服務(wù)價(jià)值23Waste of Operator Motion 操作員動(dòng)作的浪費(fèi)操作員動(dòng)作的浪費(fèi)Looking for tools or equipment 尋找工具或設(shè)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(jī)器或材料太遠(yuǎn)（行走時(shí)間）Confusing Motion during Work 工作期間的混亂運(yùn)動(dòng)Poor

22、machine / operator effectiveness機(jī)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(dòng)作的浪費(fèi)操作員動(dòng)作的浪費(fèi)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(biāo)準(zhǔn)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(dòng)計(jì)劃No meetings 沒有會(huì)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(tuán)隊(duì)成員的意見或想法T

24、eam members not participating in improvement activities團(tuán)隊(duì)成員不參與改進(jìn)活動(dòng) 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(rèn)為是重要的Leaders are expected to decide

25、what actions need to be taken領(lǐng)導(dǎo)人將決定需要采取什么行動(dòng)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(fèi)的種類浪費(fèi)的種類Overproduction 生產(chǎn)過剩生產(chǎn)過剩Bad Quality 不良品質(zhì)不良品質(zhì)Transportation 運(yùn)輸運(yùn)輸Overprocessing 過度加工過度加工Inventory 庫存庫存Waiting Time 時(shí)間等待時(shí)間等待Operator Motion 操作員動(dòng)作操作員動(dòng)作Failing To Utilise Employees Creativity 未能利用員工的創(chuàng)造力Identification and Elimination of Waste識(shí)別并消除浪費(fèi)識(shí)別并消除浪費(fèi)A Contributor To Waste:浪費(fèi)的原因浪費(fèi)的原因 Overburden負(fù)擔(dān)過重負(fù)擔(dān)過重29Overburden 負(fù)擔(dān)過重負(fù)擔(dān)過重Definition: 定義Occurs When People or Machines are Pushed Beyond Their Natu