【正文】 r shapes raw materials or information to meet customer requirements. 一個(gè) 把原材料和信息轉(zhuǎn)換成符合客戶要求的活動過程168。Introduction to Lean Manufacturing (Kaizen)精益生產(chǎn) （改善）簡介The Toyota Production System豐田生產(chǎn)體系A(chǔ) solution to the particular problems Toyota faced, developed through trial and error on the shopfloor, to address:為二戰(zhàn)后面臨之特殊窘?jīng)r覓尋出路 ,豐田在生產(chǎn)現(xiàn)場通過不斷嘗試發(fā)展而來的一套體系，以解決 :– A small market 市場甚小– for a large variety of vehicles 車型繁多– with little space, money, and capital 場地和資本饋乏– with a goal of productivity at the levels of Ford’s Mass Production of black Model Ts. 且要達(dá)到福特黑色 T型車的大規(guī)模生產(chǎn)水平的高效率Average Lean Results 精益生產(chǎn)平均收效? Set up time 換摸時(shí)間 60%? Lead time 交付周期 50%? Cycle time 循環(huán)時(shí)間 20%? Down time 停工時(shí)間 50%? Operator required 人員需求 30%? WIP DOH 在制品庫存 60%? . DOH 成品庫存 40%? Distance traveled/part 零部件流轉(zhuǎn)距離 50%? Floor space 場地面積 30%? Rework 返工 70%10 Rules for Kaizen Success精益生產(chǎn)成功的十大準(zhǔn)則1 Keep a positive attitude and an open mind to change. 以積極的態(tài)度和開放的思想來進(jìn)行改變2 Change is good, more change is better / 變更是好事，多變更佳3 Create a team environment (there is no “I” in team).創(chuàng)建團(tuán)隊(duì)環(huán)境（在團(tuán)隊(duì)中不以我自居）4 One person, one vote, no position, no rank.每人都有表決權(quán)，不分職位、等級5 There is no such thing as a dumb question. / 多多提問（不恥下問）6 Creativity before capital / 創(chuàng)造先于資本7 Respect each others / 相互尊重8 Plans are only good if they can be implemented. Plans succeed only if the gains are sustained / 只有可以實(shí)施的計(jì)劃才是好計(jì)劃，只有堅(jiān)持執(zhí)行計(jì)劃才能成功9 There is no substitute for hard work / 努力工作，艱苦拼搏10 Just do it! / 及時(shí)行動is a manufacturing philosophy which shortens the time between the customer order and the product build / shipment by eliminating sources of waste. 是一個(gè)通過祛廢來縮短從客戶定貨到發(fā)貨周期的哲學(xué)Lean Manufacturing 精益制造Business as Usual 循規(guī)道距式經(jīng)營PRODUCTBUILT SHIPPED 生產(chǎn)并發(fā)貨生產(chǎn)并發(fā)貨CUSTOMERORDER 客戶定貨客戶定貨Time 時(shí)間Waste浪費(fèi)PRODUCTBUILT SHIPPED 生產(chǎn)并發(fā)貨生產(chǎn)并發(fā)貨CUSTOMERORDER 客戶定貨客戶定貨Time (Shorter) 縮短的時(shí)間Waste浪費(fèi)Lean Manufacturing 精益制造A TimeBased Strategy時(shí)間策略研究、開發(fā) 預(yù)先計(jì)劃 生產(chǎn) 分銷 收款實(shí)際完成的時(shí)間（從設(shè)計(jì)至收款的過程）Individual Efficiency vs. Total Efficiency單個(gè)與整體效益Pricing: The New Reality定價(jià)：新的現(xiàn)實(shí)問題l The Old Model 舊公式 : Cost to make + Profit = Selling Price 制造成本＋利潤＝銷售價(jià)格l The New Model 新公式 :Customer sets Price Profit = Manufacturing Cost 客戶設(shè)定的價(jià)格－利潤＝制造成本Leadtime 交付周期168。Value Added Activity 增值活動216。NonValue Added Activity (Waste)非增值活動 （浪費(fèi)）216。Value Added Time is only a very small percentage of the Leadtime. 增值時(shí)間僅是交付周期的很少一部份168。LEAN THINKING FOCUSES ON NONVALUE ADDING ITEMS. 而精益思想則著重于 非增值項(xiàng)目Traditional vs Lean Results 傳統(tǒng)與精益之比較Traditional vs Lean Results 傳統(tǒng)與精益之比較Lean Results 精益結(jié)果Maximize ValueAdd 增值最佳化Job Analysis Results崗位分析結(jié)果Examples 例子 :? Walking to get parts 走動取零件? Transporting to warehouse 輸送至庫房?Extra processes 多余工序?Over processing 加工過度?Too much weld 焊接過度?Banking to avoid c/o 為避免換摸而過量生產(chǎn)?Rework 返修?Scrap 廢品Examples 例子 :?Reach for parts 取零件?. check 質(zhì)量檢驗(yàn)?Change over 換摸?Storage 儲存Examples 例子 :?Bending 彎管?Stamping 沖壓 ?Welding 焊接?Making mufflers 制消 Waste浪費(fèi)60%Not needed at all in doing the work. 徒勞9 TIME時(shí)間 6312In this exampleValue Added 此例增值 = 10%Value Add增值10%Value added work changes the form or function of a part or assembly 增值工作 改變工件的形狀或性能NonValue AddNecessary非增值但卻必要30%No added value but must be done under the present work conditions. 非增值但目前還必須做IDENTIFYING WASTES 識別浪費(fèi)1. A value added 。3. A nonvalue added step that is not required. 一種不需要的不增值步驟。? Parts get lost 零件丟失? A stack of containers fall over and parts get damaged 一疊周轉(zhuǎn)箱翻到并砸壞零件? Must use facility floor space to keep inventory 占用場地? Engineering or product change happens so inventory must be scrapped, reworked or sold at a discount 工程或產(chǎn)品更改致使庫存報(bào)廢，返工或減價(jià)買出? Sales drop so inventory must be sold at a discount to clear it out of the system 銷售大跌，只好降價(jià)清倉處理庫存? Poor forecast results in wrong product sitting in longterm storage. 預(yù)測不準(zhǔn)生產(chǎn)出不對號產(chǎn)品長期壓庫INVENTORY HIDES WASTE 庫存掩蓋浪費(fèi)RAW MATERIAL 原材料FINISHED PRODUCT TO CONSUMER成品至客戶SEA OF INVENTORY 庫存的 “汪洋大海 ”POORSCHEDULING不妥當(dāng)?shù)纳a(chǎn)計(jì)劃MACHINE BREAKDOWN設(shè)備故障QUALITYPROBLEMS質(zhì)量問題LINEIMBALANCE生產(chǎn)線不平衡ABSENTEEISM缺勤LACK OFHOUSE KEEPING現(xiàn)場臟亂LONGSETUPTIME長換摸時(shí)間供應(yīng)商交付VENDORDELIVERYCOMMUNICATIONPROBLEMS 信息不暢LONGTRANSPORTATION長距離搬運(yùn) 11RAW MATERIALExposed Waste 浪費(fèi)外露12FINISHED PRODUCT TO CONSUMER成品至客戶SEA OF INVENTORY 庫存的 “汪洋大海 ”POORSCHEDULING不妥當(dāng)?shù)纳a(chǎn)計(jì)劃MACHINE BREAKDOWN設(shè)備故障QUALITYPROBLEMS質(zhì)量問題LONGTRANSPORTATION長距離搬運(yùn)LONGSETUPTIME長換摸時(shí)間供應(yīng)商交付VENDORDELIVERYLINEIMBALANCE生產(chǎn)線不平衡ABSENTEEISM缺勤LACK OFH