Waste Identification 4t 7大浪费识别 - 日本专家

识别浪费TimeLineReduction缩短时间线TheToyotaWayTheHeartoftheTPS:Eliminatingwaste.丰田生产体系的核心：消除浪费.Lean精益Weshouldnotfocusonresultsandthenrallyateamtofixtheproblem.Thisisareactionbasedapproach.我们不应该遇到问题后，就组织一个团队去解决，这是应急措施的方法Bybuildingastrongfoundationfrombottomup,focusingonthetoolsprovided,automaticallypositiveresultswillbeabyproduct.如果我们从基层到高层建立一只强大坚实的基础，在关注我们精益方法的应用，好的结果会自动出现。Improvingperformance提升绩效Leanproductionisaimedattheeliminationofwasteineveryareaofproduction精益生产就是瞄准生产区域的浪费的消除Itsgoalistoincorporate它的目标包含–lesshumaneffort,最少的人员消耗–lessinventory,最少的库存–Lessscrap最少的报废–lesstimeand最短的周期–lessspace最少的设备Tobecomequickertorespondtocustomerschangesindemandwhilemakingtopqualityproductsinthemostefficientwaypossible.以最快的速度响应客户的需求同时以最有效的方法提供高质量的产品The7Wastes7大浪费T=Transport搬运I=Inventory库存M=Motion动作W=Waiting等待O=Overproduction过量生产O=Overprocessing过度加工D=Defects缺陷TypicallythefollowingisthebreakupVA/NVAinthemanufactureofapart.增值/非增值活动所占比例Valueadded=5%增值NecessaryNVA=45%.必须的不增值NVA(Waste)=50%浪费Typically95%ofTotalLeadTimeisNon-ValueAdded!!!95%的活动都是不增值的Valueadded增值5%Non-valueadded不增值LEAN=ELIMINATIONOFWASTETypesofActivities活动的分类ValueAddedWork增值工作Thepartofthejobthecustomerwantstopayfor客户愿意付钱的活动HiddenWaste隐藏的浪费Workthatdoesn’taddvaluebutisrequiredunderthecurrentoperatingconditions不得不做的工作，但不增值ObviousWaste明显的浪费Workthatdoesnotaddvalueandisnotnecessary不必须也不增值的活动WASTEWhatisValueAddedWork?什么是增值工作？Workwhichincreasesthevalueofapart.i.e.thatwhichthecustomeriswillingtopayfor增加部件的价值，哪些客户愿意付钱的的部分e.g.如Press冲压Polish抛光Assemble组装Forge成形Heattreat热处理Plate电镀Bend折弯Cut剪切Drill钻孔Cast压铸Weld电焊Paint油漆………..5%WhatisHiddenWaste?什么是隐藏的浪费Workthatdoesnotaddvaluebutisrequiredunderthecurrentoperatingconditions不增加价值但不得不做的工作–toolchangeover换模–Inspection检查–partshandling手持部件–transportingparts搬运部件–unwrappingofpurchasedparts外购件拆包–Paperwork文字工作–Decanting转移容器–progresschasing追赶进度–storagespace储存空间–Meetings会议–managinginventory库存管理……..1.Transportation搬运Customersdonotpaytohavegoodsmovedaround,soanymovementofmaterialinafactoryisawaste.客户不会为工厂内无效的搬运付钱，所以搬运是浪费–Materialsstoredalongwayfrompointofuse存储地相距使用点太远–Unnecessarymovingorhandlingofparts不必要的搬运–Handlingequipmentmovingwithoutanypartsbeingmoved搬运设备的空移动–Feedbackonqualityisinverselyrelatedtotransportlength长距离搬运导致质量的隐患–increasesthelikelihoodofdamage!增加损坏的可能性1.Transportation搬运CellularManufacturingprovides细胞化生产方式提供–shortdistances,shortlead-times,smallbatches颈段距离，周期时间，更小批量–LowWIP,lowcost,Goodproblemsolving&teamspirit低库存，成本，号的问题解决精神PressPlatingWeldingShippingAssyPackingPolishing1025feet30Days200feet1Day1.TransportationThetraditionalApproach;传统方法Specialistdepartments独立的分工PressPlatingWeldingShippingAssyPackingPolishing–Longdistances长距离–longlead-times长周期–bigbatches大批量–highwip高在制品–highcost高成本–poorproblemsolving差的问题解决能力2.Inventory库存Largestocks大量库存–Stockpileoffinishedgoods大量的成品库存–HighWIP高的在制品–Highrawmaterials原材料–Excessiveracking多余的货架–Excessivewarehousespace多余的仓库面积–Excessivehandlingequipment多余的搬运设备–Extramanagement额外的管理–Obsolescence报废–Poorlayout不合理的布局–Restrictivelayout限制的布局–Excessivetransportation多余的搬运–Unnecessarysearchingandmovingofmaterials不必要的寻找2.InventoryThemaincausesforinventoryare库存的主要原因是–Processunreliability(tocoverdowntime)不稳定的工艺（弥补损失时间）–Poorprocessresponsiveness(tocoverchangeovers)较慢的相应流程（来弥补长的换型时间）–Pushsystemsofmanufacture差的制造系统Inventoryincreasesthemanufacturingleadtime,thisleadsto:库存增加制造周期，导致：－slowerintroductionofengineeringchangesandprocessimprovements更慢的工程更高相应–increasedqualityrisk质量风险增加–increasedriskofobsolescence报废增加Itleadsto导致–Concealedproblems隐藏的问题–Increasedleadtimes加长的周期时间–Preventsrapididentificationofproblems阻碍快速识别问题–Increasesspacerequirements增加额外的空间需求–Andtherebydiscouragescommunication因此导致沟通不畅–Inventorydeliberatelyhidesproblems隐藏问题–Qualityconcernsarenotconsideredimportantifextrapartscanbeusedinplaceofdefectiveparts由于可以多生产，导致忽略质量问题–Concealsimbalanceinprocesses掩盖生产不平衡的问题Thetruecostofinventoryisthemoneytiedupinit库存的成本是资金的积压3.Motion动作Unnecessarymovementofoperatorsandmachinesastheycarryoutcyclesofwork不必要的人员和设备动作–doublehandling二次搬运–triplehandling三次搬运–Reaching伸手–Bending弯腰–Stretching伸长–Walking走动–Twisting踮脚–morethantwoturnstoloosenbolts松螺丝超过2圈–undulyexertingthemselvesinanyway任何形式的不当的用力3.MotionMOVEdoesnotnecessarilyequalWORK.动作不等于工作Anoperatormaybekept“busy”forhourslookingfortoolswithoutaddinganyvalueforthecustomer操作员可能很忙的花1小时在找寻工具，但不是增值的活动4.Waiting等待Thewasteofwaitingoccurswhenevertimeisnotbeingusedeffectively.等待浪费是时间没有真正有效的利用起来–Waitingformaterial等料–Waitingformaintenance等维修–Waitingfortoolchange/setter等工具–Waitingforqualitycheck等质量检查–Waitingfornextstation等下一个工序–Operatorsslowerthanline动作慢导致等待–Animbalanceintheline不平衡–Materialswaitingformachinechangeovers材料等机器还型–Abottleneckprocessshortofwork瓶颈工序引起的–Operatorswatchingmachinestocompletecycles操作员看作设备操作，等待下料Waitingistheenemyofsmoothflow5.WaitingWhenoperatorsarewaitingforworkorwaitingforsomethingtodo,itiswaste.Canthetimenotbebetterspentonanotheroperation?有等待就有浪费，不管是在等料还是其它–Training培训–Cleaning清扫–5S–maintainingequipment设备维护–checking(machineryandquality)检查–practising