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Leanproductionisaimedattheeliminationof

waste

ineveryareaofproduction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=ELIMINATIONOFWASTEWhatisHiddenWaste?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.TransportationThetraditionalApproach;传统方法Specialistdepartments独立的分工PressPlatingWeldingShippingAssyPackingPolishingLongdistances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.InventoryThemaincausesforinventoryare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InventoryisEVIL库存有罪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.MotionMOVEdoesnotnecessarilyequalWORK.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.WaitingWhenoperatorsarewaitingforworkorwaitingforsomethingtodo,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5Smaintainingequipment设备维护checking(machineryandquality)检查practisingachangeover换型improvementactivities改善活动Whatisyourbestuseoftime?5.OverProduction过量生产5.OverProductionOverproductionoccurswhen当如下情况发生Buildplansaregeneratedbasedonaforecastwhich“guesses”thedemandandpushesinventoryup.按照预测生产建库存Processesarenotlinkedtogether工艺间衔接不好Bonussystemsencourageoutputthatisnotneeded不合理的激励措施，如计件制Performancemeasuresencouragehighmachineutilisationwhenproductionisnotrequired当产量不高时，一味的强调用足设备资源Inappropriateequipment(longchangeovers,producingfasterthantakt,poorprocesscapability)不合适的设备条件（长换型时间，比节拍时间做的更快，不稳定的流程）5.OverProductionOverproductionisaproblembecause:过量生产将导致Usesresourceunnecessarily(People,MaterialandMachines)浪费人机料资源Createscashflowproblemsbylockingincash现金流问题Leadstoextendedleadtimesbycreatingwaitingtimealongthewholeprocess加长整个流程等待时间CreatesunnecessaryInventory(requiringextraspace,extratransportation,extraequipment,andextraresource)制造不必要的库存等一系列的问题Increasesscrapcostsandcanleadtoobsolescence导致报废MachineMaintenanceandImprovementactivitiescannottakeplacewhilstMachinesandPeopleareOverproducing没有时间做设备保养UltimatelypreventstheFLOWofmaterials阻碍物料流动6.OverProcessing过度加工Unnecessaryactionsorinappropriateprocesses不必要的动作或不适合的流程Wrongchoiceofequipment选错设备Baddefinitionofcustomers’needs对客户需求的错误定义Unnecessaryoperations不必要的操作Excessiveinspections过度的检查Unnecessaryinspections不必要的检查Complexmachinery复杂化的设备duetopoorSupplierquality供应商的质量问题Bottlenecks瓶颈Unbalancedprocess不平衡的流程Additionalworknecessarytobeabletocompleteajob

超过完成一项工作的必须的步骤.Producingtoahigherspecificationthannecessary

按照过高的标准来生产6.OverProcessing过度加工“Usingahammertocrackanut”.Thinkingonebigmachineratherthanseveralsmallerones.“杀鸡用牛刀”leadtopressuretorunmachineasoftenaspossible频繁的使用设备encouragesgeneralpurpose,morecomplexmachines更复杂的设备poorlayout&extratransportation不合理的布局和额外的搬运

Usethesmallest,simplestmachine,capableofproducingtherequiredquality,attherightspeedandcanbepositionedatthepointofuse使用最小巧,简单的设备以合适的速度来生产需要的数量,且放置在使用点.7.Defects缺陷LessthanperfectpartsScrap报废Trimming修理Rejects不合格品Sorting分类排查Rework返工Quarantine隔离Waitingfordecisions等待决议Delayduetodefects由于缺陷延迟Transportationduetodefects缺陷搬运Re-inspecting&sorting重新检查Reworkarea/linesinproductionprocess返工区域Overtimetocatchbackdemand加班7.Defects缺陷Typesofmistakes错误的分类Negligence疏忽Misunderstanding误解Wrongidentification错误的识别Lackofexperience缺少经验LackofStandardOperations缺少标准流程NotfollowingStandards没有指示标准Wronginformation错误信息Lackofknowledge缺少知识Carelessness粗心Doh!Toavoidmistakes:避免错误Inventerrorproofingdevices开发防错设备Checklists检查清单Dowelpinsandlocationpins定位销Errorandalarmdetectors错误报警探测器limitortouchswitches限位接触开关Detectors,readers探测器，读数proximitydetec