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1、Waste Elimination消除浪费消除浪费2Why change and improve?我们需要改善吗我们需要改善吗3Top MgtMiddle MgtFront LineAssociateBreakthrough Daily ManagementSupervisorKaizenHow Should You Spend Your Time?工作角色与时间分配工作角色与时间分配4Change Is Not Easy求变并非易事求变并非易事Change and Improvement Do Not Come Easy改变和改进来之不易Basic premise基本前提基本前提Physic
2、s tells us物理原理告诉我们物理原理告诉我们Human nature人类本性人类本性Why?为什么？为什么？Therefore因此因此The greater the resistance阻力越大阻力越大To improve we must continuously change要提高就必须不断改进For every action(change)there is an equal&opposite reaction每一次用力（改变）都会有相应的反作用力People resist change(i.e.look for excuses,wait and see,etc.)人们抗拒变化（如：
3、寻找借口，等待，坐视旁观等等）Because change takes people outside their comfort zones因为变化会使他们脱离舒适的环境The more you change the greater the resistance变化越大阻力也越大The more difficult it is to improve改进就越难5Purpose of Training培训目的培训目的Introduce the concepts of the 7 kinds of waste介绍7种浪费的概念Define and discuss value added and no
4、n-value added定义和讨论“增值”与“非增值”Identify and discuss ways to eliminate waste辨认和探讨消除浪费的方法6Input输入输入Energy 能源People 人力Capital 资本Water 水Materials 材料Tools 工具Output 输出输出Products 产品Services 服务Waste 浪费浪费Value Added增增 值值Focus of traditionalimprovement programs传统方式侧重于传统方式侧重于Work longer 增加工作时间Work harder 增加工作强度Ad
5、d people 增加人手Add equipment 增加设备Faster cycle times 加快周转时间Focus of lean production精益焦点精益焦点Eliminate waste 消除浪费Identification of Waste 浪费的识别浪费的识别7增值增值 客户愿意为何付费客户愿意为何付费?增值增值 客户愿意付费的将原材料或信息转换成产品或服务的步骤或活动客户愿意付费的将原材料或信息转换成产品或服务的步骤或活动That Change A Raw Material Or Information Into A Product Or Service For Wh
6、ich The Customer Is Willing To Pay当确定价值时我们必须从客户的观点出发当确定价值时我们必须从客户的观点出发We Must Think From The CustomersPerspective When Determining Value!不增值不增值-不需要的步骤或活动不需要的步骤或活动,增加的流程时间和成本多于价值增加的流程时间和成本多于价值 Non-Value Added Nonessential Steps Or Activities That Increase Process Time And Add Costs Rather Than Value8
7、Is it Value Added(VA)or Non-Value Added(NVA)?请判断是否增值？VA增值NVA不增值Cutting operation切削工序Value Added Examples增值案例增值案例9Is it Value Added(VA)or Non-Value Added(NVA)?请判断是否增值？VA增值NVA不增值Cutting operation切削工序Value Added Examples增值案例增值案例10Is it Value Added(VA)or Non-Value Added(NVA)?请判断是否增值？VA增值NVA不增值Cutting op
8、eration切削工序Grinding operation磨削工序Value Added Examples增值案例增值案例11Is it Value Added(VA)or Non-Value Added(NVA)?请判断是否增值？VA增值NVA不增值Cutting operation切削工序Grinding operation磨削工序Value Added Examples增值案例增值案例12Is it Value Added(VA)or Non-Value Added(NVA)?请判断是否增值？VA增值NVA不增值Cutting operation切削工序Grinding operatio
9、n磨削工序Heat Treatment热处理Value Added Examples增值案例增值案例13Is it Value Added(VA)or Non-Value Added(NVA)?请判断是否增值？VA增值NVA不增值Cutting operation切削工序Grinding operation磨削工序Heat Treatment热处理Value Added Examples增值案例增值案例14Is it Value Added(VA)or Non-Value Added(NVA)?请判断是否增值？VA增值NVA不增值Cutting operation切削工序Grinding op
10、eration磨削工序Heat Treatment热处理Moving Material搬运Value Added Examples增值案例增值案例15Is it Value Added(VA)or Non-Value Added(NVA)?请判断是否增值？VA增值NVA不增值Cutting operation切削工序Grinding operation磨削工序Heat Treatment热处理Moving Material搬运Value Added Examples增值案例增值案例16Is it Value Added(VA)or Non-Value Added(NVA)?请判断是否增值？VA
11、增值NVA不增值Cutting operation切削工序Grinding operation磨削工序Heat Treatment热处理Moving Material搬运Inspection检查Value Added Examples增值案例增值案例17Is it Value Added(VA)or Non-Value Added(NVA)?请判断是否增值？VA增值NVA不增值Cutting operation切削工序Grinding operation磨削工序Heat Treatment热处理Moving Material搬运Inspection检查Value Added Examples增
12、值案例增值案例18of allmanufacturing time is non-value added!95%的生产时间是的生产时间是不能增值的不能增值的95%Non-Value Added 非增值非增值19增值增值 vs.非非-增值增值增值增值非增值非增值必要必要不必要不必要 通过通过KAIZEN持续提高持续提高如果可能消除如果可能消除,如果不可能如果不可能Kaizen 如果可能消如果可能消除除,如果不可如果不可能能Kaizen 立即消除立即消除20Inventory 库存库存Motion 多余动作多余动作Transportation 搬运搬运Waiting 等待等待Overproduct
13、ion 过量生产过量生产Processing 过程不当过程不当Correction 返工返工Unused talent/skillsNon ergonomics workstationIdentify and Eliminate 9 WastesIM TWO PC+UN21Any supply in excess of process requirements necessary toproduce goods任何超过加工必须的物料供应Waste of Inventory 库存浪费库存浪费22Inventory Hides Problems!库存会隐藏库存会隐藏问题问题！Inventory H
14、ides Waste!库存会隐藏浪费！库存会隐藏浪费！Water=Inventory水水=库存库存ROCKS=PROBLEMS 暗礁暗礁=问题问题LongChangeovers换模时间过长Variation 变更Equipment Downtime设备停机时间Inventory Level 库存量Large Lot Sizes过大的批量Supplier Quality供应商的质量 Poor layout糟糕的厂区布局Inventory Hides Problems过多的库存会隐藏问题过多的库存会隐藏问题23Low Down Inventory To Expose Problem通过降库存暴露问
15、题通过降库存暴露问题交货问题交货问题质量问题质量问题效率问题效率问题维修问题维修问题库存水平库存水平24Any movement which does not contribute value to the product or service 任何不增加产品或服务价值的人员和设备的动作Waste of Motion 多余动作多余动作25Any movement of material that does not support a lean system不符合精益生产的一切物料搬运活动Waste of Material Transportation物料搬运物料搬运26Idle Time Th
16、at Is Produced When Two Dependent Variables Are Not Fully Synchronized当两个关联要素间未能完全同步时所产生的空闲时间Waste of Waiting 等待等待27Waste of Overproduction 过量生产过量生产 生产多于下游客户所需生产多于下游客户所需生产多于下游客户所需生产多于下游客户所需 Making More Than NeededMaking More Than Needed 生产快于下游客户所求生产快于下游客户所求生产快于下游客户所求生产快于下游客户所求 Making Faster Than Nee
17、dedMaking Faster Than Needed劳模？劳模？28Overproduction Waste生产过剩生产过剩Overproduction is considered the worst waste!生产过剩被认为是最严重的浪费！Why?为什么？29Overproduction spins off allother types of waste生产过剩生产过剩超过了超过了其他所有的其他所有的浪费形式浪费形式 Overproduction生产过剩生产过剩 Need more boxes 需要更多箱子需要更多箱子 Need many pallets 需要更多托盘需要更多托盘 Ne
18、ed fork lift 需要叉车需要叉车 Need fork lift drivers 需要叉车司机需要叉车司机 Need additional floor space需要额外的地面空间需要额外的地面空间 Need warehouse 需要仓库需要仓库 Need warehouse operators 需要库房管理员需要库房管理员 Many parts get rusty 许多零件生锈许多零件生锈 Need sorting operator 需要分类管理员需要分类管理员 Need rework 需要返工需要返工 Make scrap 产生废料产生废料Overproduction Waste生
19、产过剩生产过剩30Effort which adds no valueto a product or service对最终产品或服务不增加价值的过程 Waste of Processing过程不当过程不当/过多的工艺过多的工艺31Rework of a Productor Service to Meet Customer Requirements为了满足顾客的要求而对产品或服务进行返工Waste of Inspection/Correction/Rework 检验检验/校正校正/返工返工32 The Approach 方式方式 The Means/Tools 工具工具 The Strategy
20、 策略策略ELIMINATION OF WASTE消除浪费消除浪费COSTSLEADTIME生产周期生产周期COSTS成本成本QUALITY THEFIRST TIME一次交验的一次交验的质量质量WORKPLACE ORGANIZATION车间组织车间组织及布局及布局5S/VISUAL CONTROLS5S/目视化管理目视化管理QUICK CHANGEOVER快速换模快速换模KANBAN 看板看板DEDICATED LINESONE PIECE FLOW特定单件流动生产线特定单件流动生产线ONE PIECE FLOW 单件流水生产单件流水生产STANDARD WORK标准化作业标准化作业QUA
21、LITY 有效的质量管控有效的质量管控Lean Manufacturing精益制造精益制造Continuous Improvement by the Elimination of Waste通过消除浪费而不断改善通过消除浪费而不断改善33观念转变，观念转变，消除浪费消除浪费消除浪费消除浪费，价值流管理，团队精神及，价值流管理，团队精神及5S，持续改进持续改进设设备备总总有有效效性性自自动动化化及及防防错错作业快速转换作业快速转换流动生产流动生产设备布局设备布局多技能员工多技能员工小批量生产小批量生产缩短生产周期缩短生产周期均衡混流生产均衡混流生产看板拉动看板拉动准时化生产准时化生产库存降低库存
22、降低消除浪费降低成本消除浪费降低成本全全面面质质量量管管理理全全面面生生产产维维护护精益企业精益企业Lean Enterprise精益企业之屋精益企业之屋3434!I HearI ForgetI SeeI RememberI DoI Understand357 Kinds of Waste 七大浪费七大浪费库存多余动作运输等待过量生产多余流程质量缺陷变化变化/未使用的创造力未使用的创造力(the 8th Waste)36“Growing Eyes”观察与思考观察与思考Were now going to do an exercise现在让我们做个练习Each person will be ass
23、igned a place within the plant,and will have time to observe what is going on around them每个人都将被安排在工厂的某个地方，然后要求花一段时间去观察周围的情况We will get back together,and you will discuss and diagram the waste you saw in the plant然后我们回来集中，来讨论你们在工厂里所看到的浪费情况We will then discuss the findings as a group and how to elimin
24、ate.我们将会以组为单位进行讨论，并探讨如何消除浪费的方法37Summary总结总结During the last couple of hours we have:在过去的时间里我们：Introduced the concepts of the 7 kinds of waste 介绍了7种浪费的概念Defined and discussed value added and non-value added定义并讨论了增值和非增值 Began to identify and discuss ways to eliminate waste in our plant开始辨认并探讨了在我们工厂消除浪费的方法Questions/Comments问题/建议