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Summary of lean production
As mass production manufacturing in the 20th century is a landmark achievement, lean production is considered to be the 21st century the most advanced business management pattern. The emphasis with less manpower, less space, less investment and less time, meet customer requirements of the business management method, make its pioneering company Toyota to become the industry leader, also benefit all later brought this pattern of Chinese and foreign enterprises. The enterprise implements the management of giant leap, in the case of ascension or maintain customer satisfaction, only half of the money and manpower. And lean mode for the benefit of the enterprise, is not limited to these specific financial Numbers, yet it from the following five aspects: overall improve enterprise core competitiveness:
1) reduce the cost
2) improve the quality
3) to shorten the delivery time
4) improve security
5) boost morale
By the American association of lean production for more than 1000 to implement the lean production mode of enterprise survey data show that directly save costs more than $20. In great wits consulting cooperation of customers, many enterprises in the five aspects of the average income level (as shown in figure 1). According to the survey of the consulting services of past customer's wisdom, and the average for these clients on these metrics (as shown in figure 2).
Pillar and the principles of lean production
Essentially, lean production contribution by eliminating waste in the enterprise and the achievement, which is the essence of the Toyota production system (TPS). Eliminate waste at the same Time to ensure quality and delivery Time of ideas, through the two pillars of TPS implemented In every link of the value chain, the two pillars is just-in-time (Just In Time) production and automation (Jidoka), they are also regarded as architecture foundation of lean production. Related to the two pillars of all kinds of management methods and tools, their relationship is often "house" to explain and show in the legend.
Eliminate waste, to ensure product quality and customer satisfaction of thoughts and Deming (Edward Deming) of total quality management philosophy, eventually be summed up as the lean principles:
1. Eliminate waste
2. The inventory to minimize the
3. The maximum flow
4. Demand
5. To meet customer requirements
6. Do the right at a time
7. Develop authorized employees
8. Taking suppliers for partnership
9. The ban on local interests
10. Create a continuous improvement culture
The core of lean thinking
The core of the lean manufacturing is to eliminate all invalid labor and waste, it determined the goal in perfection, by continuously reduce costs, improve quality, increase production flexibility, scrap and zero inventory is realized to ensure that enterprises in the advantage in the market competition, at the same time, the lean production delegating responsibility to all levels in the organizational structure, adopting team execution of work and fully arouse the enthusiasm of all staff and ingenuity, waste defects and eliminate in a timely manner at every position. Lean production mode is not only reflected in the advantages of manufacturing system, are also embodied in the product development, coordination, marketing network and management aspects, it will become the twenty-first century standards of the global production system.
Lean production methods in manufacturing system, the main thought is embodied in the following four aspects:
A, person standard
Lean production emphasis on the importance of human resources, the employee's wisdom and creativity as a motive force of the enterprise's precious wealth, and the future development, 1, fully respect the staff; 2, attaches great importance to the training; 3, work together;
B, inventory is a "curse"
High inventory is one of the characteristics of a mass production mode. Due to the instability of the equipment operation, unreasonable process arrangement, high rejection rate and the production of uneven, often appears phenomenon and timely supply, inventory is considered to be essential to "buffer". But for a lean production, inventory is enterprise's "evil", the main reason is: 1, inventory increased the operation cost; 2, inventory covers the problem of enterprises;
C, never satisfied
Lean production mode is the "endless pursuit of perfection" as the management goal, the pursuit of the products continuously improve quality, cost and service. The idea is different from a large number of important characteristic mode of production, lean production is the spiritual motive force of success. Just-in-time (JIT) production mode and continuous improvement process (CIP) is the idea of lean production perfection;
D, enterprise internal and external environment harmonious and unified
Lean production mode is the key to the success of the firm's internal activities and the external market (customer) requirements in harmony in the enterprise development goals.
Lean production applied object
Although the lean production method derived from the auto industry, but it is also in the automotive industry to show they on the Boeing, IBM, dell, Motorola, Acelor, SASS, Calgate success, marked the lean approach has won nearly all the industry wide recognition. In fact, the Chinese companies or foreign companies in China's factories have full or part of the introduction of lean production mode. Arrogance of consulting service industry customers, also can be seen (as shown). Generally, lean production will cause you to be on the following issues are expected to benefit from:
1, customers often request change the order;
2, customer call for a small amount of supply mode;
3, the enterprise of the date of delivery is always can't meet the needs of customers;
4, a large backlog of stock and production field, lead to the confusion;
5, the production quality is not stable, lead to a large number of returns and customer complaints;
6, face competition pressure is more and more big;
7, industry price war led to a sharp fall in the number of corporate profits.
No matter your business size, nature and industry, more than if you face these problems, technically, will let you get to lean production management way is not only a real return on cash.
A small enterprise launched the "project" lean production, after the project, not the expected benefit. Great wits consulting after analysis of these companies, found the following four most main reasons:
1, the lean production when the "movement", do mobile warfare. Impatient for success, the lack of "lean thinking", which seriously violate the continue improvement of lean production
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