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Time, cost, quality in the lean production process
The tools and methods, management principles and implementation process included in lean production are a very large set of methodologies. Books such as (lean thinking) (machines that change the world) (Toyota model) describe this set of methodologies in more detail. This book does not expand these contents, but only dabbles in the basic concepts of lean production for some products.
Lean production contains a very large set of methodology, including tool method, management principle and implementation process, which is described in detail in books such as (lean thought) (machine that changes the world) (Toyota model). This book does not expand these contents, but only covers the basic concepts of lean production for some of the products.
Lean production (Lean Production) is the product of the market constraints of "resource scarcity" and "many varieties and few batches" encountered by the Japanese automobile industry after World War II. Through the changes in system structure, personnel organization, operation mode and market supply and demand, the production system can quickly adapt to the changing needs of users, and all useless and superfluous things in the production process can be streamlined, A production management method that ultimately achieves the best results in all aspects of production, including market supply and marketing. Different from the traditional large-scale production mode, its characteristics are "multi-variety" and "small batch".
Lean production is the product of the market restriction of "resource scarcity" and "multiple varieties and less batches" in Japanese automobile industry after World War II. Through the changes of system structure, personnel organization, operation mode and market supply and demand, it enables the production system to adapt to the changing needs of users quickly, and enables all useless and superfluous things in the production process to be refined Jane, a mode of production management that ultimately achieves the best results in all aspects of production including market supply and marketing. Different from the traditional large-scale production mode, it has the characteristics of "multi variety" and "small batch".
At the beginning of the 20th century, since Ford Motor Company founded the first automobile production line, large-scale production line has been the main feature of modern industrial production. Mass production is based on standardization and mass production to reduce production costs and improve production efficiency. This method adapted to the national conditions of the United States at that time, and the emergence of the rolling water line of automobile production turned the automobile from a luxury of a few rich people into a popular means of transportation. As a result, the American automobile industry has rapidly grown into a major pillar industry of the United States, and has driven and promoted the development of a large number of industries, including steel, glass, rubber, mechanical and electrical, and even the traffic service industry. Large-scale flow production is of great significance in the history of production technology and production management. However, after the Second World War, society has entered a new stage of diversified development of market demand, and accordingly requires industrial production to develop in the direction of multiple varieties and small batches. The weakness of single-variety and large-scale production methods has become increasingly obvious. Up. In order to comply with the requirements of the times, the lean production initiated by Japan's Fengquan Automobile Company has been explored and created in practice as a high-quality and low-consumption production method under the conditions of multi-variety and batch mixed production.
Since the first automobile production line was founded by Ford Motor Company in the early 20th century, large-scale production line has been the main feature of modern industrial production. Large scale production is to reduce production cost and improve production efficiency by standardized and mass production. This way adapted to the situation of the United States at that time. The emergence of the rolling water line of automobile production changed the automobile industry from the luxury of a few rich people to a popular means of transportation. The American automobile industry has also grown rapidly into a major pillar industry of the United States, and promoted and promoted the development of a large number of industries including steel, glass, rubber, mechanical and electrical, and even transportation and service industries. Large scale flow production is of great significance in the history of production technology and production management. However, after the Second World War, the society has entered a new stage of diversified development of market demand. Accordingly, industrial production is required to develop in the direction of multi variety and small batch. The weakness of single variety and large batch production mode is becoming increasingly obvious. In order to meet the requirements of this era, the lean production initiated by Japan's Fengquan automobile company has been explored and created in practice as a high-quality and low consumption production mode under the conditions of multiple varieties and batch mixed production.
In 1950, Japan's Hideji Toyoda inspected the Ford sedan factory in Detroit, USA. At that time, the factory could produce 9000 cars a month, more than Toyota's annual output. In his investigation report, the gang wrote: "there is still the possibility of improvement in the production system there". Japan's post-World War II economic depression, lack of capital and foreign exchange 9 days at that time it was not possible to fully introduce the United States complete sets of equipment to produce cars, and Japan's total production at that time was only a few tenth of the United States. The law of "economies of scale" is facing a test here. In the past, Tian Yingji and his partner, Naiichi Ono, conducted a series of explorations and experiments, and put forward a solution to the problem according to Japan's national conditions. After more than 30 years of hard work, a complete Toyota production method was finally formed, making Japan's automobile industry surpass that of the United States. Toyota's production method is an important part of Japan's industrial competition strategy, which reflects Japan's management thinking in the repetitive production process. The guiding ideology of Toyota's production mode is: through the overall optimization of the production process, improving technology, rationalizing logistics, eliminating overproduction, eliminating ineffective labor and waste, effective use of resources, reducing costs, improving quality, and achieving maximum output with the least input.
In 1950, Toyoda Yinger of Japan inspected the car factory of Ford company in Detroit, USA. At that time, the factory was able to produce 9000 cars a month, more than Toyota produced in a year. "There is still the possibility of improving the production system there," he wrote in his research report. After the Second World War, Japan's economy was in a depression, lacking funds and foreign exchange. 9 at that time, it was impossible for Japan to fully introduce American complete sets of equipment to produce automobiles, and Japan's overall production was only one tenth of that of the United States. The law of "scale economy" is facing a test here. Tian Yinger and his partner, Ono Naiyi, have carried out a series of explorations and experiments. According to Japan's national conditions, they have put forward solutions to the problems. After more than 30 years of efforts, it has finally formed a complete Toyota production mode, making Japan's automobile industry surpass the United States. Toyota mode of production is an important part of Japan's industrial competition strategy, which reflects the management idea of Japan in the process of repetitive production. The guiding ideology of Toyota's production mode is to achieve the goal of maximum output with the least input through overall optimization of production process, improvement of technology, rationalization of logistics, elimination of excessive production, elimination of invalid labor and waste, effective use of resources, reduction of cost and improvement of quality.
The basic idea of lean production can be summarized in one sentence, namely: Just In Time(JIT), which translates into Chinese as "aiming to produce the required products when needed and in the required quantity". Therefore, some management experts also call lean production methods JIT production methods, just-in-time production methods, just-in-time production methods or kanban production methods. The basic tools of the lean production approach include the following.
The basic idea of lean production can be summed up in one sentence, that is, just in time (JIT), translated into Chinese is "to produce the required products according to the required quantity when necessary". So some management experts also call lean production as JIT, JIT, just in time or kanban. The basic tools of lean production include the following.
(1)5S and visual control
(1) 5S and visual control
"5S" is the abbreviation of the five words (SEIRI), rectification (SEIToN), cleaning (SEISo), cleaning "SEIKEETSU") and literacy (SHITSUKE). 5S is a process and method to create and maintain an organized, clean and efficient workplace. It can educate, inspire and develop good "human nature" habits. Visual management can identify normal and abnormal states in an instant, and transmit information quickly and correctly.
"5S" is the abbreviation of five words: Seiri, Seiton, Seiso, seikeetsu and Shitsuke. 5S is a process and method to create and maintain an organized, clean and efficient workplace. It can educate, inspire and develop good "human nature" habits. Visual management can instantly identify normal and abnormal conditions, and quickly and correctly transfer information.
(2) Timing Billion Production (JIT)
(2) JIT (just in time)
The just-in-time production method originated from Toyota Motor Corporation of Japan. Its basic idea is that H only produces the required products when needed. The core of this mode of production is to pursue a production system without inventory, or a production system with small inventory.
Just in time production is originated from Toyota Motor Company of Japan. Its basic idea is that h only produces the required products according to the required quantity when needed. The core of this production mode is to pursue a production system without inventory or a production system with small inventory.
(3) Kanban management (kan-ban)
(3) Can ban management
"kan-ban" is a noun, which means a label or card hung on or attached to a container or a batch of parts, or a variety of colored signal lights, TV images, etc. on the assembly line. The exhibition board can be used as a means of communicating production management information in the factory. Kanban cards contain quite a lot of information and can be used over and over again. There are two kinds of commonly used kanban: production kanban and shipping kanban.
"Kan ban" is a terminological term, which means a kind of label or card hung on or pasted on a container or a batch of parts, or a variety of signal lights and TV images with different colors on the assembly line. Display board can be used as a means to exchange production management information in the factory. Kanban cards contain quite a lot of information and can be reused. There are two kinds of Kanban in common use: production Kanban and delivery kanban.
(4) Zero inventory management
(4) Zero inventory management
Factory inventory management is a part of the supply chain, but also the most basic part. As far as the manufacturing industry is concerned, strengthening inventory management can be short and gradually eliminate the retention of raw materials, die forging semi-finished products, precision forgings finished products, reduce invalid operations and waiting time, prevent out of stock, improve customer pairs. Quality, cost, delivery time. Three elements of satisfaction.
Factory inventory management is a part of the supply chain, but also the most basic part. As far as manufacturing industry is concerned, strengthening inventory management can shorten and gradually eliminate the detention time of raw materials, semi-finished products of die forging and finished products of precision forging, reduce the invalid operation and waiting time, prevent the shortage of goods and improve the customer satisfaction. Quality, cost and delivery time. Satisfaction of the three elements.
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