 |
Kaizen Methodology |
| |
Tel：+86(0)755 22352797
Fax：+86(0)755 22352797
E-mail：ck@ckaizen.com
Web：http://www.ckaizen.com
Add： |
2F, Block A, Oastar Building, Zhongkang Road, Shangmeilin, Futian District, Shenzhen City, Guangdong Province, China
|
|
|
 |
Features
Lean production is characterized by the elimination of all waste, the pursuit of excellence and continuous improvement. Production processes to remove all the useless things, each of the arrangements for workers and their principle job is to add value to the removal of all non-value-added positions. To streamline its core, to streamline the product development design, production and management of all non-value-added work, aimed at the best quality, lowest cost and most efficient on the market demand for the fastest response.
In the 'machine that changed the world' in his book, Lean production are summarized in five aspects are discussed the characteristics of lean production. These five areas are: the factory organization, product design, supplier links, customers and business management. To sum up, the main features of lean production are: external to the user as 'God', at home 'person' as the central institutions in the organization in order to 'streamline' as a tool for use in the methods of work of 'Team Work' and ' Concurrent Design, 'the way in the use of supply' JIT 'way for the ultimate goal of' zero defect. '
1) To the user as 'God' user-oriented products, keep in close contact with the user, the user into the product development process to changing products, the shortest possible delivery time to meet the needs of users, the real embodiment of the user is ' God's 'spirit. Not only to provide good service, but also to anticipate the user's ideas and requirements in order to produce marketable products. Marketability of products, suitable price, good quality, fast delivery speed, quality service is the basic contents of user-oriented.
2) 'Person' as the center of all activities is the main body of enterprises should be people-centered, promoting the group of independent work. Front-line workers and give full play to the enthusiasm and creativity to enable them actively to improve the quality of the product to put forward ideas to the front line workers to really become a 'zero defect' production of the main force. To this end, business-to-love works employees, such as family education, and from the system to ensure that the interests of workers and enterprises linked to the interests. Devolution of power should be part of people who have the right, have the responsibility and obligation to solve problems encountered at any time. Would also like to meet people to learn new knowledge and the desire to achieve self-worth to create unique and competitive awareness of the corporate culture.
3) In order to 'streamline' the organization as a means to streamline its institutions, and remove all the redundant links and personnel. To achieve reduction in the level of vertical, horizontal break down departmental barriers, will be the level of sub-workers, management models into a distributed parallel network management structure. In the production process, the flexible use of advanced processing equipment to reduce the number of direct production workers, so that each worker is really value-added products. In addition, the use of JIT and Kanban management of logistics, even the achievement of substantial reduction in inventory, but also a reduction of inventory management personnel, equipment and premises. In addition, lean manufacturing not only means to reduce the complexity of the process, but also in reducing the complexity of products offers a wide range of products.
4) Team Work the concurrent design and lean production methods to emphasize the work of Team Work the concurrent design of products. Team Work (Integrated Working Group) is prepared by the enterprise sector composed of multi-professional design team, product development and production of guidance and strong integration capabilities. The Working Group has overall responsibility for integrated product development and production of models, including product design, process design, budgeting, materials acquisition, production preparation and production and so on. Adjusted according to the actual situation and the original design and plans. Integrated Working Group on all aspects of enterprise integration is a form of talent.
5) JIT supplier JIT approach can work to ensure that the smallest stocks and at least a few products. In order to achieve this delivery method should be established with suppliers good relations of cooperation, mutual trust, mutual support, the interests of a total dip.
6) 'Zero defect' goal of Lean Production is not the goal of 'better, as far as possible' but 'zero defect.' That is the lowest cost, best quality, no waste, and inventory and product diversity. Of course, this is a realm of ideal, but it should be no limit to the pursuit of this goal will be to maintain the progress of the enterprise will always, always walk in front of others.
Advantage and significance
Compared with the large number of production methods, the superiority of lean production is mainly manifested in the following areas: 
1. The necessary human resources both in product development, production systems, or other departments of factories, with a large number of modes of production compared to the factory, the minimum can be reduced to 1 / 2.
2. The new product development cycle - the minimum could be reduced to l / 2 or 2 / 3.
3. The production process inventory in the products - can be kept to a minimum of a large number of the general level of production of 1 / 10.
4. Factory space - can be kept to a minimum the use of a large number of modes of production of 1 / 2.
5. Finished stock - the lowest mode of production could be reduced to a large number of average inventory levels of 1 / 4.
6. Product quality - can be substantial.
Lean production is completely in pursuit of the rationality of production, efficiency; flexibility to adapt to the needs of the production of high-quality products, production technology and management skills, and many of its basic principles and methods, the manufacturing sector has a positive meaning. The core of lean manufacturing that is, on the production planning and inventory management control, as well as the basic idea of the enrichment and development of modern production management theory also plays an important role.
Compared with Management of large quantities production and thinking
Lean Manufacturing as a management objectives ranging from the environment to the management of all new ideas, and success in practice, not simply the application of the 12 kinds of new management tools, but an enterprise environment, culture and management method a high degree of integration of the management system, so their lean production system is a degree of autonomy.
(1) Different optimization range
Mass production methods from the United States, is based on the relationship between the United States enterprise, emphasizing market-oriented, and optimize the allocation of resources, each business relationship to financial limits, to optimize their own internal management. And related companies, whether suppliers or distributors, competitors are to be relative.
Lean production processes for products with lead, organizing the supply chain are closely related, on the one hand reduce the transaction costs of collaboration, on the other hand, to ensure the stability of demand and supply in time to the entire large-scale production systems to optimize the objectives.
(2) Different attitude towards stocks
Mass production of the inventory management approach to stress 'is a necessary evil stock material.'
Lean production methods of inventory management stressed that 'inventory is the root of all evil'
Lean production methods to the production of all the stock as a 'wasted', at the same time that the inventory system to cover up the production of defects and problems. On the one hand, it stressed the guarantee of supply of production, on the other hand, emphasis on inventory requirements, thus constantly exposed to the production of the basic aspects of the conflict and to improve constantly to reduce inventory stocks have to eliminate the 'wasted.' Based on this, the lean production of 'the elimination of all waste' slogan. To pursue the goal of zero waste.
(3) Different concept of operational control
The traditional way of employing high-volume production system is based on the two sides of the 'employment' relationship between the business management to achieve a person's work emphasized the division of the principle of efficient and strict auditing to promote the business with the assurance that audit work at the same time work to prevent individuals from enterprises negative effect.
Lean production originated from Japan, by Oriental cultural influence, in the professional division of labor and mutual cooperation, stressed the streamlining of business processes (including verification of unnecessary work) - the elimination of the business of 'waste.'
(4) Different duality
The traditional mode of production will be a certain amount of defects as the inevitable result of the production.
Lean Production decentralized organization based on collaboration with the view that their own producers to ensure the absolute quality of products can be * is feasible, without sacrificing the continuity of production. Its core idea is that the probability of giving rise to such cause of quality problems are not the probability of nature, through the elimination of quality problems arising from the production to 'the elimination of all waste brought about by defective', the pursuit of zero non-performing.
(5) Different attitude of treat people Approach emphasizes the management of high-volume production in the strict hierarchy. The requirements of the staff is strictly to complete the task of the higher authorities, were attached to the posts as 'equipment.'
Lean production emphasizes personal intervention of the production process, to give full play to the initiative, while stressing the coordination, evaluation of individual employees is based on long-term performance. This approach will be more staff as business groups, rather than machines. Give full play to the grass-roots initiative.
Countries in the world of the practice of lean production
With the Japanese manufacturing industry in the international competition and the victory of the rising countries in the world of lean manufacturing gradual deepening of the study, lean production methods in practice has been gradually adopted by many enterprises.
First of all, in the automotive industry, almost all major automobile manufacturers are beginning to absorb the idea of lean production, the implementation of 'just-in-time (JIT)' production, to strengthen inter-firm collaboration ┅┅. Especially in the part of the improvement of production methods, and some companies even more than the implementation of lean manufacturing enterprises in Japan. Subsequently, in a growing number of enterprises in other industries, lean production methods of production organization, personnel management and enterprise collaboration methods have been widely and to promote absorption. In recent years, the world-wide on the reform of personnel management of enterprises and some of the activities of recycling companies, many have been thinking of the impact of lean production.
In the worldwide implementation of lean production and practice, and some was a great success, but a considerable number of enterprises has not been the success expected, and even brought about a considerable negative effect (According to statistics, about 1 / 3 is not satisfied with the business or have a negative effect). The reason is very complicated, there are problems in the implementation process, and the production features the industry issues, but also social and cultural issues, different terms. |
|
