Tools and Implementation of Lean Production Management
2020-11-20
1: What is Lean Production
2: Four Characteristics of Lean Production
3: Six Advantages of Lean Production
4: Ten Tools of Lean Production
1: What is Lean Production
Lean Production (Lean Production, abbreviated as LP) is a term of praise by experts from the International Motor Vehicle Program (IMVP) at the Massachusetts Institute of Technology for the Japanese "Toyota JIT (Just In Time) production method."
Lean means not investing excess production factors and only producing the necessary quantity of urgently needed products at the appropriate time.
(or products urgently needed by the next process).
Benefit means that all business activities must be beneficial and effective, with economic efficiency.
Lean production is currently the best production organization method in the industry. Lean production is a production method that aims to minimize the resources occupied by enterprise production and reduce management and operational costs, pursuing excellence.
2: Four Characteristics of Lean Production
1. Eliminate all waste, pursue perfection.
The characteristic of lean production is to eliminate all waste, pursue perfection, and continuously improve. Remove all useless elements in the production process, and the arrangement principle for each worker and their position is to add value, removing all non-value-adding positions. Streamlining is its core, streamlining all non-value-adding work in product development, design, production, and management, aiming to respond to market demand with the best quality, lowest cost, and highest efficiency.
2. Emphasize the role of people and unleash human potential.
The lean production method maximally transfers work tasks and responsibilities to workers who directly add value to the product. Moreover, tasks are assigned to groups, with workers within the group collaborating to undertake them. This requires workers to be proficient in multiple jobs, reducing non-value-adding workers, and increasing workers' autonomy in production. When a production line malfunctions, workers have the right to decide to stop, find the cause, and make decisions. Group collaboration expands the scope of workers' work, stimulates their interest and innovative spirit, and is more conducive to the implementation of lean production.
3. Zero waste goal.
High inventory is one of the characteristics of mass production. Due to unstable equipment operation, unreasonable process arrangement, high scrap rates, and production imbalances, there are often delays in supply, and inventory is seen as an essential "buffer." However, lean production considers inventory to be a "harm" to enterprises, mainly for the following reasons: ① Inventory increases operational costs; ② Inventory conceals problems within the enterprise.
Ineffective labor in production and excess labor entering inventory in advance are both waste. The lean production method requires ruthlessly removing non-value-adding links and positions.
4. Pursue perfection, never be satisfied.
The lean production method pursues continuous improvement in product quality, cost, and service. This idea is an important feature that distinguishes it from mass production methods. Just-in-time production (JIT) and continuous improvement processes (CIP) are manifestations of lean production.
The lean production method strives for rationality and efficiency in production, pursuing production technologies and management techniques that can flexibly and diversely produce high-quality products that meet various demands. Its basic principles and many methods have positive significance for the manufacturing industry.
3: Six Advantages of Lean Production
Compared to mass production methods, the advantages of lean production are mainly reflected in the following aspects:
1. Whether in product development, production systems, or other departments of the enterprise, the required human resources can be reduced by half compared to enterprises under mass production methods;
2. The new product development cycle can be reduced by more than half;
3. The work-in-progress inventory during the production process can be reduced to one-tenth of the general level of mass production;
4. The space occupied by the enterprise can be reduced to half that of enterprises using mass production methods;
5. The finished product inventory can be reduced to one-fourth of the average inventory level of mass production enterprises;
6. Product quality can be improved threefold.
4: Ten Tools of Lean Production
1. Just-in-Time Production (JIT)
The just-in-time production method originated in Japan, and its basic idea is to "produce the required products only when needed, in the required quantity." The core of this production method is to pursue a production system with no inventory or to minimize inventory. When we carry out production operations, we must strictly follow standard requirements, produce according to demand, deliver materials as needed on-site, and prevent abnormal inventory.
2. 5S and Visual Management
5S (Sort, Set in order, Shine, Standardize, Sustain) is an effective tool for on-site visual management and also an effective tool for improving employee quality. The key to successful 5S is standardization, which allows employees to maintain the cleanliness of the site while exposing and solving on-site and equipment problems, gradually developing standardized professional habits and good professional qualities.
3. Kanban Management
Kanban can serve as a means of communicating production management information within the factory. Kanban cards contain a considerable amount of information and can be reused. There are two common types of kanban: production kanban and transport kanban. Kanban is relatively direct, visible, and easy to manage.
4. Standardized Work (SOP)
Standardization is the most effective management tool for achieving high efficiency and high quality in production. After value stream analysis of the production process, textual standards are formed based on scientific process flows and operating procedures. Standards are not only the basis for determining product quality but also the basis for training employees in standardized operations. These standards include on-site visual standards, equipment management standards, product production standards, and product quality standards. Lean production requires that "everything must be standardized."
5. Total Productive Maintenance (TPM)
By involving all employees, create well-designed equipment systems, improve the utilization of existing equipment, achieve safety and high quality, and prevent failures, thereby enabling enterprises to reduce costs and improve overall production efficiency. This not only reflects the ability of 5S but also emphasizes work safety analysis and safety production management.
6. Use Value Stream Mapping to Identify Waste (VSM)
The production process is filled with astonishing waste phenomena, and Value Stream Mapping is the foundation and key point for implementing lean systems and eliminating process waste:
• Identify where waste occurs in the process and recognize opportunities for lean improvement;
• Understand the components and importance of the value stream.
• Master the ability to draw "value stream maps" in practice;
• Understand the application of data in value stream mapping, and prioritize improvement opportunities through data quantification.
7. Production Line Balancing Design
Due to unreasonable assembly line layout, production workers move unnecessarily, thus reducing production efficiency; due to unreasonable action arrangements and process routes, workers repeatedly pick up or put down workpieces. Evaluating the situation is very important, and on-site planning is also crucial. Saving time and effort is the best approach. Achieving twice the result with half the effort is essential.
8. Pull Production (PULL)
Pull production refers to using kanban management as a means, adopting a "material withdrawal system" where subsequent processes produce based on market needs, taking the same amount of work-in-progress from previous processes when there is a shortage in the current process, thus forming a pull control system throughout the entire process, ensuring that no extra products are produced. JIT (Just In Time) needs to be based on pull production, and the pull system operation is a typical feature of lean production. The zero inventory pursued by lean is mainly achieved through the operation mode of the pull system.
9. Quick Changeover (SMED)
The theoretical basis for quick changeover is operations research and concurrent engineering, aiming to minimize equipment downtime through team collaboration. When changing product lines and adjusting equipment, it is possible to compress lead time to the maximum extent, and the effect of quick changeover is very significant.
To minimize waiting waste during downtime, the process of shortening setup time involves gradually eliminating and reducing all non-value-added operations and transforming them into processes completed during non-downtime. Lean production is achieved by continuously eliminating waste, reducing inventory, minimizing defects, and shortening manufacturing cycle times, among other specific requirements, and reducing setup time is one of the key techniques to help us achieve this goal.
10. Continuous Improvement (Kaizen)
When we begin to accurately identify value, recognize the value stream, and allow the steps that create value for specific products to flow continuously, while enabling customers to pull value from the enterprise, miracles begin to happen.
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Tools and Implementation of Lean Production Management
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