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1、Waste Elimination消除浪费,Why change and improve?我们需要改善吗,Top Mgt,Middle,Mgt,Front LineAssociate,Breakthrough,Daily,Management,Supervisor,Kaizen,How Should You Spend Your Time?工作角色与时间分配,Change Is Not Easy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Physics tells us物理原理告诉我们Huma
2、n nature人类本性Why?为什么？Therefore因此The greater the resistance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：寻找借口，等待，坐视旁观等等）Because change takes people
3、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,Purpose of Training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 non-value added定义和讨论“增值”与“非增值”Identify and discu
4、ss ways to eliminate waste辨认和探讨消除浪费的方法,Input输入Energy 能源People 人力Capital 资本Water 水Materials 材料Tools 工具Output 输出Products 产品Services 服务,Waste 浪费,Value Added增 值,Focus of traditionalimprovement programs传统方式侧重于Work longer 增加工作时间Work harder 增加工作强度Add people 增加人手Add equipment 增加设备Faster cycle times 加快周转时间,F
5、ocus of lean production精益焦点Eliminate waste 消除浪费,Identification of Waste 浪费的识别,增值 客户愿意为何付费?,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That Change A Raw Material Or Information Into A Product Or Service For Which The Customer Is Willing To Pay,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 De
6、termining Value!,不增值-不需要的步骤或活动,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 Value,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,Is it Value Added(VA)or Non-Value Ad
7、ded(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,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Grinding operation磨削工序,Value Added Examples增值案例,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Grinding o
8、peration磨削工序,Value Added Examples增值案例,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Grinding operation磨削工序Heat Treatment热处理,Value Added Examples增值案例,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Grinding operation磨削工序Heat Tr
9、eatment热处理,Value Added Examples增值案例,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Grinding operation磨削工序Heat Treatment热处理Moving Material搬运,Value Added Examples增值案例,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Grinding opera
10、tion磨削工序Heat Treatment热处理Moving Material搬运,Value Added Examples增值案例,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,Is it Value Added(VA)or Non-Value Added(NVA)?请判断是否增值？V
11、A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,of allmanufacturing time is non-value added!95%的生产时间是不能增值的,95%,Non-Value Added 非增值,增值 vs.非-增值,Inventory 库存Motion 多余动作Transportation 搬运Waiting 等待Overproduction 过量生产Processing 过程
12、不当Correction 返工Unused talent/skillsNon ergonomics workstation,Identify and Eliminate 9 WastesIM TWO PC+UN,Any 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,Inventory Hides Problems!库存会隐藏问题！Inventory Hides Waste!库存会隐藏浪费！,Water=Inventory水=库存,RO
13、CKS=PROBLEMS 暗礁=问题,Inventory Level 库存量,Poor layout糟糕的厂区布局,Inventory Hides Problems过多的库存会隐藏问题,Low Down Inventory To Expose Problem通过降库存暴露问题,交货问题,质量问题,效率问题,维修问题,库存水平,Any 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,Any movement of materi
14、al 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,Idle Time That 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,Waste of Overproduction 过量生产,生产多于下游客户所需 Making More Than Needed生产快于下游客户所求 Making F
15、aster Than Needed,劳模？,Overproduction Waste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？,Overproduction spins off allother types of waste生产过剩超过了其他所有的浪费形式,Overproduction生产过剩 Need more boxes 需要更多箱子 Need many pallets 需要更多托盘 Need fork lift 需要叉车 Need fork lift drivers 需要叉车司机 Ne
16、ed additional floor space需要额外的地面空间 Need warehouse 需要仓库 Need warehouse operators 需要库房管理员 Many parts get rusty 许多零件生锈 Need sorting operator 需要分类管理员 Need rework 需要返工 Make scrap 产生废料,Overproduction Waste生产过剩,Effort 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/过多的工艺,
17、Rework 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/校正/返工,The Approach 方式 The Means/Tools 工具 The Strategy 策略,ELIMINATION OF WASTE消除浪费,COSTS,LEADTIME生产周期,COSTS成本,QUALITY THEFIRST TIME一次交验的质量,WORKPLACE ORGANIZATION车间组织及布局,5S/VISUAL C
18、ONTROLS5S/目视化管理,QUICK CHANGEOVER快速换模,KANBAN 看板,DEDICATED LINESONE PIECE FLOW特定单件流动生产线,ONE PIECE FLOW 单件流水生产,STANDARD WORK标准化作业,QUALITY 有效的质量管控,Lean Manufacturing精益制造,Continuous Improvement by the Elimination of Waste通过消除浪费而不断改善,Lean Enterprise精益企业之屋,34,!,I Hear,I Forget,I See,I Remember,I Do,I Under
19、stand,7 Kinds of Waste 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,“Growing Eyes”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 assigned 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 di
20、scuss 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 eliminate.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,Summary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,
