7大浪费经典介绍中英文版.ppt

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1、7大浪大浪费经典介典介绍中英文版中英文版2Top MgtMiddle MgtFront LineAssociateBreakthrough Daily ManagementSupervisorKaizenHow Should You Spend Your Time?工作角色与时间分配工作角色与时间分配2020/11/3023Change Is Not Easy求变并非易事求变并非易事Change and Improvement Do Not Come Easy改变和改进来之不易Basic premise基本前提基本前提Physics tells us物理原理告诉我们物理原理告诉我们Human

2、nature人类本性人类本性Why?为什么？为什么？Therefore因此因此The greater the resistance阻力越大阻力越大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 ta

3、kes people 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2020/11/3034Purpose of Training培训目的培训目的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

4、”与“非增值”Identify and discuss ways to eliminate waste辨认和探讨消除浪费的方法2020/11/3045Input输入输入Energy 能源People 人力Capital 资本Water 水Materials 材料Tools 工具Output 输出输出Products 产品Services 服务Waste 浪费浪费Value Added增增 值值Focus of traditionalimprovement programs传统方式侧重于传统方式侧重于Work longer 增加工作时间Work harder 增加工作强度Add people 增

5、加人手Add equipment 增加设备Faster cycle times 加快周转时间Focus of lean production精益焦点精益焦点Eliminate waste 消除浪费Identification of Waste 浪费的识别浪费的识别2020/11/3056增值增值 客户愿意为何付费客户愿意为何付费?增值增值 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 W

6、hich The Customer Is Willing To Pay当确定价值时我们必须从客户的观点出发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 Determining Value!不增值不增值-不需要的步骤或活动不需要的步骤或活动,增加的流程时间和成本多于价值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

7、2020/11/3067Is 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增值案例增值案例2020/11/3078Is 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增值案例增值案例2020/11/3089Is it Value Added(VA)or Non-Value Added(

8、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增值案例增值案例2020/11/30910Is 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增值案例增值案例2020/11/301011Is it Value Added(VA)or Non-Value Added(NVA)?

9、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增值案例增值案例2020/11/301112Is 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增值案例增值案例2020/11/301213Is it Value Add

10、ed(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增值案例增值案例2020/11/301314Is 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 Mat

11、erial搬运Value Added Examples增值案例增值案例2020/11/301415Is 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增值案例增值案例2020/11/301516Is it Value Added(VA)or Non-Value Added(NVA)?请判断是否增值？VA增值

12、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增值案例增值案例2020/11/301617of allmanufacturing time is non-value added!95%的生产时间是的生产时间是不能增值的不能增值的95%Non-Value Added 非增值非增值2020/11/301718增值增值 vs.非非-增值增值增值增值非增值非增值必要必要不必要不必要 通过通过KAIZEN持续提高持续提高如

13、果可能消除如果可能消除,如果不可能如果不可能Kaizen 如果可能消如果可能消除除,如果不可如果不可能能Kaizen 立即消除立即消除2020/11/301819Inventory 库存库存Motion 多余动作多余动作Transportation 搬运搬运Waiting 等待等待Overproduction 过量生产过量生产Processing 过程不当过程不当Correction 返工返工Unused talent/skillsNon ergonomics workstationIdentify and Eliminate 9 WastesIM TWO PC+UN2020/11/30192

14、0Any 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 库存浪费库存浪费2020/11/302021Inventory Hides Problems!库存会隐藏库存会隐藏问题问题！Inventory Hides Waste!库存会隐藏浪费！库存会隐藏浪费！Water=Inventory水水=库存库存ROCKS=PROBLEMS 暗礁暗礁=问题问题LongChangeovers换模时间过长Variation 变更Equipment Downtime

15、设备停机时间Inventory Level 库存量Large Lot Sizes过大的批量Supplier Quality供应商的质量 Poor layout糟糕的厂区布局Inventory Hides Problems过多的库存会隐藏问题过多的库存会隐藏问题2020/11/302122Low Down Inventory To Expose Problem通过降库存暴露问题通过降库存暴露问题交货问题交货问题质量问题质量问题效率问题效率问题维修问题维修问题库存水平库存水平2020/11/302223Any movement which does not contribute value to

16、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 多余动作多余动作2020/11/302324Any movement of material 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物料搬运物料搬运2020/11/302425Idle Time That Is Produced When Two Dependent Variables Are Not Fully Synchronized当两个关联要

17、素间未能完全同步时所产生的空闲时间Waste of Waiting 等待等待2020/11/302526Waste of Overproduction 过量生产过量生产 生产多于下游客户所需生产多于下游客户所需生产多于下游客户所需生产多于下游客户所需 Making More Than NeededMaking More Than Needed 生产快于下游客户所求生产快于下游客户所求生产快于下游客户所求生产快于下游客户所求 Making Faster Than NeededMaking Faster Than Needed劳模？劳模？2020/11/302627Overproduction W

18、aste生产过剩生产过剩Overproduction is considered the worst waste!生产过剩被认为是最严重的浪费！Why?为什么？2020/11/302728Overproduction spins off allother types of waste生产过剩生产过剩超过了超过了其他所有的其他所有的浪费形式浪费形式 Overproduction生产过剩生产过剩 Need more boxes 需要更多箱子需要更多箱子 Need many pallets 需要更多托盘需要更多托盘 Need fork lift 需要叉车需要叉车 Need fork lift dri

19、vers 需要叉车司机需要叉车司机 Need additional floor space需要额外的地面空间需要额外的地面空间 Need warehouse 需要仓库需要仓库 Need warehouse operators 需要库房管理员需要库房管理员 Many parts get rusty 许多零件生锈许多零件生锈 Need sorting operator 需要分类管理员需要分类管理员 Need rework 需要返工需要返工 Make scrap 产生废料产生废料Overproduction Waste生产过剩生产过剩2020/11/302829Effort which adds n

20、o valueto a product or service对最终产品或服务不增加价值的过程 Waste of Processing过程不当过程不当/过多的工艺过多的工艺2020/11/302930Rework 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 检验检验/校正校正/返工返工2020/11/303031 The Approach 方式方式 The Means/Tools 工具工具 The Strategy 策略策

21、略ELIMINATION OF WASTE消除浪费消除浪费COSTSLEADTIME生产周期生产周期COSTS成本成本QUALITY THEFIRST TIME一次交验的一次交验的质量质量WORKPLACE ORGANIZATION车间组织车间组织及布局及布局5S/VISUAL CONTROLS5S/目视化管理目视化管理QUICK CHANGEOVER快速换模快速换模KANBAN 看板看板DEDICATED LINESONE PIECE FLOW特定单件流动生产线特定单件流动生产线ONE PIECE FLOW 单件流水生产单件流水生产STANDARD WORK标准化作业标准化作业QUALITY

22、 有效的质量管控有效的质量管控Lean Manufacturing精益制造精益制造Continuous Improvement by the Elimination of Waste通过消除浪费而不断改善通过消除浪费而不断改善2020/11/303132观念转变，观念转变，消除浪费消除浪费消除浪费消除浪费，价值流管理，团队精神及，价值流管理，团队精神及5S，持续改进持续改进设设备备总总有有效效性性自自动动化化及及防防错错作业快速转换作业快速转换流动生产流动生产设备布局设备布局多技能员工多技能员工小批量生产小批量生产缩短生产周期缩短生产周期均衡混流生产均衡混流生产看板拉动看板拉动准时化生产准时化

23、生产库存降低库存降低消除浪费降低成本消除浪费降低成本全全面面质质量量管管理理全全面面生生产产维维护护精益企业精益企业Lean Enterprise精益企业之屋精益企业之屋2020/11/303233!I HearI ForgetI SeeI RememberI DoI Understand2020/11/3033347 Kinds of Waste 七大浪费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变化/未使用的创造力(the 8th Waste)2020/11/303435“Growing Eyes”观察与思考观察与思考Were now going to do an exercis

24、e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 discuss 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2020/11/3035