Lean production starts with improvement, turns traditional experience into scientific and effective methods, eliminates MUDA, and then obtains more profits for enterprises.
First, improve awareness
1. 20 guidelines for improvement actions
In this training course, xu teacher first wrote us twenty rules for improving actions, which I personally think are quite good for guiding improvement, as follows;
(1) Good is bad, bad is good, and endless improvement is needed.
(2) The endless pursuit is the pursuit of a) improving labor productivity b) reducing the rate of defective products c) shortening delivery time d) reducing inventory e) saving space.
(3) There are problems that need to be improved. Don't wait until there are no problems to improve.
(4) It is necessary to break the traditional concept that one person operates one process in a fixed way and develop into a flexible demand that one person operates multiple processes.
(5) To master the five principles of on-the-spot, on-the-spot, reality, doing and checking, don't just look at written records.
(6) If you are fifty percent sure, you can try to do it. Don't wait until you 100% are sure to make improvements.
(7) Improvement can only be achieved by trying, not once.
(8) It is necessary to implement the spirit of slow work and fine work, and achieve it overnight. Don't think and discuss in the meeting room.
(9) Use wisdom to overcome problems, not money to solve them.
(10) March towards the ideal posture, and don't find reasons why you can't do it.
(1 1) The ideal posture is: a) pre-production, b) single-stream production and c) post-pulling kanban production.
(12) Give full play to the spirit of teamwork, don't fight alone, and Qi Xin will work together to achieve the goal.
(13) Ask why five times and find out the real root of the problem.
(14) Consider the overall situation first and make an exception.
(15) It is necessary to observe whether there are any problems (Big Wood, Muli, Mula, No Three Phenomena) that need to be improved.
(16) Improvement is welcome, but maintenance is more important.
(17) Maintenance means following standard operation.
(18) We should have four improvement cycle awareness: a) quality awareness (plan) b) maintenance awareness (implementation) c) problem awareness (inspection) d) improvement awareness (action disposal).
(19) Doctors prescribe medicine, patients take medicine, teachers teach improvement and students maintain it.
The problem is opportunity, and improvement is making money.
2. Two ways to solve the problem:
One is innovation, but the latest and best technology or equipment must be applied. This method must invest a lot of money.
One is improvement, which can be achieved with common sense concepts and methods without spending much money.
3. Improved five "hearts":
(1) Confidence: I believe these improvement activities can bring you benefits.
(2) determination: make up your mind to do it as soon as possible, and don't be depressed.
(3) Patience: Keep making progress forever, and the results will come naturally.
(4) Care: Show your care and attention to employees.
(5) Love: Encourage or reward people to inspire their morale.
Second, improve the organization of activities.
1. Ways to improve activities:
Significance of improvement activities: under the guidance of consultants, small teams composed of cross-departmental members improve specific topics within a specific time.
Frequency of improvement activities: once a month
Days of improvement: generally 3-6 days.
Number of improved groups: 2-3 groups.
Number of people in each group: generally 3-9 people.
2. Improve the program arrangement of activities:
(1) Start the meeting (usually in the conference room 1-2 hours)
Purpose:
A) Review the progress of the last improvement activity;
B) Report the difficulties of improvement activities in the previous stage.
C) The leader of the improvement team will report the improvement theme at this stage. (The reports involved mainly include: registration form of independent research association, value flow chart, assignment table of operators, standard operation table, record table of achievements, and comparison table before and after improvement. )
D) the improvement direction of the tutor.
E) Recite the twenty rules of improvement actions.
(2) On-site implementation of improvement activities (3rd to 40th hours)
A) All improvement team members and consultants go to the site for improvement.
B) Carry out improvement activities according to the eight steps of improvement (eight steps: setting the theme, setting the goal, investigating the current situation, analyzing the reasons, trying the countermeasures, confirming the effect, maintaining the standards, and planning the future improvement).
C) master five principles (on-site, now, reality, doing now and checking now)
D) Make improvement in the spirit of "slow down, be clever and be late".
(3) Prepare the report materials in the conference room (last 3-4 hours)
The main materials prepared are: value flow chart, improvement case, Plato, five-question table, performance record table and future plan.
(4) Hold the last meeting (last 2 hours)
A) improvement team reports improvement activities. (Related forms: registration form of independent research association, value flow chart, improvement express, Plato, five-question table, improvement case, improvement result table, standard operation sheet, operator assignment table (after improvement), future plan)
B) Instructor comments.
C) opinions of the top management of the company
D) close the meeting.
Three. Practice of improvement activities
1. Eight steps of improvement:
(1) account selection
Form of use: registration form of independent research association.
Key points: the theme should be written according to the description of verb+noun, such as improving labor productivity and shortening delivery time.
(2) Goal setting:
Form of use: registration form of independent research association.
Key points: Select and improve the appropriate subject measurement indicators. The index quantification is realized by using the pre-improvement index and the improved target index.
(3) Investigation of current situation:
Usage forms: time observation table, value flow chart, operator allocation table, standard operation combination ticket, processing capacity table, Plato, five questions table and improvement result table.
Key points: it is a status survey, not data collection and status survey. It means "finding the real cause" at the same time and mastering the principle of "five present".
(4) Lu Xun:
Usage table: improved express, five-question method and operator allocation table.
Key points: Using the "seven methods to explore the true cause" are: five-present method, five-question method, comparison method, amplification method, dissection method, map method and diving method.
(5) Trial countermeasures:
Usage: improve reports and examples.
Key points: a) Eliminate three noes, namely none, irrationality and instability. B) slow and clever; C) Use wisdom to solve problems, not money. D) Make improvement with 50% certainty, and don't wait until 100% to make improvement.
(6) Effect confirmation:
Use tables: hourly production status table, production schedule and improvement result table.
Point: If the effect is not good, repeat 3-5 steps. The results should be quantified.
(7) standard maintenance:
Usage forms: standard operation ticket, operator allocation table, hourly production status table, production schedule table, operation standard book and human error table.
Key points: Visual management tools should be strengthened, and measures should be taken immediately to correct any abnormal situation.
(8) Future plans:
Usage: improve the express train
Key points: first set up a demonstration line of observation and learning, and then try to expand the improvement action to other places.
2. Measures to improve the results:
(1) labor productivity = output/labor input (productivity = output/input).
(2) Delivery time = inventory quantity/daily productivity
Manufacturing lead time = (material+WIP+finished product)/daily output
Production lead time = WIP/ daily productivity
(3) First pass rate = [(total production-total defective products)/total production ]* 100%.
(4) Mobility = moving time/production planning time
(5) Accuracy = Accuracy * Punctuality * Accuracy.
Accuracy rate = actual yield of good products/planned yield of good products.
Punctuality rate = number of good products completed according to the order requirements/planned completion quantity.
Quasi-continuity rate = number of projects completed in sequence/number of planned continuous projects produced.
(6) Total qualified rate of supply = quality efficiency * cost efficiency * delivery efficiency (QCD)
(7) Mold changing time: the time to stop production due to the change of product model and the need to change molds or rearrange production conditions.
Die changing man-hours: the man-hours consumed in die changing.
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