2010165438+1October 4th to165438+1October1I attended the rationalization and lean production training course organized by Jianfeng Company in Taiwan Province Province. In the seven-day course, the word waste is the word I heard the most, which completely changed my original view and gave me a new understanding of the "seven wastes" and "lean production" in production. My experience is summarized as follows:

I. Re-understanding of the Seven Wastes

Before I attended the class, I knew that the seven major wastes were: 1, excessive/premature waste. 2. The waste of waiting. 3. Handling waste. 4. Inventory waste. 5. Waste of manufacturing defective products. 6, the waste of processing itself. 7. Waste of action. But there are only vague concepts about these kinds of waste, and the understanding is not profound. Through listening to the class, I have a deeper understanding of the seven wastes.

(1) Too much/too early waste is to make what customers need when they need it. Too much or too early production is also a waste, that is, the "just-in-time system" emphasized by lean production, but why do our enterprises always produce too much and too early again and again? The biggest reason is that we don't understand that this is a waste. Instead, I think that doing more can improve efficiency, and doing it early can reduce the loss of production capacity. ), obviously this is a great misunderstanding. Overproduction leads to a large number of products in process, occupying production space, increasing the workload of intermediate handling and management, increasing the chances of producing defective products and covering up many problems in the production process.

(2) The waste of waiting means that when the workload is small, or when the machine stops working, the operator is idle and the process is uneven. Common waiting phenomena are: insufficient supply of materials leads to waiting for materials; Equipment failure leads to production stagnation; Quality problems led to work stoppage. Common reasons for waiting: unbalanced production line; The production plan is unreasonable; Unreasonable equipment maintenance; The material supply is not timely.

(3) Handling waste refers to unnecessary handling distance caused by temporary placement (to be placed) or waste caused by repeated handling. On some occasions, carrying is a necessary action, because how to do the next homework activity without carrying? Many people have this idea. Because of this, most people acquiesce in its existence without trying to eliminate it. It's like a waste of inventory. A small inventory is necessary, but not too much. The main reasons for waste treatment are: unreasonable production layout or material placement, resulting in too long treatment route; The handling tools are unreasonable. One of the measures to reduce handling waste is to adjust the production layout and reduce the handling distance. Therefore, when handling cannot be completely eliminated, the layout of production and processing or material placement should be readjusted to minimize the handling distance and improve the handling efficiency. Another method is to improve the handling mode and make full use of pallets, handling carts, etc. In order to carry it efficiently at any time.

(4) Lean production mode holds that "inventory is the root of all evil". Because a large amount of inventory will produce unnecessary waste such as handling, accumulation, placement, protection and search. Daily management, picking list and even inventory also need extra time. It not only occupies production space, wastes manpower and material resources, but also occupies working capital and loss management expenses. With the increase of storage time, the value of goods tends to decrease and even become waste. Most importantly, the safety of inventory often covers up problems such as equipment failure, quality problems and supplier's supply capacity, which delays the fundamental countermeasures to solve these problems.

(5) The waste of manufacturing defective products is due to the fact that defective products not only waste all processing time, but also hinder production. The most serious problem is that no defects were found in the process, which led to the flow of defective products into the market. Money can't buy back the trust of customers because of defective products.

(6) The waste of processing itself refers to the waste of resources caused by the processing quality or accuracy exceeding the customer's requirements, including wasting too much working hours and energy, increasing equipment loss, occupying working space, etc. In the manufacturing process, some processing procedures can be omitted, merged, rearranged or simplified to achieve the purpose of operation. If we look closely, we will find that there are many wastes waiting for us to improve.

(7) Action waste refers to the waste caused by unreasonable actions of the operator at the production site. There are usually different actions to achieve the same work goal. Which actions are necessary and which are unnecessary? Do you need to take it so often? Is it necessary to turn around, walk, bend over, aim, etc? Is the scope of action too large? Are there any unnecessary actions that are repeated? If the design is good, you can omit many worthless actions.

Second, the company's waste status analysis

At present, the company's production site can be said to be full of waste. Through the analysis of our workshop site, it is considered that the waste in the workshop is seriously manifested in the following aspects: the waste of handling, the waste of waiting, the waste of manufacturing defective products and the waste of processing itself.

The waste of handling is mainly due to the product circulation between processes; Semi-finished products are transferred to the warehouse (semi-finished products will produce a lot of handling waste).

The waste of waiting is mainly the shutdown caused by the failure of special plane equipment; Work stoppage due to insufficient supply of materials; Assembly difficulties caused by poor quality or unreasonable design of assembly parts and unbalanced assembly process.

The waste of manufacturing defective products is mainly caused by too much rework and repair; And the company's reputation loss caused by defective products entering the market.

The waste of processing itself mainly refers to the repeated testing of finished products. Although repeated testing can control some defective products of the company, it often makes us ignore the fundamental problems that need to be solved most.

Third, some suggestions for the company.

1. In view of the above waste, I think it is necessary to implement the employee proposal system and encourage employees to put forward some suggestions for improvement. It is necessary to create an atmosphere of eliminating waste and continuous improvement throughout the company.

2. Establish the standard time (takt time) for each product and each working procedure, and provide scientific basis for line balance and production planning.

3. Set up IE (industrial engineering) department, and help us improve our work with seven methods of IE (anti-bulging method, power reform method, process method, five-five method, man-machine diagram, hands-on method and spot check method).

4. Replace the traditional assembly line operation with grouping and unit operation.

5. The handling of product quality problems can't just stay at the level of post-event management. Formulate a system to improve problems, create conditions for continuous improvement, create an atmosphere of courage and willingness to face problems, train employees in methods, strengthen their ability to trace back and solve problems, and truly realize the goal of total quality.

Finally, I want to say that resources are limited and there is no end to improvement. As long as we can start from small things and gradually infiltrate the concept of lean into daily production, lean will bring us unexpected gains.