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1、Starting with Toyota in the late 50s and catching on in the mid 80s in the reminder of the industrial world, Lean Manufacturing has become a key strategy for manufacturers 起源于20世纪50年代丰田汽车公司，而在80年代中期被欧美企业纷纷采用。随着微利时代的来临，精益生产模式成为企业竞争的有力武器,Lean Thinking and Lean Manufacturing System 精益思维和精益生产系统,Marketin
2、g Competition and Globalization 市场竞争及全球化,Shorter lead time and on time delivery 快速并准时交货 Grow the mix，special configurations 需求品种增加，特殊定制 Maintain / improve quality and reduce price 不断改进质量及降低销售价格 Total life cycle of product becoming shorter and shorter 产品的生命周期越来越短 No boundary，business globalize villag
3、e 无国界，业务“地球村”,Marketing Competition and Globalization 市场竞争及全球化,The are two ways to think about the relationship of Price, Cost and Profit 在价格，成本和利润的关系中，有两种不同的思考方法： 1。传统的方法 销售价格 = 成本 + 利润 2。新的方法 利润 =销售价格 成本,Lean Thinking and Lean Manufacturing System 精益思维和精益生产系统,The Cost / Lean Relationship 精益生产与成本的关
4、系,灵巧的双手,投资,直接员工,Automation Continuum,全自动,Life Cycle Cost In Different System 不同系统中的成本,精益生产系统之产品 生命周期成本,大规模生产模式下的 产品生命周期成本,Manufacturing Evolution 制造系统演化史,Henry Ford Assembly line mass production Produce in high volume with low variety Single skill 福特首创的装配线是大规模低品种生产方式的代表，简单技能,Toyota Production System
5、 (TPS) Just-In-Time Production (produce only what is needed) Pull System Produce enough volume to meet customers needs High variety to meet customers wants 丰田系统是建立在准时化观念上的拉动 式生产模式，以应付小订单多品种的挑战,Craft 手工生产,Mass 大规模生产,Synchronous 同步生产,Agile 敏捷生产,敏捷型,组织,Key Points for Manufacturing System 制造系统要点,Low vol
6、ume Customized 低产量 个性化,Large batches of similar products Inflexible machinery Manufacture of goods by process 大批量少品种 工序式生产 设备大难组合,Focused on total elimination of waste Ongoing efforts to improve Quality, Productivity, and Responsiveness Attention to detail Recognition of employee abilities 消除浪费 不断改进
7、 员工参与,Builds on synchronous manufacturing Emphasize on lead time reduction Improve asset utilization Built to customer demand 在同步生产的基础上，强调缩短生产周期 提高资源利用率 需求驱动,Remove constraints to respond to customer demand through the entire supply pipeline (supplier-customer) Capable plants linked to lean concepts
8、 改善整个价值链 节点上连着精益工厂,Lean -“精益”释义,精益：形容词 1： a：无肉或少肉， b：少脂肪或无脂肪 2： 不富裕 3： 在必要性，重要性，质量或成分方面稀缺 4： 文体或措词简练 同义词：薄，极瘦，过分瘦长，骨瘦如柴，瘦削的， 似 骨的，消瘦的，细长的，瘦长的 反义词： 肥胖的，多肉的，过重的，不结实的，过分 肥胖的，丰满的，粗短的，肥大的，软的,What is Lean Manufacturing 什么是精益生产-五个原则,Whatever You Call It 不管你称呼它什么,Lean Manufacturing Flow Manufacturing Contin
9、uous Flow Demand Pull Demand Flow Technology Toyota Production System _ Production System etc?,精益生产 流动制造 连续流 需求拉动 需求流动技术 丰田制造系统 _ 制造系统 等等.,Focus on SPEED and SIMPLIFICATION Pull materials through the process Balanced operations based on customer demand Minimal build unless tied to customer order Ext
10、end to Supplier Base 着眼于速度和过程简化 在生产过程中“拉动”材料 根据客户的需求平衡操作 除非受订单的限制，否则最小批量生产 延伸至供应商,Lean Manufacturing - Key Characteristics 精益制造 - 关键特性,What is Flow Manufacturing? 什么是流动生产？,A time based system that pulls material through a production system with no interruptions 建立在时间基础上，无障碍地拉动物料流经生产系统,Time and Impac
11、t 时间与影响,原材料 在制品 成品,供应商 L/T,运送,顾客,根据需求 生产,传统做法,根据预测 生产/采购,顾客,流动制造/精益生产,原材料/在制品/成品,Time in Manufacturing 生产中的时间,With Lean Manufacturing You Can Get 通过精益生产可以实现,生产时间减少 90% 库库减少 90% 到达客户手中的缺陷减少 50% 废品率降低 50% 与工作有关的伤害降低 50% The amount of human effort, time, space, tools, and inventories can typically be c
12、ut in half very quickly, and steady progress can be maintained from this point onward to cut inputs in half again within a few years. -精益思维, Womack & Jones,Benchmark Results 定标结果,5年生产效率的提高,5年生产成本的改进,5年一次性合格生产的提高,650% 的较优,40% 的提高,52% 的提高,广泛应用缩短周期时间与流动制造,Benchmark Results 定标结果,Lean Manufacturing Found
13、ations 实施精益的基础,Eliminate Wastes 5S and Visual Workplace Error Proofing People Involvement 消除浪费 工作场地组织及直观管理 差错预防 员工参与,Correction 返工 Overproduction 过量生产 Conveyance 搬运 Motion 多余动作 Waiting 等待 Inventory 库存 Processing 过程不当,Eliminate Wastes 消除七种浪费,Definition of Wastes 什么是浪费？,Anything other than absolute mi
14、nimum resource of material， machine and manpower required to add value to the product 除了使产品增值所需的材料，设备和人力资源之绝对最小量以外的一切东西 Anything Other Than Necessary 任何非必需的东西！,Producing More Than Needed Producing Faster Than Needed 生产多于所需 快于所需,Waste of Overproduction 过量生产,Definition: Rework of a Product or Service
15、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 Correction 校正 / 返工,Definition: Any movement of material that does not directly support a lean system 不符合精益生产的 一切物料搬运 活动,Waste of Material Movement / Conveyance 物料搬运,DEFINITION: Effort which adds no value to 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,Definition: Any supply in excess of process requirements necessary to produce goods 任何超过加工必须的 物料供应,Waste of Inventory 库存浪费,Definition: Idle Time That Is Produced When Two Dependent Variables
