Through the implementation of 5S management, we can change the face of the work site, create an orderly working environment, reduce all kinds of search time, improve efficiency, realize the habit of all employees to abide by the regulations, and constantly seek to improve their professional quality.
2. Step 2: Realize synchronous production.
Synchronize the production between processes, and try to keep the number of WIP between processes to a minimum. In other words, as soon as the processing of the previous process is finished, the product will be transferred to the next process immediately. By arranging the equipment, personnel and production line as follows, it will help to realize synchronous production.
① one piece flow;
(2) Arrange the equipment according to the process sequence, and simplify the equipment as much as possible;
(3) performing beat production;
(4) Layout the working area according to the principle of ergonomics; ?
⑤ Cultivate all-round workers and realize fewer people; ?
⑥ Try to use small equipment to facilitate relocation; Arrange the production line in a u shape; Implement standardized operations. ?
Step 3: Implement balanced production.
Reduce the inventory of raw materials, semi-finished products and finished products. How long it takes to produce a product by lean thinking is not determined by the running speed of machines or personnel, but by the market demand. So in lean production mode, only "how long does it take to produce a product", which is beat production. If the daily market demand is 100 pieces and the working time is 300 minutes, then the production line should produce a product every 3 minutes, so that each link can arrange its own rhythm according to the demand of balanced production, instead of doing it as quickly as possible continuously.
4. The fourth step is to implement JIT procurement and JIT logistics.
Lean thinking must extend to the upstream and downstream of the enterprise manufacturing chain, and the whole supply chain and logistics system should be lean, so that every link of the enterprise can play the maximum benefit. In lean thinking, in order to eliminate the waste in the procurement process, it is advocated to reduce the number of qualified suppliers and establish long-term mutually beneficial cooperative relations with suppliers. Only in this way can we establish mutual trust and information sharing, realize rapid communication, solve quality problems and ensure timely delivery. In the process of logistics, we advocate advanced means of transportation, communication and information technology. At the same time, in the organizational structure of enterprises, vertical levels should be reduced as much as possible, departmental barriers should be broken, and efficiency should be improved through technical means to meet customer needs.
5. Step 5: Kanban management.
In order to implement "pull" production and realize synchronous production, "Kanban" management tool is usually adopted. In order to effectively implement kanban management, it is sometimes necessary to rearrange the equipment, so that all the parts needed in each process are only obtained from the previous process, and the logistics should have a clear and fixed moving route in the whole production process. Logistics and information flow are divided into inter-process and intra-process logistics and information flow, which are controlled by delivery kanban and production kanban respectively. Therefore, the kanban referred to in lean production mode is the instruction and information link connecting the upper and lower processes, which is different from ordinary kanban. Kanban management needs to abide by the following five usage rules:
(1) Without kanban, production cannot be carried out and materials cannot flow;
(2) Kanban can only come from the latter process, and the former process can only produce parts taken from the latter process;
(3) The previous procedure is produced in the order of receiving kanban;
(4) Kanban must be with the real thing;
⑤ Defective products cannot be passed on to subsequent processes.
6. Step 6: Implement flexible production organization and management.
Flexible production organization mainly includes two aspects: one is the flexibility of output; Second, the flexibility of time. To realize the flexibility of production, it is usually necessary to establish the flexibility of the whole enterprise system. Generally speaking, in manufacturing enterprises, the main implementation contents are as follows:
① Modular design of R&D department
When designing a product, it is necessary to consider the possibility of several modules forming a product. This will help each unit to be disassembled, upgraded and improved independently, and reduce the difficulty of production and maintenance.
② Flexibility of equipment line and personnel in manufacturing department.
Flexible production requires the implementation of unit production mode, fixed variant production mode and trolley flexible production line. , as well as the combination of different production modes, to ensure that it can not only meet the requirements of production efficiency optimization, but also have the ability of flexibility.
(3) Accelerate the organizational work of enterprises.
Through lean business process and effective authorization management, the time spent in handling and decision-making of any business in any department can be shortened.
④ Establish the flexibility of production organization structure.
In the enterprises carrying out lean production, apart from the permanent departments, it is often necessary to set up temporary organizations across departments to form a more flexible and more adaptable project promotion team to coordinate and promote the implementation of refined management. ?
The study and application of lean thinking in enterprises must be based on the actual situation of enterprise management, with the standards of lean in-depth introspection and thinking, and promoted by senior leaders of enterprises. Through the command, control and supervision of the leadership (in a broad sense), all employees are encouraged to participate, to consciously improve, to follow the PDCA process method, to continuously optimize the value process, to continuously improve and to eliminate waste. Realize mutual benefit and harmony from the production process to the whole production supply chain. Finally, the lean thought will be "corporatized" and step into the "lean journey" of enterprise management. ?