The first step of introducing lean production into the system
First of all, the first step is to guide people to lean thinking, so that all employees of the enterprise, especially the members of lean project team, such as production department, material management department, purchasing department, product engineering department and industrial engineering department, can understand the connotation of lean thinking. Five principles of lean thinking: value, value flow, flow, pull and pursuit of perfection are the basis of lean production. The pursuit of perfection, in addition to "continuous improvement", is easier to understand with "speed" and "quality".
The second step of introducing lean production into the system
The second step is to establish the foundation of field improvement, namely 5S and TPM. With the foundation of 5S and TPM, the "flow" of the production line can be smooth and the visual "pull" can be achieved.
The third step of introducing lean production into the system
Next, the focus of lean production is to establish "logistics", and its purpose is to realize uninterrupted continuous production. This is also the concept of "action power" in the five principles of lean thinking. To ensure uninterrupted and continuous production, it is necessary to balance the whole production process, supply materials on line in time, and there will be no quality problems in the production process. Therefore, it is necessary to establish three processes of balanced production, supply chain management and total quality management in "logistics".
The fourth step of introducing lean production into the system
It is not enough to flow only in lean production, but also to "pull". Therefore, in the "information flow" link, it is necessary to establish "Kanban pull" and "lighting system". Kanban pulling here is the characteristic of Toyota's production mode, and "lighting system" is also a visual management tool, that is, to inform the production line supervisor and relevant personnel where there are problems that need to be solved immediately.
Step 5 of introducing lean production into the system
In the process of establishing the above four steps, it is necessary to standardize and implement them one by one. A good "execution" mechanism needs to be established here. Continuous improvement, total quality management and visual management are the key factors to guide people's whole process.
Lean production system pursues the maximization of value, and the drawing of 5S and value flow chart is a favorable tool to guide lean production system in the early stage, and it is also the simplest method to test lean production system after guiding lean production system. The value flow chart can provide a good visualization tool, let us see the waste without added value, then eliminate the waste and let the real value flow. Therefore, it is suggested that while introducing lean ideas in the first and second steps, we should draw the current situation map of value flow to understand the areas that can be improved.
The five principles of lean thinking, lean production mode and lean strategic management system are the basic structure of the whole lean production system. The above introduces how to systematically introduce lean production. The infrastructure of lean production system is a process of establishing "flow" and "pull" through ten tools of lean production based on logistics and information flow. Before that, it is necessary to guide people to think lean and establish the foundation of on-site improvement. After the establishment of logistics and information flow, establish standardization and emphasize execution.