1, function
① Reduce the company's inventory.
Lean production management is a production system that pursues non-stock production or minimizes inventory. The purpose of reducing inventory is to solve problems and reduce costs. Low inventory needs efficient processes and stable and reliable quality to ensure. When many companies implement lean production, they think that lean production is zero inventory, and only ask the following companies to reduce inventory without reforming the process and improving the quality first. As a result, it is conceivable that the cost has not decreased, but has risen sharply, so lean production is not suitable for my industry and my company. This misunderstanding needs to be avoided.
② Pay attention to the process and improve the overall benefit.
What kind of process will produce what kind of performance. To improve the process, we should pay attention to the goal of improving the overall efficiency, rather than improving the efficiency of local departments. For the overall efficiency of the company, even at the expense of the efficiency of local departments, process management in lean production management counseling is very important. Good process management will greatly improve the overall efficiency.
(3) Establish an uninterrupted process and respond quickly.
It is very important for lean production guidance to establish an uninterrupted process and shorten the time of the whole process as much as possible, so as to meet the needs of customers quickly.
④ Eliminating the Eight Wastes
Eight kinds of common waste in companies involve: overproduction, waiting time, transportation, inventory, process (process), action, product defects and neglect of employees' creativity. Only by fundamentally eliminating these wastes can the company develop rapidly.
(5) High quality in the whole process, and doing it right once.
Quality is made, not tested. Inspection is only an after-the-fact remedy, which is not only costly but also can't guarantee no mistakes. Therefore, quality should be built into design, process and manufacturing, and an error-free quality assurance system should be established to get it right at once. Lean production companies need low inventory and uninterrupted processes.
⑥ Production is based on customer demand.
Only the required quantity is produced when necessary, and production and sales are synchronized. That is to say, production is carried out according to the sales speed, so as to maintain the balance of logistics, and any early production or late production will cause losses.
⑦ Standardization and work innovation
The role of standardization is self-evident, but standardization is not a kind of restriction and bondage, but a way to fix the best practices in the company, so that different people can do their best to maximize their effectiveness and efficiency. Moreover, standardization is not static, and standards need constant innovation and improvement.
8 Respect employees and empower them.
Respecting employees means respecting their wisdom and ability, providing them with a stage to play their wisdom and do better for the company and themselves. Employees manage themselves and do their own things well within the scope of the organization's responsibilities. They don't have to worry about being punished for mistakes in their work. There must be internal reasons for making mistakes. As long as they find the reason and take countermeasures, they won't appear next time. Therefore, lean companies hire "a complete person", rather than non-lean companies only hire "a pair of hands" of employees.
Pet-name ruby meet customer needs
Meeting customer needs means constantly improving customer satisfaction, and it is quite short-sighted to sacrifice customer satisfaction for a little immediate benefit. Companies should practice with practical actions. Although the supply of products is in short supply, we will never blindly expand the scale before everything is ready, maintain a steady and pragmatic style and win the respect of customers.
Participate in lean supply chain
In a lean company, suppliers are valuable assets for the long-term operation of the company and external partners. They enjoy information, take risks and benefits, and they will gain honor and lose it. Unfortunately, many domestic companies run counter to this lean concept when implementing lean production consulting. In order to achieve the goal of "zero inventory", they pushed all the inventory to the supplier, which made the supplier complain: your inventory has decreased, but my inventory has increased sharply. The goal of lean production is to reduce the inventory of the whole supply chain. Simply moving inventory from one place to another without making efforts to carry out process transformation will not solve any problems. When you keep squeezing and exploiting your suppliers, can you expect them to provide any high-quality support and service? You were the last to get hurt.
"introspection" and "on the spot"
The purpose of "self-reflection" is to find out your own mistakes and constantly improve yourself. When mistakes occur, instead of punishing individuals, corrective measures are taken, and the knowledge learned from each experience is widely spread in the company. This is completely different from the practice of fines in many domestic companies-most of the problems are caused by the system process itself, and punishing individuals will only make everyone try their best to cover up the problems, which will not help solve them.
combine/join forces (with sb)
In lean companies, flexible teamwork has become the most common organizational form. Sometimes the same person belongs to different teams and is responsible for completing different tasks. The strength of the team is very strong. A company can't just rely on its boss and leaders. It must have its own strong team.
2. Advantage analysis
① Advantages of human resources utilization
Through the effective pull of users, the typical "batch queuing" production system is transformed into continuous flow, which can greatly improve the labor productivity of the whole system and shorten the production time.
② The product quality is higher.
The variety of products is more in line with the market demand, and at the same time, the waste products and industrial accidents in the production process will also be reduced. The data shows that under the lean production management mode, the product quality can be improved by 3 times, and the waste products and industrial accidents can be reduced by more than 5 o%.
③ New product development cycle is short.
According to statistics, the product design and development adopts concurrent engineering, which can shorten the development cycle by 50%-70%, save the development cost by 30%-40%, reduce scrap and repair by more than 50%, and reduce the number of design changes by more than 50%, so that the product has good manufacturability and standardization.
(4) WIP inventory is very small.
Lean production guidance can realize zero inventory production, greatly reduce capital occupation and shorten production cycle. At the same time, the inventory of finished products and manufacturing costs are very low. Due to on-time production and strict production according to requirements, the inventory of finished products is 1/4 of the inventory level of mass production. The goal of zero inventory and the requirement of zero defect can reduce the manufacturing cost of products.
⑤ The workshop space is small.
Using lean production, the production area of the same scale factory is only 1/2 of that of the large-scale production factory, and the investment is only 1/2.