Any defective product will cause waste of materials, machines and manpower.

◆ Early detection of defective products facilitates determination of the source of defective products, thus reducing the generation of defective products.

◆ The key is to do things right the first time and achieve "zero defects"

The waste of time, manpower and material resources that the factory needs to deal with because of defective products, and the related losses caused by it. This kind of waste specifically includes: the loss of materials, the transformation of defective products into waste products; Loss of equipment, personnel and working hours; Loss of extra repair, appraisal and extra inspection; Sometimes it is necessary to reduce the price of products, otherwise the reputation of the factory will be reduced due to the delay in delivery.

Second, the treatment (waste treatment)

◆ Definition: It refers to unnecessary processing that has nothing to do with the project schedule and processing accuracy, and it is also called excessive processing waste, which mainly includes two meanings: the first layer is redundant processing and excessive processing, such as the waste of resources caused by excessive actual processing accuracy; Secondly, redundant operation time and auxiliary equipment are needed, which also increases the waste of energy such as production electricity, air pressure and oil, and also increases the working hours of management.

◆ Some processing procedures can be omitted, replaced, reorganized or merged.

Many times, I will get used to it and think that the current practice is better.

Third, waste action.

12 kinds of action waste:

Hands idle, one hand idle, intermittent pause, the amplitude is too large, left and right hands are exchanged, and there are many steps.

◆ Large turning angle ◆ Changing state while moving ◆ Unknown skill ◆ Stretching back action ◆ Bending action ◆ Repeating unnecessary actions.

The waste of these actions caused unnecessary consumption of time and physical strength.

Four, transportation (waste handling)

◆ At present, many domestic enterprise managers think that handling is necessary, not a waste. Therefore, many people turn a blind eye to dealing with garbage, let alone eliminating it. From the JIT point of view, handling is an action that does not produce added value, and the work that does not produce value belongs to waste.

◆ Use the "conveyor belt" to overcome it, ok? This practice costs a lot of money to reduce the physical consumption of workers, and actually does not rule out the waste of handling itself.

1, take and put waste; 2. Waiting for waste; 3. Excessive waste of work in process; 4. Waste of space.

◆ The waste of handling is reflected in the waste of actions such as placing, stacking, moving and arranging, which brings the waste of space and time and the occupation of human tools.

Five, the waste of inventory

Excessive inventory covers up the problem and reduces inventory exposure.

◆ Lean production believes that "inventory is the root of all evils", and all improvement actions will be directly or indirectly related to eliminating inventory.

(1) Unnecessary waste such as handling, stacking, placing, protective treatment and searching. (FIFO operation difficulty.

(3) Interest loss and management expenses (4) The value of goods will decrease and become dull goods.

⑤ Take up workshop space, resulting in repeated workshop and warehouse construction. ⑤ misjudgment of equipment capacity and personnel requirements.

◆ Intangible losses caused by inventory are by no means inferior to the above-mentioned tangible losses. Lean producers think that inventory will hide problems, and "problems" are regarded as treasures by lean producers. If we can constantly find and solve problems, we will continue to generate benefits.

1, there is no management tension, which hinders improvement:

2. If there is more inventory, the adverse consequences caused by mechanical failures and defective products will not be immediately apparent, and there will be no countermeasures.

3. With sufficient inventory, when there is a problem, you can use the inventory first, and the problem can be solved slowly or even not. At the very least, it is covered up, there is no hurry, and it will not be investigated by superiors, so the work performance of this department will come out. According to the past management concept, people think that inventory is a bad thing, but it is necessary. JIT thinks that inventory is unnecessary, and even thinks that inventory is the root of all evil. Due to the large inventory, problems such as failures, defective products, absenteeism, less stops, wrong planning, too long adjustment time, inconsistent quality and unbalanced production capacity have all been covered up.

For example, in some enterprises, the production line breaks down, which leads to shutdown and line stoppage, but it is not out of stock because of inventory, thus covering up the shutdown and line stoppage caused by the failure and delaying troubleshooting. If we reduce the inventory, we can completely expose the above problems on the horizontal plane, and then gradually solve these inventory wastes.

6. Overproduction (overproduction or premature waste)

◆TPS emphasizes "timely production".

◆ Doing more can improve efficiency, and doing it well in advance can reduce the loss of production capacity (if you don't do it for nothing, isn't the machine still stopped? )

1, used up the cost of materials and labor in advance, and didn't get any income.

2. Hide "waiting for waste" and let managers ignore the occurrence and existence of waiting.

3. The backlog of WIP makes the production cycle L/T longer (invisible), which will enlarge the working space on site and unconsciously devour our profits.

4. It is difficult to carry and accumulate garbage, and it is difficult to enter first in first out. Doing too much or too early, running out of production costs ahead of schedule, not only has no benefits, but also hides the waste brought by waiting and loses the opportunity for continuous improvement. Some enterprises, because of their strong production capacity, have increased work in process, shortened product cycle, enlarged space and increased the waste of handling and accumulation in order not to interrupt production and waste production capacity. In addition, excessive or premature manufacturing will bring huge inventory and increase the interest burden, which will inevitably increase the risk of depreciation.

Seven, the waste of waiting

◆ Variety switching of production line ◆ Nothing to do when the workload is small ◆ There is always a shortage of materials and equipment is idle.

The upper process is delayed, and there is nothing to do downstream. Equipment failure. The production line is out of balance.

◆ Uneven work and rest ◆ The manufacturing notice or design drawings are not delivered.

Waiting for nothing to do because of the interruption of raw material supply, unbalanced operation and improper production plan is called waiting for waste. Switching between different varieties on the production line, if not fully prepared, will inevitably lead to the waste of waiting; The daily workload changes too much, sometimes busy, sometimes people and equipment are idle; There is something wrong with the upstream process, resulting in nothing to do in the downstream process. In addition, the uneven work and rest of the production line is also an important reason for waiting for waste.

Eight, waste management

Management waste refers to the extra waste caused by managers taking corresponding countermeasures to remedy problems after they occur. Management waste is a problem caused by inadequate management in advance. Scientific management should have considerable foresight, rational planning, and strengthen management, control and feedback in the process of promoting things, so as to greatly reduce the occurrence of management waste.