1.5s and visual control
"5S" is the abbreviation of Seiri, Seiton, Seiso, Seikeetsu and Shitsuke, which originated in Japan. 5S is a process and method to create and maintain an organized, clean and efficient workplace, which can educate, motivate and cultivate good "human nature" habits. Visual management can identify normal and abnormal states in an instant, and can transmit information quickly and correctly.
2. JIT production
Just-in-time production mode originated from Toyota Motor Corporation of Japan, and its basic idea is to "produce the required products only when needed and in the required quantity". The core of this mode of production is to pursue a production system without inventory, or a production system with minimum inventory.
3. Kanban
Kanban is a Japanese noun, which means a label or card hung or pasted on a container or a batch of parts, or various color signal lights and TV images on an assembly line. Kanban can be used as a means to exchange production management information in factories. Kanban cards contain a lot of information and can be reused. There are two kinds of kanban commonly used: production kanban and transportation kanban.
4. Zero inventory management
Factory inventory management is a part of supply chain and the most basic part. As far as manufacturing industry is concerned, strengthening inventory management can shorten and gradually eliminate the detention time of raw materials, semi-finished products and finished products, reduce invalid operation and waiting time, prevent out of stock, and improve customer satisfaction with the three elements of "quality, cost and delivery".
5. Total Production Maintenance (TPM)
TPM originated in Japan, which is to create a well-designed equipment system with the participation of all employees, improve the utilization rate of existing equipment, achieve safety and high quality, and prevent failures, so as to reduce costs and improve overall production efficiency.
6. Use the value stream diagram to identify waste.
There are amazing waste phenomena everywhere in the production process, and value stream diagram is the basis and key point for implementing lean system and eliminating process waste.
7. line balance Design
Unreasonable assembly line layout leads to unnecessary flow of production workers, thus reducing production efficiency; Because of unreasonable action arrangement and process route, workers pick up or put down the workpiece again and again.
8. Pull system and auxiliary pull system
The so-called pull production is based on Kanban management and adopts the "material-taking system", that is, the next process is produced according to the market demand, and the shortage of WIP in this process is taken from the previous process, thus forming a pull control system in the whole process, and never producing more than one product. JIT needs to be based on pull production, and pull system operation is a typical feature of lean production. Lean pursuit of zero inventory is mainly achieved through the operation of the system.
9. Reduce the Setup Reduction.
In order to minimize the waste of offline waiting, the process of shortening the setup time is the process of gradually removing and reducing all non-value-added operations and transforming them into non-offline time completion. Lean production is achieved by continuously eliminating waste, reducing inventory, reducing defects, shortening manufacturing cycle time and other specific requirements. Shortening the setup time is one of the key ways to help us achieve this goal.
10, one piece flow
JIT is the ultimate goal of lean production, which can be achieved by eliminating waste, reducing inventory, reducing defects and shortening manufacturing cycle time. One piece flow is one of the key means to help us achieve this goal.
1 1, continuous improvement.
Kaizen is a Japanese noun, equivalent to CIP. When we began to accurately determine the value, identify the value flow, and make the steps of creating value for a specific product continuous, so that customers can pull value from the enterprise, miracles began to appear.