Sparing virobnitstvo: small crumbs for a great dream. Principles for promoting lean manufacturing in a company

Oleg Levyakov

Lean (from English Lean - stringy, squeaky) virobnitstvo and the logistics of "sparing" virobnitstvo called for a colossal increase in the productivity of the production process and the main system of virobnitstva in the rich economy of the world.

Lean manufacturing is an American name Virobnicha system Toyota. Tayiti Vono, the creator of prudent manufacturing, rozpochav first until the optimization of manufacturing in the 1950s. At that time of war, Japan lay in ruins, and the country needed new cars. Ale, the problem was in the fact that I would drink not a great floor, so that I would really buy a hard bending line, for a Ford. It was necessary to have a lot of different types of cars (cars, small and medium-tonnage vantazhivki and іn.), but it will drink on a specific type of car, but not large. The Japanese had a chance to learn how to effectively practice, creating faceless different models for the minds of a low-profile skin model. Such a task before them, without violating anything, to the fact that efficiency was understood exclusively in terms of mass viability.

Lean variability in the transfer of knowledge to the process of optimizing the business of the skin care provider and the maximum focus on the caregiver.

The main point of sparing virobnitstva is a value for a spazhivacha. At the glance of the end of the life, the goods (servants) are gaining more value only once, if there is an uninterrupted processing, preparation of these elements. The heart of thrifty manufacturing is the process of spending money, which is called “muda” in Japanese language. Muda is one of the Japanese words, as it means to spend, go out, so be-like activity, as you save resources, but do not create values. For example, it is not necessary to save money, so that the finished product or some of the details were in the warehouse. Tim is no less, in the traditional system of managing warehouse windows, as well as all the windows, connected with reworks, with a suit and other indirect windows, are shifted to a spare.

Obviously, to the concept of sparing flexibility, the entire activity of business can be classified as follows: operations and processes that add value to the patient, that operation and processes that do not add value to the patient. Henceforth, everything that does not add value to a gentleman, with a look of sparing virobnits, is classified as spent, and may be sunk.

The main goals of sparing cultivation are:

• shortened vitrat, labor zocrema;
• short term terms;
• short-term harvesting and storage areas;
• guarantee of delivery of products to the deputy;
• maximum pitch for singing vart or minimum pitch for singing var.

As already mentioned above, the history of the LIN system began with Toyota. Sakishi Toyoda, one of the founders of the Toyota company, having taken into account that there is no way for the company to enter the market of competitiveness, the need for a steady move forward, the completion of all manufacturing processes. The result of this philosophy was the kaizen strategy, which is carried out at Toyota facilities, - "without interruption to perfection." Sakishi Toyoda has made great investments in the development of new cars.

Kіїshiro Toyoda, son Sakіshi, rozumіv, scho you happened to be able to work in order to be successful with American auto giants (for example, like Ford). For the beginning of the century, on their own undertakings, they understood "exactly at the same time" (Togo and Wartman), which meant that whether a part of the car was to be blamed, it was not earlier than it was needed. That is why the Japanese, on behalf of the Americans, had great warehouses of spare parts, their Japanese saved more than an hour and resources. The methods of Kaizen and Togo and Wartman became the basis of the Toyoda family's philosophical philosophy.

The advent of the Eiji dynasty Toyoda, having revealed his activity by having developed a fivefold plan for improving the methods of virobnitstv. For whom, in the company Toyota, as a consultant for requests, Tachichi Ono, who sent the cards “kanban” - “replenishment of stocks”. Taїchi It taught the workers to report on the methods of "kaizen" and "Togo and Wartman", modernizing the possession and establishing the correct drawing of the operations to be completed. As if it were a problem with the folding of the pipelines on the conveyor, then the conveyor instantly sounded, so that it was easy to know that there might be some problems. Toyota has been implementing its visionary philosophy for over twenty years, including with its post-employees.

Soishiro Toyoda became president, and then head for the directors of Toyota Motor Corporation in 1982. Through yoga, Toyota has become an international corporation. Having shared his work with perfection of quality in the company of the work of the American expert with quality E. Deming. Quality management at Toyota's businesses has become clear, it has been implemented at all company's subsidiaries.

Thus, through the efforts of several generations of engineers of the Toyota company, a unique quality system was broken up, which formed the basis of the LIN system.

The most popular tools and methods of Lean manufacturing are:

1. Value Stream Mapping.
2. Vityaguє streaming virobnitstvo.
3. Kanban.
4. Kaizen is uninterrupted perfection.
5. The 5C system is a technology for creating an efficient workspace.
6. SMED system - Schwidke changeover facility.
7. TPM system (Total Productive Maintenance)
8. JIT (Just-In-Time) system.
9. Visualization.
10. U-like centers.

Mapping the flow of value creation- it is necessary to draw up a simple graphic scheme that depicts the material and information flows that are necessary for the production of a product or the services of a end-of-life support. A map to the flow of value alignment gives the opportunity to immediately improve the flow of time, and on the basis of this analysis, reveal all unproductive vitrat and processes, develop a plan for improvement. Mapping the flow of value creation includes the following steps:

1. Documentation of the flow card will become.
2. Analysis of the flow of production.
3. I will become a creation of a picture of the future.
4. Rozrobka to the plan shdo okraschennya.

Vityaguє virobnitstvo(eng. pull production) - a scheme for organizing the production, if the wines for the production of the skin production stage are determined exclusively by the needs of the upcoming stages (the decision - by the needs of the deputy).

The ideal is “single piece flow”, that is. the post-employee (or the internal post-employee), who knows more along the stream, doesn’t vibrate anything, while he is calm (or the internal post-employee), who is known lower, you can’t tell me about it. In such a rank, the skin offensive operation “tightens” the products from the front.

A similar way to organize robotically tightly coupled is also from balancing lines and synchronizing flows.

Kanban system- the whole system that ensures the organization of an uninterrupted material flow for the availability of stocks: stocks are supplied in small batches, at the point of the stocking process, bypassing the warehouse, and ready products are immediately available for purchases. The order of managing the product variety is reverse: from the i-th stage to the (i-1)-th.

The essence of the CANBAN system lies in the fact that all commercial enterprises are provided with material resources only in the amount of such a term, which is necessary for the appointment. Assignment for finished products goes to the last stage of the manufacturing process, to get through the necessary obligation of unfinished manufacturing, as if it were possible to go beyond the previous stage. Similarly, from the predostanny stage, Ide will ask for the first stage of the selection of the number of alcoholic beverages. That is why the expansion of virobnitstv on this dilyantsi is determined by the needs of the offensive virobnichoy dilyanka.

In this rank, between the skin two suddnіmi stages of the fermentation process, there is an underlying link:

• from the i-th stage at (i - 1)-u are energized ("stretched") the necessary amount of unfinished production;
• From the (i - 1)-th stage, at the i-th stage, the material resources in the required quantity are replenished.

A special transmission in the CANBAN system is special cards ("canban", in translation from Japanese language, - a card). Stop two types of cards:

• cards of the selection process, which indicate the number of details that can be prepared at the front stage of the selection process. The cards of the molding are to be guided from the i-ї stage of the molding to the (i - 1)-th stage and є substantiated for the molding of the molding program (i - 1) of the plot;
• selection cards, which indicate the number of material resources (components, parts, products) that can be taken to the front of the processing (warehousing). Selection cards show the number of material resources, actually taken away by the i-th picker from the (i - 1)-th.

Such cards can circulate not only in the middle of the enterprise, which is the CANBAN victorious system, but also between them and other branches, as well as between corporations that are spivpracyuyut.

Pidpromniy, the vicorista system canban, to incite the vibral resources of the pile to be able to take the length of the day, such a rank of reserves of the PIDPRIMIT can be at the same time to be at the RIK OTOS, Todi Yaks on the pydprimni, Vikoristovan 20 times on river For example, in 1976 Toyota Motors Corporation received three times a day for one of its virobnichnyh plots, and in 1983 roci - even skin sprouts of thinness.

Pragnennya reduction of stocks, moreover, by the method of revealing and virishennia of virobnicheskih problems. The accumulation of reserves and the protection of the verge of virobnitstva allow you to take part of the breakdown and the teeth of the possessor, virobnichiy shlyub. Shards in the minds of minimization of stocks of variability can be passed through the gateway at the advanced stage of the technological process, then the main one of the CANBAN system, the most "zero stocks", the most "zero defects". The CANBAN system is practically impossible to implement without a one-hour commissioning of an integrated yakkistyu control system.

Important elements of the CANBAN system are:

• information system, which includes like cards, as well as variant, transport and post-delivery schedules, technological cards;
• a system for regulating the demand for professional rotation of personnel;
• TQM and vibrating ("Jidoka") systems for quality control of products;
• virobnitstva virіvnyuvannya system.

The main advantages of the CANBAN system:

• short production cycle, high turnover of assets, high reserves;
• vіdsutnі or nadzvichayno nіzkі vtrati on zberіgannya virobnichih і commodities stocks;
• high quality of products at all stages of the manufacturing process.

An analysis of the light status of the CANBAN system stagnation showed that the given system gives the possibility to change the production stock by 50%, commodity stocks by 8% with a significant accelerated turnover of turnover costs and an increase in the quality of finished products.

The main shortcomings of the "just in line" system:

• foldability of security of high employment between the stages of production;
• Significant risk in terms of the development and sale of products.

Kaizen- tse pokhіdne vіd dvoh ієroglіfіv - "change" and "good" - sound like "change on the better" or "uninterrupted polypshennya".

Applied sense Kaizen has the philosophy and management mechanisms that stimulate specialists to promote improvement and implement them in the operational mode.

There are five main components of Kaizen:

1. Interaction;
2. special discipline;
3. Polypsheny moral camp;
4. Cola of Yakosti;
5. Propositions should be thoroughly;

5C system - technology for creating an efficient workspace

Under zim znachennyam vіdoma system of putting things in order, cleanliness and zmіtsnennya discipline. The 5C system includes five mutually dependent principles in the organization of the work place. The Japanese name for the skin principle is derived from the letter "C". At the translation of the Russian language - sorting, rational sorting, cleaning, standardization, thoroughness.

1. SORTING: sort out necessary items - tools, parts, materials, documents - in the form of non-necessary items, to tidy up the rest.
2. RATIONAL DISTRIBUTION: rationally place those that are left out, place the leather object in its place.
3. CLEANING: keep cleanliness and order.
4. STANDARDIZATION: to be careful for the regular count of the first three S.
5. DEFINITELY: conversion to the start of the established procedures of those thoroughly.

Schwidke changeover (SMED - Single Minute Exchange of Die) Literally translated as "Change to the stamp for 1 quill". The concept was broken up by the Japanese author Shigeo Shingo and made a revolution in the approaches to retooling and retooling. As a result, the implementation of the SMED system to change any tool, that changeover can be done for just a few minutes, or for a few seconds, "in one dot" (the concept of "OTED" - "One Touch Exchange of Dies").

As a result of numerical statistical data, it was established that the time for the change of operations in the process of changeover is divided as follows:

• preparation of materials, stamps, additions. - thirty%;
• fixing and making stamps and tools - 5%;
• centering and placement of the tool - 15%;
• sample processing and regulation - 50%.

As a result, the following principles were formulated, which allow you to spend an hour reloading dozens and repeat hundreds of times:

• subdivision of internal and external operations,
• transformation of internal activities into external ones,
• zastosuvannya functional zatskachiv or outer fastening,
• vikoristannya dodatkovyh outbuildings.

TPM system (Total Productive Maintenance) mainly serve to improve the quality of possession, focus on the most efficient way to improve the quality of the global system of preventive maintenance. The emphasis of this system is to try to prevent and early manifestation of defects in the system, which can lead to more serious problems.

Operators and repairmen take the fate of TRM, as they all at once ensure the promotion of confidence. The basis of TPM is the scheduling of a schedule of preventive technical maintenance, oiling, cleaning and overhaul. Zavdyaki tsyomu will ensure the promotion of such an ostentatious display yak Povna Effektivnist Obladnannya.

JIT system (Just-In-Time - exactly on the hour) - a material management system for manufacturing, if the components of the previous operation (or in the form of an external postal worker) are delivered by itself at that moment, if the stench is needed, but not earlier. Tsya system leads to a sharp contraction of unfinished production, materials and finished products in warehouses.

The system "exactly on the hour" transmits specific delivery to the selection and evaluation of post-employees, foundations on robots with a high number of post-employees, which are selected for their construction to guarantee the delivery of "exactly at the same time" component parts of high quality. At the same time, the number of post-employees rush two and more times, and with the post-employees, who are left behind, tribal government ties are established.

Visualization- tse be-yaky zasib, some kind of informing about how the robot can be victorious. This is the distribution of tools, parts, packaging and other indicators I will become virobnitsva, at a glance, I can understand the system’s standard - the rate of compliance.

The most common victorist methods of visualization:

1. Contouring.
2. Color marking.
3. Method of road signs.
4. Markuvannya farboi.
5. "Bulo became."
6. Graphic work instructions.

U-like centers- Raztashuvannya possessing the form of the Latin letter "U". At the U-like center, the typesetting is arranged in a pied-like manner, in line with the sequence of operations. With such an expansion, the rest of the processing stage passes without intermediary near the cob stage, that operator does not need to go far to begin the onset of the onset harvesting cycle.

In the period of the most competitiveness and the crisis that is being built, there is no other way for the enterprises of the whole world, but the most advanced technology for management, to create products and services, to satisfy the customers as much as possible for the quality.

Spend in any kind of manufacturing process - there is inevitably a problem with a wealth of enterprises, as if they were turning products, and giving services. Spend - tse camp, like, softly seemingly, do not add value to the product or service. In order to show spending, it is necessary to recognize them on the cob. You can see a lot of investments, through yaks ruin up to 85% of the resources of the enterprise:

1. Waste of creative potential. If you put yourself before the spіvrobіtnik like a gvintik in the mechanism, which one can be mitigated or replaced by others, if you can get to the scheme “practice with your hands and beat the boss’s remarks”, the interest of the spіvrobіtnikіv to work falls steadily. Experts care that such an order of speeches is old, that they pull the company back, so as not to get involved in the profits of the company. In Japan, in various companies, “groups of quality” are declared, on which skins I have the right to hang my own propositions about the richness of the quality of processes. Analysts vvazhayut, that in the XXI century will be successful in these companies, if they can create in their staff from a great level of excellence to perfection.
2. Nadmіrne virobnitstvo, scho is evident in the one who releases more goods, nіzh potrіbno, abo earlier, nіzh vimagaє deputy. At the result of the resource, as it is possible to increase the increase in the quality, the increase in the quantity is spent.
3. Tricks. If the workers are idle in ochіkuvannі materials, іnstrumentіv, obladnannya, іnformatsії, zavzhdnі nasledkіlі nasty planuvannya аbo not enough nagodzhenih zv'yazkіv іz postal workers, neprodbachennyh kolivan pita.
4. Necessary transportation, if the materials and products are moved more often, lower is necessary for an uninterrupted technological process. It is important to deliver everything that is necessary in a timely manner, and for that at the enterprise, it is possible to implement a garni scheme of logistics.
5. Above-world stocks, or storage in warehouses of a greater quantity of products, less sold, and a greater quantity of materials, less necessary for the technological process.
6. Zaiva obrobka. The production is to blame for the production of the acidic flooring, so that, if possible, turn on the reworking and additional processing, and the control over the adhesiveness can be flexible and effective.
7. Defects, which need to be overcome with all forces, to that, for securing the claims of the substitutes, the supplements are taken care of: it is necessary to correct the defective virus, the hour is spent, the forces and pennies.
8. Do not change the transfer, but set up the process of delivering tools, materials in the middle of the enterprise itself, ordering the transfer of spokespeople for the job.

According to the Institute of Comprehensive Strategic Studies (ІСІ) about the expansion of sustainable production in Russia in Birch-April 2006, 735 studies of Russian industrial enterprises 32% of the vikorista became Japanese acknowledgment. At the birch-day of 2008, a re-experimentation was carried out. Lean Manufacturing on industrial enterprises in Russia in 2006-2008” at the III Russian Lin-forum "Thrifty Russia". Enterprises, as the first ones, began to zastosovuvat methods of sparing manufacturing: Gorky Automobile Plant (GAZ Group), RUSAL, EvrazHolding, Evrokhim, VSMPO-AVISMA, VAT KUMZ, Chelyabinsk forging and pressing plant (VAT ChKPZs), VAT Sollers » »("UAZ", "ZMZ"), KAMAZ, NefAZ, Oschadbank of Russia BAT and int.

Lean production (lean production) - tse:

Sistemny pіdkhіd to reveal vtrat and poshuk shlyakhіv їkh usunennya, schob change the hour mіzh zamovlennyam klієnta and vіdvantazhennyam goods;
business processes that require less human resources, capital investments, room for manufacturing, materials at all stages.

This methodology is aimed at combating costs in all manifestations: arranging warehouse stocks, interoperating backlogs, downtime, arranging relocation, and ensuring the safety of operations for personnel.

Plan dіy:

1. Calculate the value of a specific product, which may be the main characteristics and the main price in a dialogue with zatsіkavlenimi spozhivachami.
2. Calculate the entire pot_k stavlennya och_kuvanoї spozhivachem cіnnostі for skin type produktsії: vіd konceptsії to the product, scho dіyshov to spozhivacha.
3. Organize the flow of the creation of an improved value, i.e. emphasis on respect not so much on the acceptance of that possession, but in the production and "needs".
4. Constantly listen to the voice of the gentleman, allowing you to win production from the enterprise, if necessary.

The main methods and ideas of sparing production were propagated by G. Ford and were planted at the factories of the Ford company in the 20th century of the last century, and then they were fully implemented in Japan. At the company "Toyota" a system has been created, meta yakoї - speed or liquidity diyalnist, which saves resources and does not add vartist, so that you don’t have to pay for the yak.

Today, the system of production is like a manufacturing system of Toyota (Toyota Production System - TPS), the principles and tools of which have been used in the American version - the Lean Production system. There are a lot of elements in the boulevard of the Radyansk variant - scientific organization of practice (NOT).

Lean virobnitstvo - tse approach, ways, creations for changing all possible vitrates and increasing productivity. These tools are oriented towards the target part of the company. Changing the system with the improvement of the principles of prudent virobnitstva, we will soon spend internally (reserves, relocate meagerly. bud.) and inspire people, accommodation, energy.

Therefore, the staff concentrates on these types of activities, so that they add value to the product at a glance, and, therefore, do not increase the amount of (increase) variability to enterprises.

Additional information:

1. The concept of prudent virobnitstva is simple razuminnya, prote sladniche - robit those schob out has become a part of everyday work.
2. For a successful planting of a thrifty culture, it is necessary to change the culture of business.
3. The concept of prudent virobnitstva is straightened out by the maximum appearance of interests and drinking of the people.
4. Just as a constant trim in the center of respect for reducing the cost of surviving, then there is practically no difference between them, which can be reached.
5. Thrifty selection - pidhіd, directing to the quality of the product's quality will be installed by us. The principle of work according to the TPS system is described as three NOT: do not take defective workpieces into the robot, do not work with defective products, do not transfer defective products to the next operation.
6. The abbreviation TPS - Toyota Production System (Toyota Virobnicha system) is deciphered, coded, and so: Thinking Production System - Dumka virobnicha system.

The high organization of the processes allows the non-essential vitrates to disappear more and more successfully to compete for the minds of the modern market.

Chi not zaluchenіst staff and folded when carrying out changes in the company.

Delivery at the shortest term of the necessary products at the time of need, without accumulation of industrial stocks.

Implementation of Lean Manufacturing

Gentle versatility is the concept of management, as it is focused on optimizing business processes with maximum market orientation and improving the motivation of the skin practitioner. Lean manufacturing is the basis of the new philosophy of management. Method є: minimization of labor costs and lines of creation of new products; guarantee of delivery of products to the deputy; maximum yak_st for minimum vartosti. The main idea is to use usunennі vtrat be-like activity, like saving resources, but not creating values.

Tayiti Vono, the founder of the system's tsієї, naming this type of investment: through the overhead; hour after ochіkuvannya; with inappropriate transportation; through the entry stage of processing; through zayvі reserve; through non-essential movement; through the release of defective products. There are also two dangers of intrusion - “the vanity, which outweigh the possibilities” and the “irregularity of the vanity”, which in the result lead to the release of defective products.

Recycling. It is customary to call the preparation of the purchase of a quantity of products or the preparation of a real drink before the end of the hour. At the workshops, the overwork is carried out until the production of products is prepared, and in the offices - until the creation of non-essential documents or transcendental information. The preparation of the order for the quantity of products, or even the preparation of the hour beforehand, does not reduce the increase in efficiency, the shards due to the reduction of additional material and labor resources, the need to save excess products. Tse zmushu sspіvrobіtnikіv pratsyuvati shvidshe, nizh nebhіdno, scho accompanied by other expenses.

For usunennya vtrat, mindfulness of overkill, it is necessary:

Expand the technological processes in such a way that the frontal operations safely protect the feet;
- to establish virobnichi norms and standards for the skin working area of ​​the process;
- transmit signals that will prevent the early start of the vibration.

Refinement. Whether it be ochіkuvannya - people, documents, possession of chi іnformatsії - it's always a waste. Chіkuvannya means the robot is idle, and it is not necessary to bring the whole process to a grain. At the end of the course, the value is not added, and the rescuer as a whole naturally does not want to pay for downtime. Spending your mind is the simplest. The stench especially treats the practitioners. Whether the office is in a difficult situation, if the employees check for a long time on the signature of the chiefs, the ability to quickly take possession of the possessions, telephone calls, and the availability of materials from the post-employees, too.

Analyze, yakі signatures on the documents with the right necessary, liquidate all applications and standardize the new procedure;
- teach spіvrobіtnіkіv mіzhnym professіyam, schob stinks could replace one another;
- Rivnomirno rozpodіliti robochi navantazhennya stretch of the day, in order to optimally win over available labor resources;
- ensure the selection of all necessary possessions and their own supply of purchased goods and materials.

Overworld dressing. Zayvim vvazhayutsya those operations, as if not necessary for the helpless, as if they did not want to overpay pennies for their vikonannya. Often, such operations are used to file applications (for example, mutual re-verifications of the documents and other specialists), the removal of the overworld number of signatures, and the submission of a look at the documents and the results of the work.

For the adoption of which type of expenditure it is necessary:

Analyze all the robots that create the added value, optimize or use the application of the operation;
- signify that the signatures on the documents are correct, and all applications are liquidated.

Overstock. If you have extra surpluses, what you have at the enterprise, spend it. Saving such stocks will require additional areas, the stench can negatively affect the safety, harassing the passage of that wasteland. Qi stocks can appear as inconsumable and become obsolete for changing products. Sparing virobnitstvo will require a radical change by looking at the stock. The presence of a surplus obligation of stocks means the need for additional costs to manage them, it is not necessary to galvanize the excesses of other manufacturing processes, the shards are brought from the search for the necessary turnaround, buy papers and materials.

For the adoption of which type of expenditure it is necessary:

Viroblyat on the skin shop or the working area only that amount of products, as it is necessary for the people who need it, which should be lower than the hour of the production flow;
- to standardize the planning of harvesting plots and their interests;
- Ensure that everything necessary for the harvesting process is carried out exactly at the appointed hour and do not allow any obstruction with far-reaching materials from the harvesting process.

Shut up. Be it a move that is not necessary for a successful vikonnanny of the analyzed operation, it’s the second. Such ruhi is respected by one of the forms of inflow, to which the skin ruh is guilty of adding the value of the victim or service. Often the organization of the labor process is ineffective and the planning of the work tasks is incorrect, which is the cause of the collapse of the vikonavtsiv - walking, reaching out, leaning too thin.

For the adoption of which type of expenditure it is necessary:

Standardize folders for documents, hanging drawers and cabinets for the whole office, as well as more wide color coding;
- roztashovuvati files (with documents on the tables and electronic computers) in such a way to make it easier to access them;
- roztashovuvati office zagalny koristuvannya in the central part of the office, add additional possession, sob to speed up the transfer of spіvrobіtnikіv to the office.

Spend it on defects or rework. Spend money on rework, or re-exploit the already broken work, in such a defect, insanely, you can go to the category of expenses, shards of a robot, you need a loan, which will save you more money. Losses in the form of defects also include a decrease in productivity, as well as interruption of the normal overrun of the work process to correct defects or rework products. This type of unproductive vitrates is much easier to reveal, but it is easier to use other types.

For usunennya vtrat in the form of defects it is necessary:

To provide standardized methods and robots for the formation of office documents;
- rozrobiti that to help you to dopomіzhnі zasobi, scho to facilitate the work.

Transportation. It is necessary to move to a larger, lower station, or to create timely places of accommodation, to save and store, to move from a place to a place of materials, people, information or documents - all for the sake of spending time and energy. Materials and purchases are often moved from month to month in the middle of the business, until the stench reaches the residual point of recognition. Obviously, all movements must be carried out before the return. In addition, the distribution of virobiv in the places of the Timchas's savings promotes the freedom of their poshkodzhennya, spend that rozkradannya, respecting the normal flow in the middle of the enterprise.

For usunennya vtrat, zumovlenyh zayvimi transportation, it is necessary:

As soon as possible, be transported;
- Lіkvіduvati all mіstsya timchasovogo zberіgannya or storіvannya materials.

The problem of determining the economic efficiency is the need to correctly protect and analyze the level and scale of the introduction of lean manufacturing. Tse means that the efficiency of the stosuvannya methods of calculus analysis and vimir, scho transferring the interoperability between the greater scale in promoting the concept of prudent manufacturing and increasing the profit of the enterprise.

Lean manufacturing for business

At first glance, pity - tse ekonomіya, sknarіst, stinginess. In fact, sparing work is done not for short-term vitrates, which could lead to a decrease in the quality of products, but for short-term expenses, like in the skin work area, chi tokar, banker, government official, director. Such a process allows to increase the quality of the developed products and services, to ensure the growth of the productivity of the work and the motivation of the staff, which, as a rule, is driven by the growth of the competitiveness of the enterprise.

Lean manufacturing is a system of organization of manufacturing, directed without interruption to the full activity of the organization and the achievement of long-term competitiveness.

Svіtovy dosvіd pokazhnі є nіtnіє results zastosuvannya іnstrumentіv prudent vyrobnitstvom:

Increased labor productivity by 35-70%;
shortening the hour of the virobnic cycle by 25-90%;
Fast shipping by 58–99%;
Increased product quality by 40%;
Improvement in the hour of work at the right station up to 98.87%;
Vivilnennya harvesting areas by 25-50%.

In any system, in all processes - in the form of folding up to the hospitality business, health care, transport and social services - you need to spend money. The purpose of this adoption is to save millions of dollars for these organizations, as they regularly evaluate their activities for the standards of double-dealing virobnitstv. Values ​​spend more money on virobnitstva, not adding to the lower value, just what is necessary for the deputy. The stench also increases the term of return on investment and leads to a decrease in the motivation of workers. It is necessary to count, and then use up and spend.

It should be noted that the idea of ​​“sparing virobnitstv” was previously formulated and implemented by Henry Ford. Ale tsі ideї were in the nature of disparate entries and did not capture the very thought of the practitioners. It was created a streaming, low-volume, low-volume, and Ford-T brand car, not competitive in the world, for price, quality, equal service. But the ideas of Henry Ford did not grow wide, the country's economy developed dynamically, the market was closed for other powers, and there were opportunities for extensive development. Japan of such opportunities is not small, and to that time it has become a path of rational resource selection, adoption of all types of investments, promotion of initiative and efficiency of practices, constant systematic enrichment of the quality of procedures. The center for the development of this implementation of the principles and methods of "gentle harvesting" was the automotive company Toyota, as it has become the best of all the best systems of the world's companies. Even before the 80th century, Japan had revived the economy, and created the most efficient production system in the world, and began active expansion to other lands.

Turning to Russia, I would like to see 9 reasons why it is important to increase viability in the organization:

1. High product compatibility.
2. Low product quality.
3. Outdated technologies.
4. Outdated installation.
5. High energy capacity.
6. High viability of virobnitstva.
7. Destruction of terms of delivery.
8. Lack of qualified personnel.
9. High competition over the market.

The very tools of dbaylivy virobnitstva allow virishuvati tsі and іnshі problems.

If we talk about dbaylive versatility, Lean-management is often thought of as the reach of the Japanese company Toyota. There is one more word - kaizen (continuous improvement).

All these words are unimaginable for us to speak about those that the organization sets before itself a global task - to improve the day, to progress with the skin day. Pushing ahead to lie in front of the cores themselves, even if it is not enough to use tools, it is necessary to change the culture of management, the behavior of managers.

The very thing about nutrition was discussed at the conference in the city of Izhevsk "Production and promotion of "Lean" in the application of the Toyota company." It is important that the conference will discuss the practicalities of how to implement the tools of sustainable manufacturing in a modern organization.

Lean - the same type of thought

For a thrifty cultivator, the respect of the greater kerivnitstva and the first individual in the undertaking is important. As if the first person was turbulent in the promotion of sparing virobnitstv - the result will be, if not zatsіkavleniya - tse marnuvannya hour. Lean is the same type of thought. Dosvіd zastosuvannya prudent virobnitstvu, in Russia and the rozvinennyh krajn may one important feature. In Russian enterprises, the tools of thrifty manufacturing are of great importance, in foreign organizations - the formation of the ideology of thrifty manufacturing, corporate culture of management. Significantly, that the tools of dbaylivy virobnitstva without ideology do not work. The first ones are the nourishment of thought and the promotion of rational propositions. It is necessary to create a corporate culture, as if it were to adopt the system. The corporate culture at its core is rooted in the behavior of the worker and that team. And vchinki vyplyvayut іz pomyslіv, it's important to know about yakі. For this, a steam locomotive is the right idea, and then the wagons are already being built - singing instruments of Lean.

Rule - 5 why

As far as the image of diy kerіvnikіv, then the system of thrifty virobnitstva will have to reorient itself to the cause of problems, and not to the punishment of the practitioner. It is important to understand why the failure became, what caused the pardon? The thinker's thought, that everything can be done without a hitch and a bully, is wrong - be it right, no one has insurance for pardons, and you need to take lessons from them. Pardons are an incentive to optimize the process, a way to achieve that it won’t be repeated again, put it down її times and forever. Modern clerks in the pursuit of bezpomilkovistyu put in front of them clumsy tasks, it’s wrong - the tasks of guilt are foldable, and pardons, which are allowed at їх virishenny, - in the order of speeches.

The tools of sparing virobnitstvo are simple by themselves, but zastosuvannya їх vimagaє zusil. Inheriting the philosophy of the Toyota company, Lean is a science that confuses us with a hypothesis, overturning it, and confirming it. For all directives: safety, cleanliness, cleaning - the main factor for success will be the corporate culture and behavior of the worker. It is impossible to quickly change your mind (Toyota to break the cost of 60 years). And just to show the practitioners a new pidhid, to help them with the choice of an instrument, to stink themselves all the advantages of such a work.

Lean virobnitstvo is based on the 5 C system - a system of putting things in order, cleanliness, improving discipline, increasing productivity and creating careless minds of practice for the participation of all personnel. Дана система дозволяє практично без витрат не тільки наводити порядок на підприємстві (підвищувати продуктивність, скорочувати втрати, знижувати рівень шлюбу та травматизму), а й створювати необхідні стартові умови для реалізації складних та дорогих виробничих та організаційних інновацій, забезпечувати їхню високу ефективність за рахунок радикальної зміни svіdomostі pracіvnikіv, їх stavlennya up to the right.

Lean Manufacturing System

Presentation of the design of the system of sparing virobnitstva already managed to express the essence of the concept. Let's try to find out the deeds of the position of the appointment.

An important principle of the concept of sparing virobnitstvu є postіyne voskonalennya that fate of the process of the whole team.

"Creation is clearly defined as a gentle value" conveys an understanding of what is valuable for a gentleman. And here it is not possible to base yourself on the best knowledge. It is guilty to carry out the work of revealing all the components of the spozhivchoї cіnnostі, іnodі bezperedno z to the kіtsevim of the goods/services. This is the guarantee that the most gentle will be satisfied with the least amount of money (the robot's job is not included).

As the company is engaged in a charitable partnership, it means that it is necessary to put the interests of the successor, the buyer, the client, the partner and the powerful spokesmen on the spot, and everything will win. Therefore, in the promotion of thrifty planning - the best business card for presenting the company to partners and successors.

"With less labor costs, on smaller harvesting areas, with less capital and in less hour" - in the concept of thrifty harvesting, excluding all types of costs defects / reworks only).

The concept of Lean Virtue is based on five principles that serve as guidelines for managers in the transition to Lean Virtue:

Determination of the value of the skin family of goods at the glance of the client.
- Appointment of all stages of the flow of value creation for the skin family of products and the use in the world of the possibility of operations that do not create values.
- Vibudovuvannya operations that create value in a strict sequence, that ensures equal movement of the product in the pipeline, direct to the client.

At the end of the molding flow - the creation of the possibility of "vintage" by clients of value from the previous stage.

Pislya Zakinchennya Vozhnoenni Tsіnnosti, viyavannna streaming storage tsіnovosti, vasennnia of herds, viklikayut vinikennia, it is forced, and the formavnya systems - repeatedly, it is possible to know the absolutely butt.

It is necessary to explain what kind of virobnism is, what vishtovhuє, and victorious vibrancy.

Vishtovhuvalne virobnitstvo - the production of the goods in great batches with the maximum speed from the predicted demand for the upcoming movements of the goods, I will begin the stage of the warehouse, regardless of the actual pace of the work and the onset of the process of the needs of the deputy (spazhivach). At the borders of such a system, it is practically impossible to carry out the tools of double warfare.

Vityaguє virobnitstvo - a method of managing virobnіtstvom, in which future operations signal about their needs to previous operations.

The supermarket system that wins is the most popular. When it is at the skin production stage, there is a warehouse - a supermarket, in which the first collection of products is stored, which is prepared at this stage. At the skin stage, the styles of the products are vibrating, the skins were taken from the supermarket. As a rule, if the products are taken out of the supermarket by an oncoming process - slower, the rest of the force will increase the forward process of information about the selection for an additional special card (kanban) in a different way.

The skin process is replenished for the replenishment of the stock of your supermarket, so the operational management of the search for a sustainable improvement (kaizen) is not easy. At the same time, її zastosuvannya is aggravated for the obviousness of a large number of types of products that are vibrating.

The last system, which wins, dotsily victorious with a great nomenclature of products, which vibrates in one process, that is. if it is foldable or practical, it is not possible to increase the stock of skin-type products at the supermarket. Products, in the air, are fluctuating, and in their own stock, the system is reduced to a minimum. The last system helps to maintain a non-trivial and time-honored vision, requiring a good understanding of the structure of the client’s need for a prayer. The function of such a system will require a lot of hard work.

Changed the system, which wins, - transferring a combination of two resurfacing systems. Її dotsilno vikoristovuvaty, if dіє rule 80/20, then. if a small part of the types of products (approximately 20%) become the largest part of the total number of products that are released today (approximately 80%).

All kinds of products are divided into groups for an obligatory release: high obligatory, medium obligatory, low obligatory and sparse obligatory. For the group of "Ridkіsnі zamovlennya" dotsіlno zastosovuvat poslіdovnu system, scho winyaguє. For other groups - a system to the supermarket, scho vityaguє. With a change in the system, which is strong, it is possible, it will be more foldable to manage thoroughly and show respite.

The concept of sparing brewing is directed to the maximum economy of resources in the brewing process, nasamped, timchasovyh. The basic principle is assigned to the concept of revealing and adopting processes, so as not to bring additional value, but to change it (for example, processes that lead to excess stocks, the process of cleaning, the process of consignment transportation, the process for defects, the process)

Under the flow of value creation, all things are understood - just as they create value, so they do not create values ​​- they allow the product to go through all the stages of the process:

1) from the development of the concept to the release of the first product,
2) after receiving the order before delivery. These data include the processing of information taken from the client, as well as the operation of transforming the product into the world of passing it to the client.

If lean manufacturing has become widely practiced by management, it has become clear that it will require a process description of the business.

Business can be characterized as a series of interdependent and interdependent processes. Todi, if you accurately describe the skin process and learn the interrelationships of the processes, then we understand, as if the power of a business is possible and it is possible to speed up this description in different purposes.

For a practical development of a system of thrifty manufacturing, it is necessary to systematically describe business processes, so that the most important business processes, like bringing us pennies in payment for our products or services.

How to learn the bachiti process? On the undertaking of us before us, there were bachimos, equipment, transport systems, people who took their rightful place.

The process is the sequence of actions directed at the selection of singing products and/or services. Moreover, tsі di ї rozpodіlenі at the hour that space. Tsі dії seldom vdaєtsya to dance everything at once from one point. "So what?" You say. Process to go, everything works. Need to document them, describe them, it’s not enough to remember everything, like at once?

Nasampered, describe the process of speeding up the exchange of information and reducing the risks of accepting untimely and pardon decisions and decisions.

Processes can be described in words, but words are understood differently. For this one, the best and most accessible is the visualization of business processes with an additional scientific picture of the process.

Nasampered, we need a description of the process in such a way, in a way that we know at once, in order to take a point of reference for a further thoroughness. Mayuchi flow description of the process, we can encourage the "ideal" process and plan the transition to a new one. And there is nothing more than to start without interruption to the thorough process of working out of the concept of sparing virobnitstv.

Double Vibration Tools

Total Productive Maintenance (TPM) is one of the tools of thrifty maintenance, which allows you to reduce costs, due to downtime due to breakdowns and overhead maintenance. The main idea of ​​TPM is to get the entire staff of the enterprise, and not just the other services, to the service process. Successful implementation of TPM, as if it were any other tool for gentle treatment, interventions for it, some idea of ​​the method of conveying to the staff and positively accepting it.

The peculiarity of the TPM technique lies in the fact that, on a її basis, that planned transformation of the existing service system can be smoothly to a greater extent.

For this reason, the way to promote TPM can be visualized in a visual sequence of stages, skin for some reason, as a whole, as a whole, and a smut, gives a whole sensible effect:

1. Prompt repair of malfunctions - a test to thoroughly improve the service system and know the weak months.
2. Serving on the basis of forecasts - organizing the collection of information about the problems of possession and their further analysis. Planning foreign service obladnannya.
3. Corrective maintenance - improvement of the maintenance process by identifying the causes of systematic malfunctions.
4. Autonomous maintenance - rozpodіl funktіy z slugovuvannya obladnannya between operating and maintenance personnel.
5. Bezperervne polypshennya - obov'yazykovy attribute of any instrument of dbaylivy virobnitstv. In fact, it means getting the staff to work without interruption, asking for the cost of operation and maintenance, as well as asking for methods of adoption.

Visual management is the construction of all tools, details, manufacturing stages and information about the performance of the manufacturing system so that the stench is clearly visible, and so that you can be a participant in the process at first glance, evaluate the system.

Visual management is carried out at the kіlka stages:

Stage 1. The organization of work functions is being developed, the whole stage, on which it is necessary to win all the effort and opportu- nity 5S.
Step 2. Important information is visualized, as it is known at work: information about safety, how it is, about those, how the operations are counted, and about those, how and how it is guilty to win the possession.
Stage 3. The results and indicators of the effectiveness of the other process are visualized.
Stage 4. Complimentary decisions are made on the basis of visualized information.

Standard Operating Procedures (SOP) - a document, which, step by step, determines the sequence of the most common operation:

Usnі іnstruktsії zabuvayutsya and spovoryuyuyutsya, so їх іх іх ізініті on letters - SOP.
- SOP is not to blame for a lot of time for understanding, that stink is to be blamed for victorious knowledge, little pictures, diagrams, photographs, too.
- SOP may be updated regularly due to improvements in the order of operations.
- When rozrobtsі SOP sled zachіvnіvnіv, tse guarantee її veracity that does not mean trade.

Just-In-Time (JIT) - a method of speeding up the hour of the cycle, if materials, services and other resources are needed only once, if they are necessary:

A fast delivery of a batch to the minimum economically viable (ideally up to one single product).
- Balancing the number of human resources, the quantity of materials and possessions.
- "Vityaguvannya" products. The productivity of a streaming operation is determined by the need for an offensive one.
- Vykoristannya audio-visual zasobіv control over the mill product and the interest of possession.
- Delegation to the process of taking a decision on the management of moving products to the lower level.

Mapping the flow of value creation - it is necessary to draw up a simple and first-hand graphic scheme that depicts the material and information flows that are necessary for the product to serve the end of the world. A map to the flow of value alignment gives the opportunity to immediately improve the flow of time, and on the basis of this analysis, reveal all unproductive vitrat and processes, develop a plan for improvement.

Mapping is a visualization of the description of the song form of the flow (material, informational) creation of the value of the business process. Kartuvannya is carried out in the minds of “yak є”, “yak maє buti” and “yak bude”.

For the help of this tool, a map is created for the flow of value creation, in order to clearly indicate the hour of value creation and spending, which is based on the value creation flow.

The map of the flow of creation is a tool, with the help of which it is possible to visualize the material and information flows of the time of creation of value. An hour of creation of values ​​is accepted to vvazhat an hour of vikonnannya robіt, yakі remake the goods those shchob spozhivachі buli ready to pay new. Potik stavlennya tsіnnostі - all dії (what to add і yakі to add tsіnіst), nebhіdnі, schobiti goods.

Unfortunately, practice shows how much we spend to establish the left part of the process, їх expansion syagaє 80% - ce and є field of activity of the Kaizen system: without interruption; method of exercising thoroughly through the adoption of expenses; propositions about the usunenny vtrat.

It is clear to everyone that the needs of the economy are constantly growing, and also, the process of improving the same is uninterrupted, shards of directives for the transformation of the needs of the economy to specific products.

Mapping the flow of value creation includes the following steps:

At this stage, a report is made describing the process of creating a single product (or a family of products) from the designated operations and stages, the required hour, the number of practitioners, and information flows.

I’ll become a method of inducing a streaming card and revealing: diy, what do you do, be it as if you’re saving value, and diy, what don’t you do.

The rest of the activities may be necessary and may not be usunen (for example, accounting), such duties should be maximally optimized, otherwise they may be short-term or optimized (for example, transportation or storage). For whom z'yasovyvayutsya vymogi zamovnika to yakostі that domineering product.

The characteristics of the product are determined, as they cannot be changed for the day, and the characteristics, as they can be changed for the weather. Only on the basis of such information can one accurately determine whether the value is being created, but not.

The map of the future camp shows the ideal camp after all the planned changes. Carried out is also a manifestation of prihovaniyah vtrat z metoyu zha far їsunennya.

Appointment of methods on the cob of the future, recognition of specific tasks, terms and conditions for implementation.

Vbudovana Yakіst - a technique for managing the quality of products in the field of production.

Basic principles of budding vigor:

1. Possibility of a conveyor splint by a practitioner at a time of faulting the ship or a breakdown of the device (Jidoka).
2. Projecting the possession of such a rank, so that the appearance of that tooth was automatically revealed.
3. Wicker system for alerting problems on the generic line (Andon).
4. Vykoristannya methods for zapobіgannya unfortunate pardons of operators or short-lived technologies (Poka-Yoke).
5. Standardization of procedures for quality control and obligatory control over operators.

Apply dbaylivy virobnitstvom

At the undertakings of Tatarstan, with the initiative of the Ministry of Industry and Trade of the Republic, for the past three years, an active work has been carried out on the implementation of the "Lean Manufacturing" methodology.

Today, before the development of the project, the development of lin-technologies included over 80 enterprises and organizations of various institutions of the economy of the republic: machine building, light industry, oil chemistry, energy, the agricultural state, transport and communications, VAT "healthy" "Virobniche o'dnannya" Labuzkiy avtomobilniy zavod", FSUE "Virobniche o'dnannya "Plant named after Sergo", VAT "Kazan motorobudіvne virobniche o'dnannya", VAT "Kazan aviation com- munication named after S.P.Gorbunov" and other .

On the basis of a wide breadth and density of lin-technologies in the variety of activity of enterprises of various galuzev straightening of the robot between the working groups.

Particularly noteworthy is the effect of the introduction of "Lean manufacturing" technologies at the enterprises of the republic, as for a long time, systematically planting lin-technologies.

360 th. sq. m. area, subtracting the economic effect - 16 billion rubles, the costs for the development of the virobnicheskoy system accounted for less than 1% of the economic effect.

At KAMAZ in the autumn of streaming rock, the project "Mayak" was launched - a system for organizing and managing the production of the technologies of Gentle production - a joint project of KAMAZ and Daimler. The implementation of the project "Mayak" on the head conveyor of the warehouse tіlka on one line will allow the increase in the release of cars up to 48,000 cars per rіk with the work in two shifts.

Within the framework of promoting the philosophy of "Lean manufacturing" at YelAZ, over a thousand specialists were trained, 37 internal corporate trainers were trained. 11 reference works were created, nearly 2 yews were produced. proposals for polypshennia, 180 projects were implemented. The economic efficiency of resource saving was over 290 million rubles.

The second butt is "Kazan motor-building association". The implementation of the tools of the "Lean Manufacturing" on the pilot maidan of the acquisition made it possible to speed up the number of operations by 2 times, the distance of movement - by 22 times, the manufacturing cycle of processing parts - by 4 times.

The beginning of entrepreneurship, which is to follow the path of promoting the principles and tools of Lean Manufacturing, for a minimal investment, achieve the following results: increased productivity of work - up to 70%; increasing capacity - up to 60%; cultivation of harvesting areas - up to 50%; short shlyubu - for the average by 65%; abbreviated terms for the implementation of investment projects - up to 20%.

It should be noted that as a result of the implementation of the philosophy of "Lean Manufacturing" the psychology, mentality of workers, engineering and technical personnel and businessmen are changing.

The concept of double viability

The concept of "Economical (sparing) production" (lean production) appeared to me at once with the "kaizen" system. Ideology of “sparing choice”, for those who are oriented towards the most efficient use of resources, with a minimum of space, income, peace, working space, and work for the sake of work.

The origin of the concept of "Economical production" (Lean Production) is connected with the engineer Co. T. Vono is like a 1940s rock with his colleagues seeing American backwaters and laying the foundation for the organization of the Toyota Motor Company's manufacturing system.

T. Vono having developed a simple set of goals for encouraging a car detection system: to make a car as quickly as possible, to do it negligently and not to save the daily industrial stocks. Vіn dіyshov vysnovku, scho thogo can be less for the safety of the quality of all stages of the brewing process.

This system gained popularity under the name "Toyota Production System" (Toyota Production System, TPS), and the principle of the methodology was later, as if newly presented, and popularized in America, but also under the name "Economical production".

At the cob stage of TPS creation, the following tools were used:

1. Vіdmova in the form of "shtovhaє" systems that create non-required reserves at all stages of production independently from drink and transition to the "flexible" system "exactly in line".
2. Autonomization - granting the right to employees to start a conveyor or to make a mistake in order to protect the right of a defective part or a node for a further operation.
3. Decentralization of management - increased access to information about the manufacturing system, expansion of self-sufficiency and capacity of workers, their participation in accepting solutions to any problems related to their jobs.
4. The shape of the variability in the design of products - modular design is the fate of post-workers in the design of components that are supplied by them.
5. The blame for defects, shards in the future due to the availability of mortgages (reserves) of syrovina and the production of beverages is not possible.

In the traditional mass production, it is more important to see the highest types of expenses, which are used by the method of “Economical production”:

Perevirobnitstvo - vyrobnitstvo more obsyagu earlier and later, lower is necessary at the onset of the process;
zayvі store - whether it’s too much need for a one-subject flow in the production process, chi tse syrovina, intermediate products abo;
defective product - products that require re-grading, sorting, disposal, downgrading, replacement or repair;
dodatkova (zayva) processing of chi relocation - dodatkovі zusillya, yakі, at the thought of a gentleman, do not increase the dodatkovoї vartostі (value);
ochіkuvannya - interrupt at work, po'yazanі z ochіkuvannyam human resources (workforce), materials, statkuvannya that information;
people are not exactly the best for newbies and good luck, rozumovyh and creative zdіbnosti staff;
spend an hour of transportation - non-necessary moving of elements and materials in the middle of vibration.

A lot of authors, krіm tsgogo, see additional costs, for example, “hibnu ekonomіyu”, which are used in offensive actions: the choice of cheap and non-acidic syrovina and materials; simplified construction, which leads to a decrease in capacity; quick tripods, which lead to non-conforming necessary functions; raznomanіtnіst elementіv konstruktsіy, zabіv i methodіv virobnitstva, if it is possible to standardize and unify them.

The concept of “Economical Variability” comes from the fact that, as always, in the center of respect, the reduction in the costs of the experi- ences, then there is no inter-advance, which can be reached.

Krіm earlier we looked at the tools, the TRS system also propagates vikoristovuvat:

1. "5S" with the method of reducing the organization of work and the quality of work in the workplace for the establishment of order, the maintenance of cleanliness and discipline;
2. Without interruption, completely "kaizen";
3. Value stream management (VSM);
4. Mapping of the process - a graphic image of the process from the assigned flows of information, materials, reserves, metrics (standard characteristics) of operations;
5. The system of defense against pardons - a decision was made on the basis of a bugatory analysis of risks, possible conclusions and nasledkiv;
6. Rapid expansion of parties to the minimum;
7. Costs of visual control - all tools, details, virobnicha diyalnistnost and pokazyvayushchikhsya on uvazі, so scho skin tsіkavіlnіnі irradiation before the process of a person can oszumіti camp of the system from one glance. There is a wide selection of visual information (cards, maps, schemes, etc.) to show what a skin operator can do;
8. Good thought-out plan of placement of the property depending on the optimal sequence of operations. Close to that handy distribution of workpieces and tools;
9. Normalized robot. Vikonannya roboti vіdpovіdno to stanovlenih (standardized) methods, without spending money on the improvement of the practical work (ergonomics). Standardization and unification of vicory are started at the stage of product design and work;
10. Team work, like in case of vikonannі roboti, so in case of polypshenny;
11. Yakіst u protsesі roboti. Reconsideration and control of the quality assurance process is carried out by the victorious operators, in order to reconsider what the products are, in order to reach the next stage of the process of the necessary quality;
12. Storing the necessary items. Sirovina, details, information, tools, working standards and descriptions of procedures are there, if they are necessary;
13. Gnuchkіst virobnitstva. The building of a fast change of possession and remembrance of the tools allows, at the very same working place, to produce a wider range of virobivs and shorten the rozmіri of parties;
14. Pilot project. The most "high school" is selected from the selection. Vikoristovuyuchi, so ranks, pіdkhіd Kaizen Blitz (rapt attack), zdіysnyuyut prorivnі polіpshennya, and then transfer dії to other most important problem areas;
15. Analysis of the overall efficiency of possession and expenditure. Vykoristovuyuchi the Pareto diagram vyznachayut spend, with the liquidation of which you can take the greatest return.

The development of the “Economical brewery” includes the following steps:

1. Praises the decision of curation about the promotion of "gentlemanship". At this stage, it is necessary for the staff to explain the reasons for the decision, choose goals, form a team, plan and transfer resources necessary for the implementation of "economical manufacturing". Nayvische kerіvnitstvo can constantly demonstrate its zatsіkavlenіnі, take part in everyday work and give a podtrimku.
2. Selection of the primary object of the project (pilot project). Therefore, the method is to choose from 1 to 3 of the most materials and labor-intensive processes, which can give an exact effect.
3. Staff training. It is possible to go through all the participants in the rhetoric of "economical production", like a ker_vnitstvo, and ordinary vykonavts_ processes. The objectives of the training are the understanding of the goals set and the achievements of their achievement (technologies "just in line", victorious achievements, methods for evaluating the processes and products).
4. Mapping of the reorganized “yak є” process.
5. Investigation of parameters (metrics) of the orderly process.
6. Mapping the process "how can I be".
7. Razrahunok metrics of the reorganized process, and for the low efficiency of yogo dodatkovo dodatkovo.
8. Implementation of the project.
9. Creation and implementation of plans for an uninterrupted thorough process of "Kaizen".
10. Dosvіd rasgortannya "economical variation", ottrimanii on the pilot project, step by step expand on other processes.

The concept of “smart variability” of fahivtsi is important to the integration of a set of tools in the organization of variability, which in general is introduced through the system “exactly in term” (JIT), global quality management (TQM), global service command and control (TRM) organization of work and training of spivrobitnikiv until a decision is made. With a lot of fahivtsiv, it is noted that behind the zavdannya, zmist and tools, it is fundamentally not considered in the form of the “kaizen” system.

Principles of double vibrancy

The principle of Lean is the Japanese fault, which the Japanese were inspired by the history of the development of Ford Motors in the 1950s. Having worked as if they were building cars at an American warehouse - and they worked much more efficiently here, lower at home - two manufacturers from Japan developed the Toyota Production System (TPS). Tsey pidkhid having allowed to transform Toyota Corporation from a modest Japanese firm into an international giant of the automotive industry. In fact, at that hour, when most of the automakers were suffering in the downturn of the economy, Toyota recorded a 23.2% increase in net profit for the first time, compared to the same period of the previous year. It should be noted that such an increase in profits resulted in an increase in corporate income by more than 8%. "Today, if companies decide to fight for survival, Toyota will continue to work for a penny," says Sharma.

After the TPS system was launched in Toyota Corporation, it became clear that many of the system's potential advantages would be left unrealized, as it would not include the corporation's partners. Also in the 1970s. Yoshiki Iwata and enthusiasts of new principles of Toyota Corporation started the consulting company Shingijutsu, calling for a wide promotion of principles. Shingijutsu became a parent of the Jacobs Equipment Company galm mill to the Danaher conglomerate and helped transform yoga into the US first manufacturing business based on the principles of "compassionateness". As a result of the announcement in the US state of Kentucky, the Toyota Supplier Support Center (TSSC), the TPS system has become wide-spread in the USA.

For the fates that have passed after the TPS wine-growing, the principles of "comfort" have gone beyond the Japanese car industry and have expanded to other territories. Most of the international businesses that have been sold in Asia have already been promoted to the Lean program. Car dealers in the United States are already victorious with the Lean principles, but the cleaning of the galuzes is no longer beginning to grow with new possibilities.

Manufacturing companies in the United States, which have won other methods, for example, the principles of accurate scheduling of manufacturing (just in time manufacturing), could quickly and successfully implement the method of "sparing" manufacturing at their enterprises. Galuzi with a low rate of surplus, for example, car-building and manufacturing companies, have fallen among the leaders.

With the principles of Lean, the Six Sigma methodology is often used, as it allows you to ensure the uncompromising quality and consistency of the cycle. This concept was developed in the USA when Bill Smith, a senior engineer at Motorola (USA), foresaw the standardization method for the elimination of defects. At the name of the concept of vikoristan, the letter of the Greek alphabet is sigma, as it sounds like a statistic for the definition of standard definitions. Six Sigma programs, which are awarded by such different companies as GE, Allied Signal and Tyco, have a detailed analysis of data to complete all business processes. Kіntseva meta-implementation tsієї metodologii - domogtisya vіdsotka shlyubu no more than 3.4 per million. The principles of Lean and Six Sigma help to ensure the sustainability of profit.

Ten principles of "smart" brewing:

1. Take care of the great ceramics. First, don’t be afraid to work, enlist the help of support, which will take decisions from your company. "If you want to transform your business on a "sparing", podbayte, so that more curiosity has figured out what it is planned to build," says Sharma from the TBM company. Hemby of the Emerson company adds: "It is necessary to stagnate the child, which is torturing all the equals of the animals to the bottom, and not just the middle management lanka and vikonavtsiv."
2. Roll up your sleeves. The principles of Lean can lead to negative results. Ale can not say what will be easy. "A lot of people are talking about quick solutions to complicated problems, - Sharma seems.
3. Speak and learn. "We spent more than an hour talking before the cob, at the end of that next time, to be inspired by the fact that the skin has access to a complete understanding," says Van Zanten from the Pella company. - Compliance is necessary. As we strive for success, we will tell you about them effectively." Create an atmosphere of recognition, teach people - and take record results.
4. Don't be afraid of learning. The principles of "sparing" production are rich in traditions. "Plan to spend a great gap of time on changing the style of the company's mindset," said Parker. at the change of corporate culture”.
5. Tick the correct metrics. Change methods for assessing success and failure. “The old system in the form of windows had even better results, even though it was more expensive in 24/7 mode,” respects Parker. "Principles of Lean will not bring success," even wine, "so do not change the evaluation criteria." The traditional criteria for success are efficiency and victoriousness – the following are replaced by efficiency, the hour of closing, the hour of inventory turnover and the quality of production.
6. Help partners. "If you don't expand the scope of Lean's principles beyond your own business, you'll call out the dissatisfaction of your employers, - guard Modi's Oracle Corporation. - Successful companies have taught the principles of "forgiveness" to their employers." In fact, the most "forgiving" companies lure their post-employees into product development in order to promote the quality and simplicity of production. In addition, the stench reports spilnyh zusil to the full methods of communication and the speedy hour of tying up the stretch of the long lance of deliveries.
7. Think big. In the world of that, as the company has a short production cycle, experiments can be carried out more and more safely. Therefore, a skin test fully carries great potential and can be realized without serious consequences, in case of failure. "In uncertain situations, be bold," Van Zanten said. "We set aggressive numbers.
8. Change landmarks. "Don't hurry to declare victory," - for the sake of Sharma. And Van Zanten with Pella Corporation loves to tell, as through the river after the introduction of resource-saving methods, the director of IT asked him to tell him about the results. "Approximately 25%," Van Zanten estimated. Even through the river, the director of IT put the same food, but once again he took away the amount - 10%. This butt is showing that "gentle" behavior is similar to a new pair of glasses, which helps to gradually mark new ways of speeding up the investment and the good business. "The more you work, the more opportunities will open up before you," adds the Prince of the Pella Corporation.
9. Believe in success. "Uninterrupted thoroughness (Kaizen method) is the style of our life," is a representative of the industrial conglomerate Danaher, a kind of resource-saving method from the 1980s. Only constant respect and recognition of new principles allow the company to achieve excellence. "We have shown that the clients, like adopting the principles of Lean as a religion, have achieved remarkable results," Modi says.
10. Get ready for the tribal road. "Frugality" is not attributed to the achievement of the first set of goals, unless the project has been cleared with clear dates and is completed. Shvidshe tse style of business, which is guilty of constantly promoting ceramics. "From the side of currying, pilnist can be manifested," says Parker. "Zavzhd slud shukati quicker ways, - adds Robert Azavedo (Robert Azavedo), director of Oracle, who is engaged in the gallery of discrete manufacturing in Europe.

Efficiency of double vibrating

Lіn-pidkhіd allows better satisfying the needs of clients, vicory less resources, on smaller areas, with less quantity of possession, stained less than human costs, in less than an hour.

Firms that have become on the paths of thrifty production, buildings will approximately increase productivity and speed up the release hour, increase the speed of production areas, increase reserves - practically without financial investment.

Don't worry, but often you don't need to buy a new way of possession, you don't need to switch to new materials and technologies, you don't need computerization, and you don't need to use expensive ERP systems either. It was necessary to change the culture of business management, the system of mutual relations between different equals and subdivisions of business, the system of value orientation of spivrobitnikiv and yogo mutual blue.

In this way, vikoristannya principle dbaylivogo virobnitstvu can give significant effects. Professor O.S.

Spend at the dbaylivomu virobnitsvі

Thriftly virobnizstvo see this type of cost:

1. Spend overproduction (overproduction).
2. Spend transportation (excessive movement of syrovin, products, materials).
3. Cost of payment (during the working hour, there is no room for work).
4. Spend through stocks (superfluous amount of syrovina, materials, manufactured goods).
5. Spend through the manufacture of products with defects (gate).
6. Use the investment of the work (obrok, yak not to bring value or add inappropriate functionality).
7. Spend your money (do not intervene without interruption from the current virobnic activity).

The greater part of the working day is spent on spending, and less than 1/8 - the creation of value and the surplus.

It is also accepted to see 2 dzherel vtrat - muri and mura, which means apparently “overwhelming” and “irregularity”:

Mura - the unevenness of the robotic work, for example, the graph of the work is screeching, the calls are not made by the call of the end of the spozhivacha, but rather by the peculiarities of the virobnic system, but the uneven pace of the work from the victorious operation, so the operators are stunned, slow down, hurry up. At rich vipadkah managers of the building have a lot of nervousness for the time being, viruvnyuvannya planning and respectful setting up to the pace of work.
Muri - re-adjustment of the operator's work, which blames the hour of work with a greater swedish pace and with great effort for a long time - against the rozrakhunk's adventurousness (project, labor standards).

Spend some extra money

One of the most obvious ways to increase profits is to increase the productivity of business. However, in the pursuit of productivity, top managers often forget that the amount of a product, which is ready to buy a spare, is considered a market drink. There comes such a moment, if the product, which has never been so good before, accumulates in the warehouse.

Perevirobnitstvo - tse virobnitstvo bіlshої kіlkostі goods, nіzh require klієnt.

Jerel vtrat:

Dodatkovі vitrati for savings;
transcendental choice of materials and resources;
disruption of delivery schedules;
vymushenі iznizhki pіd hour sale.

Improved paths:

Virobljat less often and less those who want the client;
virobnitstvo with different parties;
shvidki perelagodzhennya.

Spend transport

Whether it be more or less folding, the next step is the transformation of the syrovin, or the brewing of the finished product. Ale mizh operations all materials need to be moved. Insanely transporting - the price is not part of the change, but it’s a great pity they don’t create value, wanting to use electricity on the floor or electricity, servicing the transport fleet, organizing the transport infrastructure (road, garage, etc.). In addition, transportation is worth the time and risk of product degradation.

Jerel vtrat:

Spending an hour on the movement of materials / products until the moment of their delivery to the internal employer;
overproduction of products and її psuvannya when saving.

Improved paths:

Control of the ways of moving valuables, short-term relocation of goods with additional rescheduling, re-arrangement of the relocation, use of the distant reserves;
short period of physical movement of valuables;
skorochennya vіdstaney mizh operator and obladnannyam.

Spend points

Spend, pov'yazanі z ochіkuvannyam cob processing of the material (details, napіvfabrikatu) point to those that the process of planning and the process of manufacturing is not suitable for each other. By itself, the process of planning to finish folding, oskolki vimagaє analysis of a large number of factors. Before such chinnikіv to be set: the structure of zamovleni spozhivachіv, the camp of the market, the productivity of the establishment, the schedule of robotic changes, just. In a right way, the optimal planning is based on serious mathematical training and in the interplay of services, procurement, procurement and production.

Reasons for scoring:

The cost of throughput on the efficiency of operations;
planning for the needs of consumers, and equipment procurement;
stockpiling for operations with high throughput.

Improved paths:

Gnuchka planuvannya virobnitstva z urahuvannyam zamovlenya;
increase in the throughput capacity of the hired productive company;
awarding the virobnicheskogo process for the daytime zamovlenya;
flexible schedule for practitioners of that possession.

Spend through reserves

Stocks - ce frozen pennies, tobto. pennies, forfeited from turnover and spend money.

Jerel vtrat:

Special warehouses for materials and products to ensure the timeliness of deliveries, so that the problems of production do not add value to the client;
materials and drinks are paid for by the company, even if they are at the stage of delivery.

Straight cut:

Analysis of the demand for products from the trivial term of saving;
analysis of timeliness of changing prices for non-liquid reserves; analysis of claims for non-liquids;
balancing virobnitstva and zbutu;
analysis of the dynamics of stocks and changes in stocks of materials and supplies between operations.

Spend through defects

The release of products, which does not seem to help slow down, pulls behind you the obvious waste of sirovini, working hours, work, waste for recycling and disposal of the hatch.

Jerel vtrat:

Vitrati for rechecking and control operations;
processing of defective products;
disposal of the hose is not subject to repair.

Straight cut:

Control of efficiency and dotsillnosti of perevirok;
vstanovlenya zv'yazku mizh parameters of the process and akіstyu;
rozrahunok ekonomіchno ї dotsіlnostі utilіzіїї slub stovno zupinok vyrobnitstva;
longing for yak_snoy robots and punishment for non-yakіsnoy;
vbudovuvannya quality control in the process of virobnizstva;
vbudovuvannya systems pobіgannya defects (Poka-Yoke).

Spend a loan

Spozhivach is ready to pay tіlki for the power of the goods, yakі represent for the new cіnnіst. For example, it’s cool, for example, ochіkuє, that the body of the TV set is guilty of buti black color (white, silvery skinny), and you have only a few green plastics and you have to prepare the body to refarb the yogo in the required color - you also need to use the zayvoї obrobki. An hour is needed for this, people, possessions, farba, and the body, which is really valuable for a gentleman, already prepares.

Jerel vtrat:

I will bring the goods to the point where I need to be calm;
automatic possession, as it requires the uninterrupted presence of the operator;
preparation of short products, less attention to customers, addition of non-essential functions and manufacturing stages, like masking defects.

Straight cut:

Purchase of syrovin, which does not require additional processing;
supervising the processes of additional processing for inter-enterprises (outsourcing);
follow-up of the need to improve products;
more important than achieving stable results, lower polypshennya.

Spend money

Zayvі ruhi, yakі proizvodit to vtrat, it is possible to call Bulo simpler - metushnya, pіdkreslivshi tsim їх uncoated and chaotic. From the side, such ruins can be filled with seething activity, but when surprised, you can remember that the stench does not save the creation of value for the calm.

Jerel vtrat:

Zayvi pass, ruhi, nalashtuvannya pіd hour vikonannya roboti;
vіdsutnіst chi inaccuracy of standards vikonannya roboti;
the essence of labor discipline.

Straight cut:

Control of compliance with the standard;
rozrobka chi thoroughly standards of work;
the manifestation of that adoption of activity does not create value;
rozpodіl vіdpovіdalnosti result vikonannya work;
teaching staff the correct work (5S);

The manufacturing process of daily production is a folding mechanism for the transformation of beverages, syrovin, materials and other items of practice into finished products, as a satisfaction to consumers. The head of the virobnichoy system, with all the flock without interruption, is completely “flow of value creation” for a calmer, which is based on a rational increase in the hour and the expanse of all the main, supplementary and service varieties. Tse permits the release of products with minimal costs of production and in the event of a deposit of economic indicators and the results of the state-owned business of the enterprise, including the co-production of products, income and profitability of the turnover of the contract, the amount of unfinished goods.

At the same time, on rich undertakings one of the main nutrition is the nutrition of the efficiency of the brewing processes from the point of view of the trivality of the brewing cycle. The main need for stained glass windows is to increase the coordination of all additional and service operations for the uninterrupted supply of the main production of syrovine, electricity, as well as its own maintenance, storage, and transportation. The situation is out of harmony with the possession of one technological stage to bring the teeth of the entire workshop to perfection. Zvіdsi, the organization of an uninterrupted effective production cycle for the enterprise is gaining special relevance and importance of optimizing the workflow and achieving the best final results.

The effectiveness of the virobnitstv at a large number of enterprises is directly related to the folding and the trivality of the virobnicheskoy cycle. The more successful this cycle, the greater the number of additional and service workers in a new job, the less effective the more effective the work is. It is explained by the regularity of the obvious need for stained glass masu zusil on the coordination of all activities of the uninterrupted security of the main production of syrovine, energy, service, possession, transportation and storage of products, navigation and storage. The inadequacy of the possession of one technological stage can lead to a breakdown in the robot's entire production, to a new tooth. In this way, it is especially important for improving the efficiency and achieving the best results in the face of the problem of the stable functioning of a successful virus system.

One of the ways to solve this problem is the implementation of the system Lean-technologies ("Prudent manufacturing"), who was asked to optimize the production processes, gradually improve the quality of the products with a constant shortening of the wine. The system is not just a technology, but also a concept of management, which transfers the maximum orientation of the variability to the market from the involved participation of all the personnel of the organization. Dosvіd in the implementation of the described technology, although it looks like a few elements, on the undertakings of various galuzes, showing its prospects, on the basis of which it does not call for doubt the need for further development of the sphere of yogo zasosuvannya.

Economic value of Lean-technologies

As an economical definition of variability, the system of transformation of syrovin, the production of and other items of practice for finished products, which can reduce the value for sustainability. Golovne zavdannya virobnichoy system polagaє in an uninterrupted thorough process of the creation of value for spozhivacha a way of rational day at the hour in the expanse of all the main, additional and service vacancies. In this way, reaching the economy of time, material and labor resources, the co-production of products changes, the profitability of the production grows, all the economic indicators of the state-owned activity of the enterprise are improved.

With the development of virobnicheskih vіdnosin develop and fully control systems virobnicheskih processes. One of the remaining ones was the Lean manufacturing system, based on the principles of efficient resource management, respect for the needs of the manager, concentration on the problem of utilizing all types of costs, and the universal achievement of the intellectual potential of the personnel of the enterprise. One of the main goals of the system is the reduction of expenses, the management of the general business, based on the constant implementation of all types of expenses.

The concept of "Gentle brewing" on the optimization of the production processes, directing the constant increase in the quality of the products with the constant shortening of the vitrate, from the radiation of the skin employee in the process. The concept is maximally focused on the markets and minds of the Lord.

For the rest of the twenty years, a new paradigm of productivity has become more and more established at the world's practice. Won a handful of vinyl from Toyota and took away the name - Toyota Production System (TPS). Vaughni is the zrostannnya for the minds of post -ndustriyali Ekononiki, if the Masovoy Vobnitvva is deployed, he will drink the guarantees, the vinikla demand from the sabotage Vobrinitvi, the buildings are baked by izhindelni to write down Kliztiv. The main task of such a selection was the creation of competitive products in the required quantity, in the shortest term with the least amount of resources.

The manufacturing that supports new technologies was called "lean" (lean, lean production, lean manufacturing), and the enterprises that improved the operational efficiency of their manufacturing, the introduction of the new system - "lean" (lean enterprise).

"Thrifty" undertakings are resurrected in the next coming:

1. The basis of the general system of such enterprises is people. The stench is the creative force in the process of manufacturing competitive products, and the technology and the adjustment are beyond the reach of the set goal. The same theory, strategy, technology does not let the success of the successful; what people can only achieve on the basis of their intellectual and creative potential.

2. Virobnichi systems of "sparing" undertakings oriented towards completely excluding costs and posting thoroughly all processes. In everyday robots, in order to avoid all possible types of expenses, and without interruption, the rest of the company's workers of the company, including workers, to the greater ceramics, take the same fate.

3. Acceptance of a decision, what to lie perspective of a distant development, in their own impudent financial interests are the primary ones. The management of such companies is not engaged in administrative work - commanding, unfairly hard control, assessment of support workers for the help of folding systems of various indicators, wines for a reasonable organization of the process of prevention of problems, their own manifestation, advancement. Uminnya bachiti and virishuvati problems in your work area are valued by a skin specialist - from the highest level of care to workers.

The key tools of the Lean system to increase the productivity of work:

• 5S system- Management methodology, recognized for the effective organization of the working space. The name resembles Japanese words that start with S, like i in Russian language you can choose analogues that start with the letter C, tse:
  • 1) Sorting of objects and/or documentation at the work station according to the level of their necessity and frequency of congestion with the elimination of all non-essential;
    2) Systematization, if the skin object is guilty of perebuvati at the singing accessible place;
    3) Dotrimannya purity and order;
    4) Standardization of the working area ordered by the previous procedures;
    5) postіyne vdoskonalennya rozroblennya standard.
  • These are clumsy and, at first glance, insignificant procedures, prote, add to the efficiency of practice, include wasting speeches and an hour, reduce the possibility of blame for burning those other supra-extreme situations, and in general create a pleasant microclimate on the worker’s mind.
• Robot standardized- Accurate and maximally visualized algorithm for monitoring the duration of the operation, which includes standards for trivality of the cycle of operations, the sequence of operations during the completion of these operations, the number of materials and items (reserve rate).
• Methodology "Break through to the flow" Pole at virivnyuvanni and increase the efficiency of the virobnicheskogo flow for the help of the creation of fixing virobnicheskih cycles. In the skin from the vision of cycles, the principles of standardized work are examined at the front point.
• The concept of TPM (eng. Total Productive Maintenance)- The system of infamous service obladnannya. This system can be on the verge of confusion of exploitation with a constant technical supervision over it. As a result of constant monitoring, that improvement in the possession of a working (helpful) staff becomes a worker, the level of expenses caused by breakdowns, downtime, through repair work, including those planned, which allows you to ensure the safety of your effective life cycle, is reduced. At the same time, the forces of the repair personnel are called in to solve the most important tasks.
• SMED (Single Minute Exchange of Die) system– the technology of carrying out swedish changeover of possession. In the process of re-adjustment of possession, two groups of operations can be divided - ovnishn, which can be carried out without a grain of possession, for example, the preparation of tools and materials, that internal, for carrying out such a break in the robotic possession. The essence of the system is based on the transfer of the maximum number of internal operations to the group of the most advanced ones, which can lead to the implementation of low-tech and organizational improvements.
• Vigorous vibrating systemє pіdkhіd up to organіzаtsії vyrobnichego flow, scho including spending, po'yazanі z nadvirobnitstvom аbo ochіkuvannya poperednya etap robit. The skin technological operation is like a bi "strong" necessary number of products from the front and transfers to the offensive. As a result of this, the manufacturing process has no excess products, no shortage.
• The system of submission and review of propositions we give to all spіvrobіtniki zrozumіli mechanism for the implementation of propositions to be thoroughly and thoroughly transferring, come in and stimulating spіvrobіtnikіv before submitting such propositions.

The complex use of Lean-tools allows without significant investments, practically less than the company's internal reserves to achieve a significant increase in productivity. According to Suti, Lean-concept-Tse Singing Pidhіd to all the native organizas of the Vobrobnitvva, Shto is not a realization of the vennovati technology, the productiveness of the Personality of the Personality, the omituity of the corporal, the bonds for the formulation of corporal culture. full-fledged activity of the company.

The process of zabіgannya pardons that zastosovuєtsya in Lean-systems

We will widely expand the method of pardoning pardons that win in Lean-systems by using Poka-yoke.

Poka-yoke- (poka - vipadkova, hateful pardon; yoke - zabіgannya pardons), (eng. Zero defects - the principle of zero pardon) - a principle that is used in searches of reasons for blame pardons and the combined methods and technologies that include the very possibility of their appearance. In other ways, if it’s right, it’s impossible for a robot to vikonate, and a robot vikonan, then, vikonan out without pardon - such is the main idea of ​​the method.

Various defects in products can be blamed on people's forgetfulness, disrespect, unreasonableness, negligence, etc. Such pardons are natural and inevitable, under such a cut you need to look for ways to know them.

Methodology for zabіgannya pardons peredbachaє:

• the creation of rethinks for defect-free robotics,
• selection of methods of defect-free work,
• systematically usunennya pardons, scho winickly,
• the introduction of foreign approaches and the introduction of simple technical systems that allow spivrobitniks to avoid a mishap.

The Poka-yoke method, which works together with the other tools of gentle brewing, is a guarantee that the brewing will be defect-free, and the process of yogo brewing will proceed smoothly.

Improving the efficiency of business management for Lean-technologies

In general, the principles of Lean can give significant effective(at times):

• increase in productivity - 3-10 times;
• change in downtime - 5-20 times;
• change in the trivality of the preparation cycle - in 10-100 times;
• change in warehouse stocks - 2-5 times;
• change in habits - 5-50 times;
• accelerate the release of new drugs to the market - 2-5 times.

The best foreign and Russian practice promotion of tools for lean manufacturing results:

• Electronic industry: quick turnaround of the brewing process from 31 to 9. Quick turnaround of the brewing cycle from 9 to 1 day. Vivilnennya 25% of harvesting area. Saving close to 2 million dollars for the delivery.
• Avіaprom: abbreviated term for closing from 16 months to 16 days.
• Automotive industry: increase in capacity by 40%
• Color Metallurgy: Increased productivity by 35%.
• Overhaul of large-tonnage vessels: removal of 25% of the harvesting area. The shortest hour of one of the main operations from 12 to 2 years. Saving close to 400 thousand dollars in 15 days.
• Storage of automobile hubs: storage of 20% of the harvesting area. Vіdmova vіd vіdіvnitstvа novіbnichoї budіvlі. Saving close to $2.5 million for the day.
• Pharmaceutical industry: fast yields from 6% to 1.2%. Decreased power savings by 56%. Savings 200 thousand. dollars aside.
• Virobnitstvo of living goods: Increased productivity by 55%. The speed of the virobnichesky cycle by 25%. Change in reserves by 35%. Savings close to 135 ths. dollars for the day.

In general, in the Russian market, there is a shortage of pharmaceuticals, and there may be an opportunity to optimize the manufacturing processes in the way of promoting the technology of “sparing manufacturing”. Lean looks at whether it's possible to optimize processes at a glance by the forces of all practitioners in the company. In this global approach, there is the main consistency of the method of “sparing selection”, shards of fahivets in the sphere can be combined with one’s own teacher and clerk, forecaster and analyst.

Visnovok

Lean manufacturing (lean production, lean manufacturing) is the concept of manufacturing production management, based on the continuous implementation of all types of inputs. For a flurry of throatiness on the basis of the Lean-system (a system of careful production), it is possible to practically implement an innovative approach to increase the productivity of practice. According to Suti, Lean-concept-Tse Pevna System, looking at the Vribnitniva organized bypass, the Vobrobnich Paradigm, and the realization of the INNOVENICH METHODOLOGICAL PIDSISHNISTICE VIBNITHNITH (this number of productive prazi) gossip. participation of personnel in the process of uninterrupted full-fledged business activities.

Acts of entrepreneurship through incorrect planning of activities do not detract from the necessary result, but rather cause problems. Then it is necessary to look over the current system and know new methods, so that entrepreneurship is not left out of business. Deyakі companies in such a situation take a guideline on dbayliv virobnitstvo. What is the essence of this concept? How effective is it for Russian business? Chi є apply positive zastosuvannya techniques? Report on all the nutrition of our article.

We can see from understanding

The term "gentlemanship" may be foreign. In the original, it sounds like lean production or lean manufacturing and translates literally "better production". Bydne - means not spared the cost, and not covered with indecent deeds and witrats.

This system of management was created in 1950 at the Toyota automobile manufacturing plant. The Japanese Taichi Ono became the founder. Having developed that supplementary concept of Сіgeo Сіngо, having put into practice the system of changeover as a possession, so it is with all stages of production preparation.

The specificity of the sparing production is based on the right to allow for the production of all possible vitrates, which does not allow direct introduction to the molding of the kіtsevoї vartostі goods for saving. The client does not want to overpay through those who are businessmen for non-profits, or through the wrong scheme of internal management. The less manipulation is required, the cheaper the cost of the product.

In the polypshenní virobnicheskogo process may take the fate of the spy workers of the enterprise, and chi are not alone cadres. So respecting Taiti Ono and yoga followers. For short-term vitrats, be it any way. For example, vіdsutnіst vіdsutnіst vіrobnіstva еtapu zberіgannya produktsії warehousing. The skin detail is only to be carried out in the necessary obsyazі and bazhano at that hour, if there is a stage in the selection.

In the car, on the conveyor, the parts are delivered according to the specified schedule and are not due to stale or delivered later, so as not to tamper with the process. Japanese tools for improving the manufacturing process in the company "Toyota" have brought success and adaptation to various business areas.

The main task of the core business management is an analysis of the manufacturing process. And also the improvement of efficiency for the rahunok of the old scheme. The main respect is directed to the manifestation of lanok, which is a process and creates the need for a dependent price.

Leather products can be of value, which is acceptable for the client. If the value of the goods is protected, then you can drink something new. Tse prizvede before restocking the warehouse and spend the corrected surplus. The type of product development will be disturbed by the process. Working force is not possible but vikoristan for confession, because it is not necessary for the short-lived state. Spacious versatility is the same management system that solves such problems.

Yak die system

If the clerks of the hospitality praised the decision about the sustenance of a thrifty brewery, then the first stage will need a consultation of the fahivtsiv of that nutritive person. You may be an independent consultant or company managers who have been retrained to develop a new concept.

The first task is a thorough analysis of the fluctuating system and the manifestation of weak legs, so as not to give value to the virobe, but to promote the kіntsev varіst.

The development of a new scheme after analysis - the use of zayvih costs, rationally zastosuvannya working force and adjustment. Ale, it’s simple to follow up without a response, so that the adoption of problems will not give a result. Therefore, the principles of prudent virobnitstva may still be implemented in sufficient quantities. Here are a few points, how to vindicate the main idea of ​​the update:

• Cіnnіst goods, oriented to klієnta, and chi is not necessary to write off all vitrati. It is necessary to do such a mind, for which no untransferred vitrates are claimed.
• Virobnitstvo is not guilty of being idle, it is necessary to organize a constant flow without downtime. Ring out the stink of blaming through the sight of the supply of sirovini, completing. At what stage do you look at each other with partners.
• Dotsilne vikoristannya obladnannya without overvoltage, tse can lead to failures of breakdowns and downtime.
• Realіzacіya goods odrazu klієntu without hiccups.
• The short-term transfer of products.
• The adoption of the possibility of a ship at an early stage, so that it will be possible to be accepted by the deputy once.
• Pragnennya thoroughness, as much as possible.
• Vicoristannya staff only for yoga profile, excluding duplicating settlements.
• Polіpshennya minds pratsі, equipping the working space vіdpovіdno to vomog.

You can think over your own methods, so that the implementation of technologies, which transfers more viability, was successful. The decisions are based on what you see in the cost of your business. The concept of lean production sees the main types of inputs:

1. Movement (transportation) of products.
2. Folding, overworking.
3. Fuss, zayvі ruhi staff pіd hour vygotovlennya, scho opіvlnyuє termіnі zdachi produktsії, zbіlshuє kіlkіst working years.
4. A simple brewing, if the components are not needed at the same time, or the delay in the preparation of the front miter will start the brewing process to the product.
5. The choice of goods at bіshіy kіlkostі, nіzh peredbacheno, without mozhlivostі realіzacії. Pіdpriєmstvo nese dodatkovі vitrati, yakі namagaєtsya compensuvati, roblyachi zayv cіnu goods.
6. Outdated technology or technology, as it is not covered for the preparation of products for the benefit of the client.
7. Shlyub virobu, which will require additional vitrates for processing.

Having improved over the overpaid types of expenses, you can significantly reduce the mark-up on products and get a high drink from the saver. Tse will improve the efficiency of the harvesting system.

Vykoristovuyuchi tools dbaylivy virobnitstva, you can know your own version of the control scheme. There are a lot of tools, so before the cob of the new scheme is introduced, the method is adapted in detail and adapted to itself. The scheme of the skin sphere is individual.

Today's practice of Japanese business methods

Thrifty virobnitstvo became demanded both behind the cordon, and in Russia. A lot of enterprises, having spent a lot of time in the situation, looked at different management systems and took lean manufacturing.

Apply Japanese conception of victories and you can work in various areas of business activity, medicine, education, government departments. Significant actions from them:

1. Vehicle manufacturing: GAZ Group of Companies, Solers Company, KAMAZ.
2. Banking systems: Oschadbank of Russia.
3. Life. Today's houses will follow the principle of sparing virobnitstv, they will soon spend not only in the life of a budding company, but further exploitation by sacks. New technologies make it possible to speed up heat consumption, change spending on utility services.
4. The nadanny of the sovereign servants also have the opportunity to promote lean manufacturing. For the prosperity of the population, functional centers are created, which follow the principle of a single window. A hulk can get away with some food to one operator and take all the information and service. There is no need to consume from a biganin from various departments. The provision of terminals for recording and electronic drawing, including the time spent for the recording.

Under the circumstances, they tried the method of sparing virobnitstva and took away a positive result, with skin fate becoming greater. Russia has created a map, denominated companies that promote the concept of lean production. Forums are held, de kerivniki share their opinion one by one and tell about their success.

A virobnicha system can be practiced without spending, so that the planning of the scheme is thought out to the point and not to stay at home, but to get better.

P_dvedemo p_dbag

The system of management "sustainable variability", having omitted the start in the automotive business, made a difference in various areas of business. Prospects for effective mining to fall in the field of quarrying. The concept is not practicable, so the optimization will be redundant on paper.

The audit does not solve the problems of over-the-counter business. Tilki active pіdpriєmtsі, yakі ready to constant work on usunennyam vitrat, zmozhut zapravadit new tools.

thrift management

Lean manufacturing (aka lean, lin-management, lean production) is a system of approaches, investments in cost reduction and improvement in the quality of manufacturing processes, which originated in the middle of the 20th century at the Toyota company and was vindicated by American successors.

Purposes of Sparing Virobnitstvo:

• 1) quick vitrate, labor zocrema;
• 2) abbreviated terms for the distribution of new products;
• 3) short term terms;
• 4) short-term harvesting and storage areas;
• 5) guarantee of delivery of products to the owner;
• 6) maximum pitch for singing vart, or minimum pitch for singing var.

The main elements of the philosophy of "Lean Production":

• 1) usunennya vtrat in all their forms;
• 2) training of all personnel of the enterprise to the full completion of the harvesting processes;
• 3) the idea of ​​​​the one who can thoroughly understand perfectly.

The Toyota company has shown these types of expenses, which seem to be typical for various types of businesses, both of a general and service nature. The struggle for liquidation became the basis of the philosophy of compassion.

• 1) Variety of surplus products. In the opinion of the owners of the Toyota company, the most expensive cost is the production of products in a great commitment, but it is necessary at the onset stage of the manufacturing process of acceptance.
• 2) Downtime due to organizational and technical reasons. Pokazniki, yakі zazvichay vykorivuyutsya for vimіryuvannya idle time and pracіvnіkіv, є efficiency of work obladnannya and productivity pracіvnіkіv. The less obvious one is a simple typing operator, who is engaged in work on unfinished products, which is not needed at the moment.
• 3) Transport. The movement of materials and details for the acquisition, as well as the subsequent or additional re-shipment (transshipment) of unfinished products do not add to the cost of final products of the acquisition. It is possible to reduce the cost of expenses, thus changing the scheme of distribution of the technological possession of the workshop, speeding up the transition between technological operations, establishing rational routes for the transportation of syrovin and beverages and making the correct distribution of the working areas.
• 4) Technological process. Dzherelom vtrat can become the technological process itself. Deyaki virobnichi operations є the result of the recent design of the components of the production process and the processing of materials and the filthy operational maintenance of the installation. Therefore, the process of thoroughly organizing the viability of them can be painlessly eliminated.
• 5) Stock up. Be sure to stock up on the responsibility of the clerk of the entrepreneurship of the organization to know the possibilities for their liquidation. However, it is necessary to fix the reasons that call for the appearance of stocks: if you eliminate these causes, you can achieve a reduction in liability (or a new liquidation) of stocks.
• 6) Rukh of the practitioner at the work station. Wondering from the side, the worker can get busy, but in truth I don’t create any added value of the robot. Greatly dzherelo reduced costs, which are blamed through the zayvi ruhi, - robit is forgiven.
• 7) Defective products. Lose your viability due to the low quality of the products often become even more significant. Zagalni vytrati on pіdtremannya kostі produktsії є richly, lower tse vzvichay vvazhєy, і it is important to show the reasons why yelling qі vitrati.

Jeffrey Liker completed the testimony of Toyota in the order of James Womack and Daniel Jones. In the book “The Tao of Toyota: 14 Principles for the Management of a Leading Company of the World”, he pointed out the eight types of investments: non-realization of the creative potential of spivrobitnikiv (waste of time, ideas, newbies, opportunities to improve and get through disrespect to the spіvrobіtnikіv, like you).

Chet Marchvinsky and John Shook show two more dzherel vtrat - mura and muri, which mean "irregularity" and "overwhelming".

Mura - the unevenness of the robotic work, for example, the graph of the work is screeching, the calls are not made by the call of the end of the spozhivacha, but rather by the peculiarities of the virobnic system, but the uneven pace of the work from the victorious operation, so the operators are stunned, slow down, hurry up. At rich vipadkah managers of the building have a lot of nervousness for the time being, viruvnyuvannya planning and respectful setting up to the pace of work.

Muri - re-adjustment of the operator's work, which blames the hour of work with a greater swedish pace and with great effort for a long time - against the rozrakhunk's adventurousness (project, labor standards).

James Womack and Daniel Jones share the following principles for lean management:

• 1) Appointment of the value of the goods.
• 2) Appointment to the flow of cіnnostі goods.
• 3) Vibudovuvannya uninterrupted flow of cіnnostі goods.
• 4) Vityaguvannya goods spozhivachem.
• 5) Pragnennya thoroughness.

Zokrema, the JIT system is designed to ensure a safe and uninterrupted flow, but it’s better to wash your mind for a significant speed change in the hour of recharging. A fast hour for re-adjustment of possession - a fast hour for a transition from one type of activity to another. Tse gives the possibility of making a trio of some details, reversing the versat, growing a trio of other details too. So the details can (and may) be prepared only once, if it helps the next stage.

The main principles of double brewing are based on the use of singing tools, for the help of which companies create their own brewing processes.

Taichi Vono wrote that Toyota's system stands on two "pillars": the jidoka system and "just in time".

Postachannya "exactly in term" (just-in-time) - a method of planning and management, as well as a philosophy of planning, a method of such a negaine satisfaction of a calm drink with high quality without cost.

The term "exactly in the term" literally reflects the best understanding. It means the release and delivery of goods and the same services, if you need them: not earlier, oscills in this weather stench check your hour in stocks, nі pіznіshe, oskolki they will be able to check on the deputy. Krіm factor time, scho mіstіtsya in JIT, before the concept of tsієї kontsії enter vomogi akostі and effektivnosti.

What is the difference between JIT and traditional approaches to the organization of the harvest? With the traditional approach to the organization of the production of speeches, the leather stage of the production process “stores” the finished product into stock. Such a stock is a buffer inventory, or an insurance stock for an offensive production stage, which is “lower” in the process of a hard process. This offensive stage of production takes the unfinished product from the stock, refines it and transfers it to the buffer stock. Tsі reserve act as a boundary, scho cremating the skin of the virobnichiy stage in the case of the suicidal stages. Buffer reserve to slacken the skin of the virobnichesky stage is apparently independent, and to that, for example, at stage “A” for some reason (for example, as a result of an out of tune) the robot starts to work, the lot “B” can continue to work for a long time. Dіlyanka "C" can continue the robot more generously, oskolki її the robot will provide two buffer reserves, and it won't be possible to attach the robot only after the destruction of the entire stock. However, the cost of insulation must be paid for by the reduction of reserves (working capital surplus) and reduced throughput capacity (increased response to the drinking of the workers). Do you think there is a head argument against the traditional approach to the organization of production.

Released for the next hour of picking "exactly at the same time" the products are delivered without interruption to the next stage of picking. Now the problems that are blamed on some sort of manufacturing stage, for the whole process of manufacturing another injection. For example, if stage "A" ceases to produce products, stage "B" is worth noting the price, and stage "C" is also sooner. The problem that vindicated the “A” stage is now quickly becoming visible to all systems, but the shards of the problem are embedding the system into the whole. As a result of this, the responsibility for solving the problem is now not less than the responsibility of the “A” personnel, but is extended to the entire staff of the enterprise. This is the essence of the imovirnist operative solution of the problem, because it is important to ignore it. In other words, not allowing the accumulation of reserves between the stages of production, acceptance will take away the mechanism of increasing the internal efficiency of the enterprise.

Jidoka (autonomization) - the introduction of human intelligence to automatic attachments, buildings independently reveal a defect, after which I will immediately pick up a line and signal about those who need help. Autonomousization wins a subordinate role. It includes overproduction, it is important for the storage of waste products, and it avoids the production of defective products.

Between the two systems, you can see the following elements of lean variability: kanban, five-S system, total productive maintenance (TPM), shift changeover (SMED), kaizen.

The term "kanban" (kanban) in Japanese terminology means a card or a signal. Such a card is the simplest way to manage; it will be zastosovuetsya in order to allow (give a signal) the supply of materials in the control system of the type that drags, similar to tієї, like winning in the JIT system. Use different types of signs "kanban": "kanban" moving or "kanban" movement. "Kanban" is moved to wink to give a signal to the front lot about those that the material can be taken from the stock and straight to the next lot.

The production "kanban" is a signal to the production process that a detail can be released for one product of the offensive and relocation to the stock.

The "Kanban" seller is victorious to signal the postal manager about the need to send the material or details to the production line. Whatever happens is similar to “kanban” relocation, but sound victorious when interacting not in the middle of the organization, but among the outermost post-employees.

Although any type of kanban system is victorious, the basic principle is always the same: the development of kanban starts the movement, the choice of supplying one product unit and the standard packaging of such units. As a rule, two “kanbans” were taken away, as a signal about the relocation, or the delivery of two single products, or two standard product packages, and so on.

Establish two rules that define the choice of the kanban system. The stench is also known as a system with one and two cards. Most of the time, the system is installed with one card, the shards are the simplest. We have no more "kanban" relocation (otherwise "kanban" is a seller for picking up materials from the same dzherel). In a system with two cards, the “kanban” movement and rotation are blocked.

The “five S” system can be used to set the basic rules for fast spending:

• 1) Sorting (Serti - Seyri). Take those that are not necessary and take those that are necessary.
• 2) Create your work place (Seiton - Seiton). Put out the tools in the order in which the stench will be easily accessible.
• 3) Keep your work place clean (Seiso - Seiso). Treat your tools in order and cleanliness; in a working place, it’s not guilty of buti smіtya that rubbish.
• 4) Standardize (Seiketsu - Seiketsu). Set a standard for everything that meets the standard.
• 5) Learn to improve the singing order (Shitsuke - Shitsuke). Develop in your own needs from the standard order, that pride in the price.

These rules add the main respect to the order of the day, the organization of the distribution of tools and other necessary items, cleanliness, standardization of the working environment. The stench is recognized for the adoption of all possible expenses, associated with insignificance, points, searches for the necessary information, which creates instability in the working environment. With the help of the adoption of everything inappropriate, as well as the replacement of tools and necessary speeches in purity, it is possible to reach the necessary order and to ensure the post-processing of necessary speeches in the very same place. Already, one thing, it would be easier for a robot to work, and the hour would be short.

The meta of complex service maintenance (total productive maintenance, TPM) in order to reduce the shortness of minds for an hour of manufacturing processes, calling for unplanned adjustments. It is possible to reach all personnel by the way to the possibility of improving the service. Specialists, who are responsible for this process, will want to take responsibility for victory, take care of daily maintenance and carry out simple repairs. At the same organizing service, the serfs of the Fakhivtsi Zekspiyatatsiy can be renounced for more than an hour for the pirdvishennya of the Kvalifіkatsiye, the priestly vocabulary of the vishgovyanniy ribs, the service of the servant systems of the billed systems.

Shvidke changeover (SMED) works with an hour of changeover (the hour required for the transition from one type of work to another). A fast hour of changeover can be achieved in various ways, for example: a short hour of searching for the necessary tools and possession, a day’s work, through a changeover, you can get stuck, as well as a quick change when you reconfigure some of the receptions.

The "kaizen" system focuses on the uninterrupted thorough processes of manufacturing, development, additional business processes and management, as well as the successful aspects of life. In Japanese language, the word "kaizen" means "without interruption to perfection." In the context of the strategy, everything is thoroughly worked out in the process - from managers to workers, moreover, the implementation requires only small material costs. The philosophy of kaizen admits that our life as a whole (labour, community and private) can be oriented towards sustainable development (Fig. 10). The scheme of linking "kaizen" and other tools of lean manufacturing is shown in Fig. eleven.

Rice.

Rice.

To promote lean thinking, James Womack chants out an offensive algorithm (Mal. 12):

• 1) Find a change agent, a leader. Call out the role of victorious one from the company's core. It is more important that you be one of the leaders, which you can take on yourself for future changes.
• 2) Gain the necessary knowledge according to the system of careful selection. The agent of change is guilty of changing the minds of the ideas of sparing virobnitstv, which is the stench of the other nature, otherwise, all the transformations of the militia will swell, with the first recession of virobnits. At the same time, there are a lot of ways to gain knowledge. Before them, we can see the literature, in which case we do not reject the initial courses (seminars, trainings), which are controlled by numerous consulting companies. We can also tell you, perhaps, about the introduction of one of the enterprises, which successfully carried out the big business.
• 3) Vikoristovuvati or create a crisis, as if you become important. The very crisis is a good motive for promoting the concept of "Lean Production" in the organization. It's a pity that a lot of company workers understand the need to win a thrifty approach, less likely to run into serious problems.
• 4) Describe the flows of creation of value. On the back of the mind, the current camp of material and information flows. Then let's create a map of the future, for which operations and processes will be turned on, which do not create value for the savior. After that, designate a plan for the transition from the lowest to the future.
• 5) Yaknaishvidshe more accessible, but important and visible to all activities. In rich situations, it is recommended to change the transformation during the process of physical transformation, so that the results of the changes become more memorable. In addition, it is possible to begin with processes, which, being very important for firms, prote, are already badly beaten.

Rice.

• 6) Pragnati take away the results of vikonan work and yaknaishvidshe. Negative turning point is one of the most important characteristics of the Lean Production concept. Pratsіvniki povinnі bachiti on vlasnі ochі, like new methods to bring results. It is psychologically important to say that the organization is really starting to change.
• 7) As soon as the good fortune appears, the distance collapses. If you remove the first local results, you can start to make changes in other parts of the flow of value creation. Slid to expand the scope of an infusion of sparing virobnitstv. For example, transfer the technique of virobnitstva to offices, vikoristovuvat practice of uninterrupted polypshenya (kaizen).