Saving flexibility is the system of business management, as it helps to save costs and increase the efficiency of the business. In the article, the essence of the system is explained, and it is about the key principles.
Thrifty virobnitstvo - tse.
To put it briefly, it is a culture of virility, and not a set of tools and methods for improving and improving the efficiency of work. The system polagaє in post-yyy pragnenny usunennya vsіh vidіv vtrat.
The implementation of the concept of lean production conveys that the practitioners of the enterprise know the basics of this theory, accept it and are ready to work their own activity in the future.
How did the system appear
The concept was born in Japan after the Other Light War, if there was a need for large-scale development of industrialism, infrastructure, the edge of the land, and the resources were in the edge of the exchange. In such minds, the founder of the concept - Tayiti Vono, introduced his control system at the factories of the Toyota company.
Late American researchers have transformed the Toyota production system (TPS) into a Lean manufacturing system, which includes not only the Toyota concern, but also the leading edge of the Ford company, the work of F. Taylor and E. Deming.
Chotiri kroki to dbaylivy virobnitstva. Zasosuvannya practice.
Philosophy of the concept
At the basis of the concept lies the assessment of the value of the final product of the spazhivach. Therefore, all the processes that are involved in the undertaking are looked at from the look of the creation of additional value. Meta - minimizing the processes and operations in the production process, so as not to add value to the product, in order to waste it.
There are 8 types of main costs:
- Perevirobnitstvo, contamination of the warehouse of finished products.
- Refinement. For vіdsutnostі nalagodzhennogo virobnichigo procesu blame prostoї, ce dodaє vartostі goods.
- Necessary transportation. The smaller the movement of material values in the open, the lower the vitrati.
- Enter the stages of processing, so as not to add the essence of value.
- Please stock up on supplies and materials.
- Shlyub that defects. It's a waste of money, as it is seen on windows and images of business.
- Unrealized potential of practitioners. Trust that respect for people is a key element of the system.
- Overwhelming that downtime due to insufficient planning.
Regardless of the position of entrepreneurship in the market and yogo financial performances, you can constantly improve your processes. The organization of the system of thrifty production is not a one-time action following the principle of “making good and everything works”, but an uninterrupted process that goes through many fates.
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Principles of double vibrancy
By the way, the methods of dbaylivy management of virobnitstv appeared. There are about thirty of them, but in the article we can look at the main ones - for the most wide range of businesses:
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Apply the most common concept of sparing cultivation in Russia
For over 15 years, GAZ Group has implemented the lean system and achieved the following results:
- 30% reduction in commitment of unfinished production;
- increase in labor productivity by 20–25%;
- shortened time for recharging up to 100%;
- Change in the production cycle by 30%.
In 2013, RUSAL began to connect to the system of careful selection of post-employees, we are ahead of the transport company, because spend on logistics to establish a greater part of the co-production of products. Such a discount gave a saving of 15% on a five-year stretch.
Comprehensive development of methods of sustainable manufacturing in the KAMAZ association has made it possible to achieve a significant economic effect:
- 1.5 times decrease in tact,
- vivilnennya 11 ths. pieces of oversized containers,
- short-term reserves for 73 million rubles.
- shortening of harvesting areas by 30%
The way to success in these companies occupied from 7 to 15 years. It's a pleasure for those who have started the system - don't send a chat for the daily results in the next month or so.
Technologies of double vibrating
1. Value Stream Mapping
Mapping - graphic representation of business processes of entrepreneurship and further optimization (div. ). The process of transferring the creation of a clear and sensible picture of the formation of value for the client - the product of service. As a result, you will find big spots on the choice and the most important paths until the situation improves.
2. Vityaguє stream production (pull production)
Sensation at tsomu, the skin of the front stage virobles less than those that call for a new attack. Let’s stay calm at the lancer’s stage, the winding mechanism means maximum customer orientation. Kіntseva tsenl - "potіk in one virіb", de goods to the skin stage are virobljaєєєєєє on zamovlennya, so there is no stock of syrovin, no unfinished production, no stock of finished products warehouse. Such a mechanism, better, utopia, but still respect for the management of stocks and the link to the minimum, is the ultimate tool for reducing costs.
CANBAN in Japanese translation is a card. The essence of the method lies in the fact that the parent - the "deputy" forms for the parent - the "post-employee" a card of the order and the "post-employee" secures the "deputy" exactly with the obligation of the syrovin, the component parts or the finished product, as it was promised. CANBAN can work not only in the middle of one enterprise, but also in the middle of the holding or in the middle of the company. In this way, industrial warehouses and warehouses of finished products change to zero. Ale zastosuvannya CANBAN tool transfers high to the world of uzgodzhennosti mizh lanki lancers of deliveries. Another important plus of the system is its own display of the ship, as if it was attached with mass deliveries. That is why the CANBAN method is not only “zero inventory”, but “zero defects”.
4. Kaizen (KAIZEN)
Zlittya two ієroglіfіv "kai" and "zen" ("change" and "good") - this is the philosophy of uninterrupted thorough business processes and the skin-enhanced process of zocrem. The tool is a good one, which shows a deep method of working on processes and can get stuck in any sphere, inspire a pose with a robot. The idea of kaizen in that, leather practitioner, from the operator to the company’s manufacturer, carries the value and pragmatic value of that part of the process, like the wine is responsible.
The 5S system is one of the methods of sustainable manufacturing. The system determines the productive organization of the work area and the improvement of work discipline.
6. Just in time (just in terms)
A tool for careful selection of the transfer of preparation and supply of syrovina, parts and components not earlier and later than the moment of vindication, consume these material values. We will describe the reason for this with the help of “Vitaguychim vrobnitstvom” and help to reduce the excess of syrovin in warehouses, save money for that relocation, and increase the penny potik.
7. Shvidka changeover(SMED - Single Minute Exchange of Die)
The method of calls to speed up an hour of idle time and an hour of changeover for the help of reworking internal operations on the phone. Internal operations - tse, yakі blyayutsya pіd h zupinki zatаtkuvannya, zvnіshnі - tі, yakі zdіysnyuyutsya, docks yystatkuvannya still work chi work.
8. Total Productive Maintenance System
The transmission system, which takes the fate of all the staff, and not only the technicians, at the service station. It is based on both the choice of the most high-yielding and modernized possession for business, as well as the security of maximum productivity, the continuation of the term of service for additional schedules of preventive technical maintenance, oiling, cleaning and overhauling.
9. Poshuk plashkovy neck
Abo, іnakshe, poshuk slabkoї lanki. An instrument of foundations on the fact that in the field of research it is necessary to know that expansion. It is necessary to deal with the search for a weak Lanka periodically, for whom the charge is thoroughly.
10. Gemba. "Battlefield"
This tool of exhortations is to make a fool of what the main day (“battle”) is above the head office, and in the workshops. Ce planning (regular) or unscheduled (for example, through a problem) vyhіd kerіvnіkіv on vyrobnitstvom, which allows you to increase the amount of brіchіnnyа karіvnіkіv before the process, take the information “first hand”, be quick between practitioners and kerіvniki.
Tse pitanya to set the enterprises of the industrial sector, the production of material goods. And it will be the core of the sphere of services, IT and social projects.
Lean Management (also called "method of sparing virobnitstvu"), like the philosophy of Kaizen and others, can be stagnant in the skin business and processes. Everything can be optimized. The goal is to think productively, and not just a tactic for betting algorithms.
Lean production
Synonyms in rich: dbaylive virobnitstvo, dbaylive management, dbaylivey mislennya... navіt thrifty transformation. Thought and transformation (in the English itself the word "reformation" can self-sufficiently mean lin-methodology) as philosophy and theory of business management, as practice.
Words reflect the idea like i virobnitstvo "exactly at the same time", at Toyota, it is the first in history to use the method of continuous assembly line assembly of automobiles. Tayiti Vono is an engineer-retailer of the principles of philanthropy following the Other Light War.
Yogo postulate:
- Usunennya vіdhodіv,
- inventory change,
- productivity boost.
At that hour, like Henry Ford on his campaign line, having boosted the resources "for better drinking", Toyota vibudovuvaly partnered with the post-employees, and after the fact they robbed the car for zamovlennya.
A lot of industrial start-ups are being started already with a transformation, zastosovuchi methods and tools from the start of the development and support of customers to the rest of the stage. The Bagatori business can also be re-awakened from the old “regime” on a new mind, if only that patience is required from the Kerivniks. Tsej slyah vygіdnіshiy v dovgostrokovіy prospects.
How the system of careful variation changes the hierarchy in the structure of the company. Deputy managers and staff form a community rich profile specialists. Use the resources of the company, inspire people - to stand on the ground, you can ask for improvement, you can change your idea in practice, and you can win a complex result. This flexibility allows you to make changes instantly, and then, and respond to the demands of the quick, vipadi competitors and praise the market.
What is Lean management
In a primitive interpretation Lean or thrifty virobnitstvo - methodology, yak usuvaє all pereskodi virobnitstvu. Take the time and resources to get the result. How can the process be broken svidche, yakіsnіshe and cheaper- Tse varto zrobiti right away.
The revision of algorithms in robotics is carried out in two stages:
- Analysis. To understand, what is the best practice for the company’s current order, conduct an analysis of all processes and fold the scheme. Script to the call center, algorithm for accepting applications, logistics, turnaround work in the online store; scripts for technical support, processing requests from bugtrackers, retrieving updates from product IT companies. Write down the whole order, vyznachte filthy mist yourself, or download the programs (whether it be software for visualization of algorithms, plush necks, resources at that hour).
- Changes made. Knowing the "inconsistency": problems of coordination of work, marriage of resources or outdated bureaucratic processes, advocate an alternative. The alternative can be used and brought to life by innovation, cardinal changes and ideal solutions. Just a better way to grow. You can sort out the options requested by the team. Only not in my head, but in practice. No one knows for sure what will appear in your project itself. Vigodi and vitrati skin alternatives look at the results of the practice. The best variant is still valid.
І tsі two stages are constantly repeated. Sparing virobnitstvo is not a vikonanim. Tse neskіchenne vdoskonalennya at drіbnitsyah. From Lean there are no grandiose innovations, only without interruption in small steps.
For director
The main head of management is the profitability of the company. One of the ways to achieve this will be to solve problems and reduce the amount of money spent on the production, and in the other - focus on the production value for the client the product has services. Naytsіkavіshe - having correctly determined the value for the client, you can straighten the strength of the team and material resources only on important ones, but speedily vitrati on unimportant ones.
This is how Lean helps to protect the company's robotic algorithms without wasting power and hacking the maritime processes.
For example: the client will need woodworking tools.
- What is really important for the buyer? Price, functionality and delivery are important for everyone. Ale є clients price oriented(budget models are cheaper) and focusing on brightness(implementation, which allow folding and exclusive projects with cuts). You must stink and want to take the verst at the master’s swidko and neatly.
- What can you optimize and improve? Raise the quality, so that the price is correct. Select licensed products with certification according to your best wishes, you can conduct instruction. Send the delivery for the help of a superior logistics agency, with the help of a taxpayer.
- What do you pick up? Take away everything that the robots respect.Є car repair plant with geographically separated workshops. Every day, managers get to the head booth for a planning meeting to satisfy the list of jobs. If you want to run a single control system on the right - you can spend an hour of planning meetings, and 7 years of skin care for the workshop for a week.
- What work and how to win loyal customers? In the eyes of the client, the purchase algorithm looks like this: firstly, accurately select the versat model, then choose the delivery address. Ask the client to authorize and enter the address until the choice of goods will not be accepted by the client. If the address is entered, then, as an online consultant at the end, which merges, additionally selects a model, configuration and other nuances - the client already knows the agreement and satisfaction. Values for the sapozhivacha dotrimano, the head of the convoy pid hour. From the side of the company, there is an algorithm - it is impossible to oversell, the docks have not been paid. Tse honestly and pozbavlyaє problems іz oshukanimi ochіkuvannyami both storіn.
Meta director of the Lean methodology: to bring the process of virobnitstva, sale and delivery of the goods to the client to іdealіzovanoї doskonalostі. Whose emphasis is on the benefits of the client, and who is not the company. The benefit of the company becomes a success, the savings of time and resources and the hour of production and increase in income.
For staff
What is the dbaylive choice for the manufacturing plant or the center of the technical support of the IT company? The methodology for protecting the sirovina is correctly established, it encourages the mind to work and helps the employees to earn more.
Lean in the undertaking needs to be done correctly. If you thoughtlessly twist the method, then the twister can:
- save - buy non-standard components
- rearrange the equipment in the workshop for quick installation between conveyors, but forget about the long supply of electric cables
- prescribe a calendar of experiments and fence unplanned creative
- launch fines for breaking working tools, but do not overdo it
- add your option.
The Lean methodology encourages a constant exchange of ideas among fellow workers.
As such, the methodology has been adopted in the team - whether a worker at the plant can propagate to the director his idea of improving the working process. That is why the practitioner, who is imperceptibly victorious over the working process, needs to work better, where it is possible to improve at this process. With the constant implementation of such propositions, the plant will significantly increase its efficiency.
And the worker will be wine-growth, as if the idea will appear as a brown one. We take carte blanche to try out our ideas in practice. Only by trial and error you can know the right way and thrifty choice recommend trying and improving gradually.
For example, a handy mobile organizer will speed up the number of missed deadlines and improve the speed of work and help marketing and design. The choice of the company will save you an hour, as well as a thrifty virobnitstvom.
For company
І kerіvnik kompanії, і ryadoviy vykonavets the project with their own dіami create cіnnіst goods for the client. Only on the basis of directing all the susilla.The benefit for the client is not blamed for some moments- the fact of the choice of goods, acceptance of purchase, complete set at the warehouse or date of delivery.
Value is created by the flow of processes, oriented towards the result:
- an online consultant helps to choose a rozmir, a model and a color;
- when making a booking, you can choose the method of payment by credit card or by a courier;
- the complete set includes a guarantee, a coupon for a replacement or a return, gift cards or a request for a thematic visit;
- you can name the date and hour of delivery, call with the courier or choose the best store for self pickup.
The non-linearity of work and all companies allow you to ask flows, change their algorithms in such a way that you can save money, increase the price for the same cost or just lower the skyline and turn.
Let's consider the net value and the number of defective examples is important to the client customization product, especially in the slower segment. If a company can, without costly expenses, change its own conveyor, viroblyat rіznі or a new model product, then we will definitely overcome it in a competitive fight. Naviti zrobiti zbіrnі individual kits from the basic details, or to apply exclusive measures for the construction, even more importantly for the market.
Muda, mura, muri tse
This is how the Lean methodology names the inputs and the vitrati. All zaive, sho varto tidy up. Everything that does not convey the value of the client. Muda, mura, muri - words from Japanese language, miraculously took root in English business slang.
- Come out, marni vitrati. Last pardons for management.
* Muda, yakі add to deyakih classifications.
- Cause muda. Nerіvnomіrnіst і nіdpovіdnіst navantazhennya, perevantazhennya.
Seasonal, regular, advertising-filled squishy drink may have a powerful rhythm, clock frequency (day, month, quarter). We analyze the decline and the anger of the drink, the demand for the over-the-counter goods from the model range. Predictable, rozpodіlyaemo vanatazhennya that zavdannya.
- Ignorance. Uncoated foldable robotic.
Muri | In industry | |
Non-core work | Put a sales manager up to the conveyor line for the shop. Appoint the third squad of gifts as the director of the plant. | Vikonannya zavdan yakі mаyut vіdnoshennia before planting and rozvinennym newcomers. Send a layout designer to the call-center. |
Poorly equipped work space | One set of tools for 4 installers. | The trainee may have a laptop, but he does not have any antivirus and the necessary specialized programs for robots. The designer has an old pirate photoshop. |
Fuzzy instructions | The annotation was able to be spelled out, swayed by the eye. | “Build a living room layout, and the buttons are just wow!” |
Vіdsutnіst іnstrumentіv і obladnannya | One printer at the office of the director of accounting is constantly working up to new. | A programmer is hired with a wet laptop and a person who needs to carry yoga to the office, so it is not possible to buy and equip it with a stationery. |
Vіdsutnіst of reliable technical service | The conveyor line is old, the technical service is stitched on the pivroku-rіk. | The system administrator does not systematize and sign the cables in the server station. The hour for the search for inaccuracies is multiplied by a sprig of times. |
Nenadynye processes | Irresistible technologies of syroving processing, abstractly bringing the methods and appearance of those sumnivnі ideas in virobnіstvі. | Monkey testing is the only way to test programs for bugs (forgiveness). |
Poor communication and call | Filthy chutnіst have racії on the territory of the shop. Fighting with the director's secretary, if it's important to mention the term about the NP. Bureaucracy. | 2 mobile numbers, 8 messengers, 3 emails and 5 social services to take good care of your business. |
The essence of a thrifty transformation is to take away all the muda, muri and mura. Razumіyuchi їх causal-hereditary links, you can focus on the coils of problems, so that later you don't clean up the skin rubbish.
Benefits of Lean methodology
A skeptic would say, now you need a more thrifty transformation, so you can just zastosuvat a couple of standard instructions for fighting from the blues of GOSTs and speed up the paper on the bureaucracy in the enterprise? Methods of sparing virobnitstva as a strong tool, but without understanding the philosophy and the structure of the structure, it is completely impossible to get away.
Tse yak univerіvske knowing-having-forgotten. If I sleep in my head, I will lose less “fuh!” and zastosuvat practically nothing. So, just once for an instruction, having put in a couple of algorithms, you won’t do it thrifty, but you won’t do it thrifty. Lean - tse permanent changes. To carry out the modernization carefully means to make the methodology true.
All essence at dosvidі, vіdpratsyuvanni practical. Only after a special report, testing theories and collecting data, it is possible to analyze and develop new stages of experiments. Put yourself such a cycle as the norm of zastosuvannya corrective action, struggle with muda, muru ta murі.
To start the project from the beginning with the lean methodology, you need:
- pick up all the information about the upcoming task,
- segment її on subtasks, expand and test їх okremo,
- allocate all terms and budget on the basis of the selected information from competitors or past government projects (rely only on real data to replace abstract theories
Principles of double vibrancy
Based on all the muda, muru ta muri, there are exactly 10 principles of sparing virobnitstv:
- Likvіduvati smіttya
- Minimize stock
- Maximize Potik
- Vyrobnitstvo lie down in the wake of a dead drink
- Nobles help clients
- Zrobiti correctly the first time
- Expand the possibilities of practitioners
- Induce the system with easy replacement of її parts
- Build partnerships blueprints from post-employees
- Create a culture of fasting
There are also three main tasks for business. The stench directs the transformation of all companies:
- Tsіl. What are the problems of the client of the company, the end value of the help?
- Process. Criteria for evaluating the cutaneous flow of the value? Re-verification of the algorithms of the lancers' tails, the struggle with outputs, underestimation and re-adjustments. Leather croque tsinniy, real, accessible, adequate and flexible, and streams that pour evenly.
- People. How do you share the viability for the skin process and the potik of virobnitstva? Close a person not for a settlement, but for a process, a trusted whole? The curator of the zavdannya forms the creation of values at a glance of business goals and actively encourages a thrifty transformation.
For an individual development in the kar'єri qі zh three basic tasks look like this:
- Yaka goal my work?
- Process to generate the best results in the most efficient way?
- Who are you people How do I create value?
The principles of the philosophy of Kaizen - without interruption to perfection
term kaizen- consists of two Japanese characters kaisen: kai - changeі zen - good. Change for the better, without interruption, thoroughly, transformed for good... It is important to say that the theory of philosophers is a practical method of management. Kaizen symbiosis both understand what allows them to promote and quickly test their ideas on how to improve the work of business. Lean transformation resembles the practical part of kaizen, and is rooted in yoga philosophy.
Kaizen is trimmed on five pillars:
- Rivnopravne interaction all peers (caregivers, managers, workers) and direct communication between them
- Individual discipline
- healthy moral camp team and skin special
- Gurtki yakosti
- Propositions according to the completions of the entire type of work and assembly line to the method of evaluating the work of the company.
Read more about Kaidze in the next article.
Algorithm
For James Womack, founder of the Lean Enterprise Institute and author of several books on reincarnation:
- Choose a leader - a leading conductor of changes
- Take a look at the nadiy dzherel knowledge about line and kaizen
- To know how to create a crisis - a problem, as you need a negative cherry
- Experiment, practice, analyze the results in a row - do not get carried away with a loose strategy (brought to you by the Wright brothers)
- To induce real and bazhany maps of the streams of the creation of values. The stench is guilty of arguing
- Ensure transparency of results for all staff
- Speed up the hour of the virobnic cycle (accelerate the flow)
- To conduct kaizen and continuously develop the company
The axis of which is the beginning of the choice of sparing virobnitstv. Possible tools:
- Value Stream Mapping
- Pull production
- Kaizen
- Poka Yoke
- Total Productive Maintenance (TPM)
- Just In Time (JIT)
- Visualization
- U-like centers
Apply zastosuvanya thrifty virobnitstvom
Competitiveness of the company often depends on the following criteria. Shvidka savory pizza delivery can just be savory pizza. Car customization at the official car dealer tsikavish for standard basic equipment. And the results of private medical analyzes will be torn apart for the best for the stingy prescriptions from the district polyclinic.
To secure superiority over competitors (speed, customization, quality of follow-up) you can continuously improve the project management system, like robbing a lot of companies in the world.
Successfully passed lines:
- USA: Toyota, Alcoa, Boeing, Pella, Emerson Electric, Jacobs Equipment Company (Danaher)
- in Europe: Motoman Robotec, Unior, Iskra Asing, Volvo, Metso, Nuon
- China: Lenovo, Suntory
- state and municipal departments of the wealthy lands.
Software and tools Lean
It is easier to transform in a modern company, less than 30 years ago. For Android and iOS there are a lot of programs of the same type that help you save money and invest in business.
The tools of sympathetic development are used to motivate the staff, encourage communication between the workshop and the kerrivnitstv, analyze the results of the promotion of new ideas and the manifestation of inputs from the work of the enterprise. Testing and experimentation, development of the pipeline system or a bug tracker for programmers - all software for line methodology.
Worksection - Saas service, in addition to the latest project management functionality, Gantt chart and call types.
Gantt chartallows you to see the interrelationships, chronology and chronological order. At the ranks, the lines of the tasks and the transfer of the budget are assigned.
At the razdіlі zavdan “for people”, the kerіvnik can see the obsyagi rob on the skin of the person who is idle. It is so easy to identify the wrong distribution of human resources.
So the fight is muda, mura and mura become more and more idle.
It is possible to create an okremium project “proposal of the team”, to create the ideas that are being developed.Set a deadline for two tizhnі chi months, test the idea, discuss the process in the comments and then analyze the result.
If the idea is good - it's enough to pass through.
Oracle
Most of the time, the company's managers zastosovuyut programs for Oracle or virtual services for project management.
Lean App
The most important addition - LeanApp for iOS allows you to systematize and control all the processes in the company.
Verdict
Companies are promoting greater viability in the whole world, but not all stinks are flourishing youmu. Too many who do not know how, do not understand philosophy, or it is wrong to put in practice the instructions.
The essence of the methodology
- Usunennya vіdhodіv,
- expanding the rights and possibilities of practitioners,
- inventory change,
- productivity boost.
The way to start is individual, to deposit in the presence of rich factors is the advantage of the segment of the market, target audience, goods and services, priority and competitiveness of the company.
Start fighting with the exits at the “naive” places, the flow is working - there, de pardon is critical.
To know the crisis and її virishiti more effectively, lower thoughtlessly to use the lin algorithm.
read
Lean manufacturing, or lean production, is more than successful in helping a lot of Russian enterprises. In 2017, the DSTU series of lean manufacturing was introduced, but far from all fakhivtsy know about this concept. For young professionals and companies, who are looking for the best way to improve efficiency, the material can become a guide to the world of lean production.
2 8 15/11/2018
Why did it all start: from the crisis to the concept
The history of thrifty virobnitstva rose from the crisis at the Toyota company. In the 50s of the 20th century, a financial crisis was brewing in post-war Japan. Vіn buv іz vysnazhennyam finansovyh i virobnicheskikh resursіv. The only way to survive the business was to increase the quality of products with an overnight decrease in co-production.
At the same time, Tayiti Ono, the father of the concept of prudent manufacturing, became the chief director of the Toyota Motor plant. After inventing and implementing a unique manufacturing system, the Toyota Production System (TPS) was later called. Vaughn was primed on the revealed operations, which added value to the patient and shortened unproductive vitras. From that moment, the gold of the century of the Toyota company began, as it successfully entered the world market, facilitating the favorable prices and the quality of its cars.
At the beginning of the 80s, Toyota cars appeared on the US market. The stench has become unbelievably popular, having taken over a small part of the market from the Great Three automakers in the United States. Shortly before Japan, a group of American scientists attacked the Toyota plant by James P. Womack and Daniel T. Jones. As a result of following Toyota's brewing system, they formulated the concept of thrifty brewing and wrote about it in their books, which later became bestsellers.
Although the concepts of lean production and TPS are based on the Toyota production system and their principles are even more similar, experts distinguish them in the following way: TPS is the path of a particular company, which is unique, and sparing variability is a set of methods, tools, frustrating the philosophy tsmu. dosvidi that can be implemented on other varieties
8 types of expenses
Tayiti Vono, standing up for the fight against unproductive expenses (muda), so that the change is to be some kind of activity, as it saves resources, and not to add value to the end of life. For whom, in the first place, it is necessary to designate an operation that will increase the value. It's not easy. And you need to pay the minimum for the decision of the operation.
Let's take a look at the butt of the farbuvannya fence. The worker takes the farb and the penzlik from the warehouse, walks to the parkan, zanuryuє penzlik at the farb, spend a few times on the parkan, repeating the cycle, regularly clean the penzlik, for example, working change wines, bring in materials that are left in the warehouse, and then the boss misinterprets the robot. From all the descriptions of the operations, only those carried out by a penzlik on the parkan add value to the survivors.
Tayitі Vіn vydіv sіm osnovnyh grupp vtrat. The eighth group was formulated by Jeffrey Liker. This type of vtrat has also become canonical for dbaylivy virobnitstva. Go about like this:
- Recycling. The reasons for the culpability of the expenses of the group are the expenses incurred by the organization, the variance of renting warehouses and the salary of the required staff.
- Ochіkuvannya cherga. The main costs associated with the cost of downtime for the staff, who are responsible for the delivery of the necessary components.
- Transportation. Cost, owing to the cost of arranging the transfer of the product itself, as well as to the supplier himself, and to the post-employees / supporters (removal of the transport installation, the variance of logistics, the appearance of the result of transportation).
- Weaving processes that do not create dodan vartosti. Ce vitrati pov'yazanі, for example, to add functionality to the goods, not to add kіnstі spozhivacha (refrigerator with vbudovanim screen), or to carry out technical operations, yakі not to add cіnnostі spozhivachevі.
- Zayvі material and virobnichi stocks. This type of investment is related to the rent of warehouses for the storage of products, the salary of the general staff, and the risks of transferring the terms of the applicability of stocks.
- Shut up. At times, you blame yourself through those who spend an hour on the way to the working space, search for the necessary tools. On deyakih dilyanka vyrobnitstva waste hour can become up to 20%.
- Spend, pov'yazanі z akіstyu. For all types of expenses, it is necessary to spend on the repair of the ship, the disposal of the defective ship and the verification of the quality of the defects.
- Spend it on the unrealized creative potential of practitioners. The stench of po'yazanі z tim, scho spіvrobіtnik vykonuє not in power, you see robіt but to rob those, to what guilt is not zdіbnosti or interest. Give the most part of the zoom to the daily tool of the search and support of the recruiting initiatives of the spivrobitniks.
The main way to deal with waste is based on the concept of prudent viability, the principles of vitiaguvannya virobnitstva and Just in time.
The principle of vitiation of virobnitsva can be on the vazі, scho zamovlenija on the skin stage of virobnizstva come in the form of an advancing stage of the virobnic process (internal respite), and all the spectacle of the need for resurrection of the final respite (outer rep - client) begins. But in the minds of the great minds of the future, it’s quite easy to reach, so the team of marketers sends a signal to this, as they quickly monitor the situation on the market without interruption. Tse allows you to get away from the vіd nadvirobnitstv.
The Just in time principle conveys that the system of planning and organization of the company's robots is motivated so that all the necessary elements are in the production process at the required moment and in the required quantity. The same principle of transferring defect-free virobnitstvo, shards of school can break the whole system of planning.
For the implementation of the concept of sustainable manufacturing, a wide range of methods is being developed.
5S
Tse, perhaps, the most popular way of sparing virobnitstv. This is the essence of the field in the rational and efficient organization of the working space. The blame for the fight against expenses, which is blamed on the result of the search for the necessary tool, as well as on the result of the gateway through the wrong possession or the uncleaned working space of the spivrobitnik. In this system, the working place is considered as an individual working place of a spy worker (from the director to the tidying room), so is the general use.
The 5S method is based on the five basic principles
Seiri - sorting
It is necessary to separate all items from the working area into groups:
- always need: to change at the worker’s space;
- sometimes they are needed: because of the working space, but they are left behind at the borders of reach;
- inappropriate: to be removed.
The main idea of this principle is: the fewer speeches we leave, it is easier to practice.
Seiton - keep things in order
For skin speech, that instrument can be assigned its own place. Tsey order needs to be trimmed. Selected months for the instruments are guilty are carried out rationally:
- rіch, as they koristuyutsya fast, always perebuvaє under the hand;
- speeches, yakі need rіbnі rіdko, nіnіnіnі zavjat svіrobіtniku.
Most of the time, when implementing 5S, the contours of speeches are overlooked at the work place, and the employees of the quality service regularly conduct an audit of the work place.
The most reasonable principle of the 5S method. I drank and ford to provoke a hat and spend it, and also, to add to the efficiency and co-operation. Most often, this principle is interpreted as a regular cleaning, as an appointment, and a working place. Prote є two nuances.
- For tidying up the working place, you need to be not only a tidy-up, but also a practitioner himself.
- Virobnitstvo is necessary to rule in such a way that it would be easier to change that entrance, and the stench is due to localization.
Shisuske - standardization
At the skin specialist, one should be guilty of a handful of instructions on how to do yoga. The stench mayut buti minimization, zrozumili, visualization. Regularly carried out are standardized revisions of the technological possession of the working space.
Seiketsu - thoroughly
For the foundation of the 5S system, it is necessary to improve the existing mechanisms, and gradually improve them. The production cycle does not stand on the job, companies change, 5S mechanisms must change together with them.
Nini vinyl system 6S. It looks like the 5S method of interpreting the rest of S. At 5S, the rest point is completely, and at 6S, the discipline of that star.
Standardization
This method can be based on the creation of basic instructions for spivrobitnikov, which describe the main processes of virobnitstva. Instructions on how to regulate all operations, like a doctor, as briefly as possible, wisely.
The maximum obligation of the instructions is to become 3 sides, and even less than one. Bazhano beat the instructions with maximum visualization, a good butt of this approach, for example, instructions for choosing IKEA furniture, instructions for protecting the work of the Artis company, rules for choosing LEGO constructors.
Cream of working instructions, in the organization briefly and wisely, all processes can be described. For this, the block diagrams will sound.
All instructions are to be drawn up according to the same rules for all organizations and are regularly updated. Posіbnik sled control vykonannya іnstruktsіy svіvrobіtnikami. At the time of development, it was necessary to carry out an analysis and determine why the spіvrobіtnik vіdkhilivsіvіd іnstruktsiy: through bazhannya ask your own life for the fault of the virobnichimu process, or know more optimal way for vikonannya operations. At the time of the yogo, the success should be ordered from the collaborators, and the companion should be awarded.
This method of directing on changing the variability of the working process, reducing the number of tails, as well as facilitating the adaptation of new spe- cialists to the manufacturing process.
Poka Yoke
The name of this method is translated by my Russian language as “Zakhist in the form of pardons” or “Zakhist in the form of a fool”. Vin directing to the creation of such minds, for such a spivrobitnik it is simply impossible to get a pardon, so that the “human factor” can be turned off as much as possible.
This method is utterly practical, there are no fundamental principles for this. For razuminnya ideas - a few examples:
- Vykoristannya constructive elements, yakі nemozhlivlyuyut incorrectly folded all designs. For example, the form of SD or flash cards does not allow you to insert them on the wrong side.
- Color marking of elements during the hour of picking. Elements, as if they could be united among themselves, are marked with one color. For example, provіd yogo roses are marked with one color: red to red, yellow to yellow.
- Automated control system. The creation of the system, so as not to miss the element on the attacking plot of virobnitstva, as if for a new one there is a gateway. For example, on the conveyor line, the worker is guilty of fixing two details, which are opened with screws. After the end of the procedure, a photocell is installed on the line, and even though one of the screws is not fastened, this element cannot go far.
This method is also vikoristovuyut for zapobіgannya virobnichemu traumatism. For example, on a conveyor belt for sawing a furniture board, a spivrobitnik needs to press on two buttons with two hands. The whole thing was broken so that the spіvrobіtnik did not zmіg with a practical cutter with one hand try to straighten the furniture shield. As soon as one of the buttons is released, the cutter starts to grind.
The use of this method, which is unique for the skin tissue organization, cannot be ignored.
Kanban
This is the main method for the implementation of JIT and powerful viability. The back of the bag was a card, like a guide on the picking line, handing it over to its internal posts, if the elements necessary for picking ended up in the new one. It is not necessary for a Vikonian to send cards, the system is automated.
Tayiti Vono, having formulated the basic rules of the kanban method:
- No one can prepare the details without taking care of them.
- The kanban card is to be attached to any part of a batch of parts.
Using the kanban method allows:
- view information about the scope and term of the goods and the transportation of products;
- zabіgat nadvirobnitstvu;
- protect the appearance of defective products, showing at what stage defects are found.
The Swedish Changeover Method (SMED)
The Danish method is both practical and unique for the skin cavity. Yogo the main task is to shorten the hour for reloading the possession. It is not allowed to viroblyat details in different parties, so that in their own hands they establish the principles of winning and JIT. It is reported to describe the technical solution of this method in an unacceptable way, most of the time, the stench is unique to the skin for the treatment.
Dovidka
More often, the most popular ones are looked at, but far from all the methods and tools of dbaylivy virobnitstva. The middle is quiet, who did not spend time looking around:
6 sigma is a methodology that directs the creation of defect-free manufacturing.
Kaizen is a system of uninterrupted completion of processes at the set.
Analysis of higher education - methodology, straightened out the search and adoption of the so-called puff neck from the veterinarian.
P'yat "why?" - a method of looking for solutions to problems that have been called.
The map of the flow of value creation is a tool that allows you to reveal operations that add value to the products of the end-of-life store.
Top-of-the-line service management (TPM) is a methodology aimed at improving the term of service and efficiency of installation.
Vizualizatsiya virobnitstv - Danish method of aiming at informing spivrobitnikiv about the camp of virobnitsva by simple visual methods and others.
Although all the methods developed have been developed for manufacturing companies, the concept of careful manufacturing is widely used in the service sector, for example, logistics, medicine, and the IT sector.
Lean - the best way of thinking. Way of thinking, which optimizes the working process. Vykoristovuє vin for tsgogo principle roboti and іnstrumenti.
Lean's gentle selection was born from Toyota's selection system. American scholars interpreted some of the ideas of Taity Ono and knew the system he had created, not only for car building, but also for some other areas.
The basis of the concept of prudent harvesting is fast spending. The second is everything that makes the product worthwhile. For a quick turnaround, the working process is optimized as much as possible, it will be asked there, where it is required. So important detail Lean є postіyne pragnennya thoroughness.
Vidi vtrat
Spend that robot over their speeds to become chimala a part of this way of thinking. Creators of prudent production see this kind of investment. In different dzherelah, they can be called in a different way.
- Chastkovo vikonan robot. If the work on the product or its component is not completed before the end, the fault does not show up and there is no value. And that means that the resources of that hour were vitracheni for nothing.
- Enter the steps of the process. Tse tі processes, yakі take away the hour of that susilla, but do not slacken the product with a dear one. In this way, you can, for example, write letters.
- Non-necessary functions or superficial functions. Nova optsіya or funktіonalnіst mozhe buti korisnoy, but if you don't need klієntu won't be, then you won't be listed on the cіnі goods.
- Bagatozadachnіst that remіshchennya. As a whole, the team performs as efficiently as possible on one task. The more tasks are beaten at once, the less efficient the work.
- Refinement. A working hour, turning over for nothing through those that the process of a moment zupinitsya or sovіlnitsya at other stages.
- Transportation chi ruh. If the practitioners are far away from one type of one, or the process of folding / working of stretching, the hour for communication or transferring the elements of the product at the stages of assembly will increase.
- Defecti. Defective products may have a low price or it will disturb the team to repair the defect.
Dzherela vtrat
Also add three tipi or dzherela vtrat.
- muda- marnist, supra-world, marnotrate. Spend what you have described above.
- mura- Nerіvnomirnіst, vіdsutnіst rhythm. Nedoliki, which is blamed through the intermittent schedule, uneven variation.
- Muri- Nezumnіst, perevantazhenіst. Zayve the interest of spivrobitnikiv, through which the stinks become less effective in the long-term prospects.
Lean principles
Sparingly vindicate revenge for a few principles and a number of values. Values here play, singsongly, a great role, shards inspire and explain this concept.
- Liquidation of expenses.
- Stronger training.
- Accepted decision for the rest of the last moment.
- Short time delay.
- Povaga to command that robot over її efficiency.
- The quality of the product.
- Bachennya re-painting.
Principles - reaching the maximum capacity and usunennya vitrat. Five stages of implementation are seen.
- Appointment of the value of the goods.<
- Appointed to the stream of creation of value.
- Safeguarding the uninterrupted flow of the flow.
- Allows you to save goods.
- Pragnennya to perfection.
Tools
Lean has a wide range of tools. Some tools regulate the change of ownership, others organize the work space, and the third analyze the results of practice. Tsikavo, that most of the tools are stagnant in different areas of manufacturing. The axis of action is from them.
Value flow map
Value flow map - this is the scheme, demonstrating the flow of product functionality by stages.
The skin stage is seen as a straight line and strikes with an arrow from the approaching one. An hour is depicted under the lancet from the rectum, which product is proven in the skin їх vitrative on moving around them. On the basis of the map, the flow of the hour is easy to change, as the stages take more than an hour, and also how many years in total or days are spent on ochіkuvannya chi pass.
5 "What?"
P'yat "What?" - The method of solving the problem. Vіn allows you to go to the troubleshooting chi vtrat. Tse reach rahunoks of the last five meals "Why?" when problems are identified. The next decision, as a rule, becomes rather obvious.
5S
5S is also one of the lean-instruments, directing to improve the organization of the workforce. The wines are added up, as you can guess, from five components or less (5 Steps).
- Sorting - subdivided all items to the needs and non-needs, sorting from the rest.
- Dotrimanny order - organizing the collection of necessary speeches in such a way that access can be easily taken away.
- Cleanliness - regular cleaning of the working area.
- Standardization is the folding of standards for the three storage boxes.
- Improvement - support for the established standards and their perfection.
Stop Lean
Thrifty virobnitstvo nayvigіdnіshe vprovadzhuvati itself in virobnichih galuzah. Lean itself allows you to seriously save and change the cost. The way of thinking and tools should be manually introduced both on the scale of the enterprise, and in small teams. In the field of software development, a sparing software development has been created - a methodology that has won the concept of Lean and its principles.
The cob of the widespread zastosuvannya of technology of double-dealing manufacturing was laid by the company Toyota. Having inherited this butt, a lot of great firms during the hour of recent crises began to find ways to reduce their costs and came to Lean. On the basis of this principle, 2/3 of the companies in the USA are supported. This is partly due to the fact that the state has adopted a wide range of methods.
In Russia, there are not so many companies that want to organize a working process for additional philosophy. Prote step by step great companies move to new methods of manufacturing. Russian Railways, KAMAZ, Irkut and Rosatom have successfully put Lean through and achieved a lot of bad results.
Literature about Lean
About thrifty virobnitstvo, as well as about gnuchki methodologies, little has been written in various literature. Three books, zavdyaki yakim can be sorted out in Lean and zastosovuvati її.
1. Lean Manufacturing: How to Cost and Achieve Your Company's Prosperity, James P. Womack, Daniel Jones.
2. "Toyoti Virobnicha System", Tayiti Vono.
3. "Virobnitstvo without spending for workers".
4. “Business from scratch. Lean Startup, Erik Mal.
The history of the development of Lean-technologies - the so-called technology of sustainable development - has been around for a decade. Regardless of the price, everywhere, especially in our country, the Lean system is adopted as a completely new and not entirely stagnant for European and American, but more Russian realities. It often seems that only Japanese practitioners, who sang to one-man diality and hearing, mastered the work of Lean technologies: rhythmic, accurate, based on team interaction. І in this case, especially take part in the permanent improvement of the skin process, the skin working area. As well as in many other methods of development of growth and business, in the concept of Lean-technologies, it is already said a lot about those that need to be educated, but not given food support, like raising. Tim is no less, with the implementation of be-like methods in practice, the need for a state of emergency in the most impersonal technical tasks. About those, like zrobiti tse with minimal expenses, that rozpovist tsya book.
From the series: Library of business people
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the company LitRes.
Broke another. Lean - technologies. From idea to perfection
To wade through the pits of the Toyota backwaters, it is necessary extraordinarily, not just a set of rules and methods, but a new philosophy, as a result, we have been encouraged by those who are engaged in the manufacture of automobiles from these firms. Lean-technologies have become such an enchanting wand. Lean is the goal of constant activity due to the increase in the competitiveness of the company. The Lean system is aimed at those who expand the workforce of the practitioners to the top of the business and direct their energy and intelligence to the company's greed. In this way, ideally, in a company, where Lean technologies are taken as a basis, the company itself, and the skin of all spivrobitniks, become successful at once.
Pratsuє dbaylivy pіdhіd, at first glance, it's very simple. First of all, it is necessary to know the bar'eri that respect the growth of the competitiveness of the firm. If so, evaluate what you can do to hem it, be quick about it. Moreover, the plan is not a single, one-time activity, not a creative streak of okremikh spіvrobіtnikіv abo kerіvnіkіv, but a trivial process, to which, however, it is learned like masters of business, so simple practitioners, like practicing in the lowest settlements.
Values and spend
In essence, Lean is a technology, whether a company can create values. And all the work is possible, so that the process of creation would change if it were virobnichii vitrati.
Value - the whole commodity or service, if you want to buy a quick one, and the process of її vyrobnitstva - the whole technological lancer in a rush, starting from a postal worker and ending up as a buyer. A lot of respect is given to planning and management, relay control of capacity, manual and efficient exchange of information between pilots. Lean - management - the ultimate optimization of production. The axis of the principle of such an approach:
processes that create value need to be continuously optimized;
processes, if they do not create any value, but if you need it, it is necessary to speed up to the absolute minimum;
spend the next turn off again!
The main difference is contrary to the traditional approach to the one who sounds warehouse stains, and navit all stains, connected with non-stained products, the gamanets of the spozhivacha are shifted.
In this way, with the victorious system of sparing virobnitstva, the entire work of the company is divided into operations and processes. They can either add value or not add it. The manager of the management is becoming a planned fast processes and operations that do not add value to the patient.
How can you rob?
It is necessary to improve the business in such a way that a specific product passes through three main stages of management:
solve organizational and technical problems;
cherubate information in the middle of the posture by vibration;
turn the cheese into a final product.
Then we will organize the process of scaling in such a way that the wine will be as efficient as possible until the value is created.
І rozpochati skorochennya hour between the rozrobkoy ideї and the release of ready-made virobіv. Gently variability gives the possibility to change the sequence of the variability of any products without interfering and, in such a way, in a very short term, to respond to the change in drink and the situation on the market.
It is impossible to forget about those that the process of improvement is not limited. Creating a product, which helps to slow down, we come to one of the main postulates of sparing production - the need to practice thoroughness.
Skin acceptance - the whole system with a number of blocks: "virbility - management - financial flows - zbut", and the main function of the short time between the development and final result - to know yourself on the cycle. This improved process of product creation is the basis for business development.
For whom it is necessary to put that virishuvati tekhnіchnі zavdannya, scho allow liquor duvat, increase productivity, shorten co-operation. And the result is to change your spending.
“Muda” is a special Japanese word, which is what they call spending, going out, so be like diyalnist, like stained resources, but don’t create any value.
The Japanese called for savings, until May 1st, the very nature of small island Japan is in its order. The stench expanded its vminnya on a great scale.
Principles of lean
It has long been understood that Toyota has a unique technology - an ideal method for the correct organization of a working process. In addition, in order to keep a safe secret, Toyota began to promote TPS, providing consulting services and conducting training.
Today, about the principles of TPS, it is written that it is said too richly. Ale Toyota like and before only one. Adzhe Vaughn started propaganda of her system for the same reason.
Toyota Production System includes 14 principles. Ale, it’s not enough just to visualize 14 points, so that your undertaking will work. TPS is the right philosophy for us.
Even more important to this, Agee Toyoda, being a ker_vnik, said that for Toyota factories it is more important than those, like a broken car, lower than those, like vins of construction. The first life confirmed the correctness of such an approach.
Because the correct process is too early to automatically cause the correct result.
Also, 14 principles of TPS.
First. The advantage of the long-term perspective: you can drink to the beat to reach the great distant goal.
Other. Virobnichiy potіk zavzhdi may be uninterrupted.
Third. Kanban: the production is organized by the “exactly at the same time” system, without saving industrial stocks.
Fourth. Heidzunka: equal rozpodіl vantazhennya virobnizstva at all stages of the technological process.
Five. Andon ta jidoka: automatic zupinka vyrobnitstva in case of failures, revealed by the way of correction of systemic shortcomings.
Shostii. Saving the accumulated knowledge: you can reach the standard.
Somy. Visual control: sometimes a simple light bulb is important for the entire monitor.
Eighth. In the case of virobnitstvo, it is possible to use better technology.
Nine. You need to win your leaders from the company, wide recognition of the company.
Ten. Form and support work teams, in the same skin as the manufacturer of the company's advice.
Eleven. Honor and develop other companies, for example, partners - post-employees.
Twelve. Genti genbutsu: before analyzing the situation and accepting the decision, the kerivnik can take everything in good faith.
Thirteen. Nemavasi: take collective decisions next only if you want more, but if you want to make a choice, then it’s negligible.
Chotirteenth. Hansei and Kaizen: whether the process of choice and management can be analyzed without interruption and thoroughly.
Philosophy Kaizen
Kaizen - in direct translation from Japanese it means "change for better".
Under the word of the Japanese, we will understand the future thoroughly, which is worthy of everything, from a stone worker to a robot worker.
It’s even more understandable, it’s impossible to go through and it’s possible to report it to me. The Japanese are concerned that if there is a change in the current situation in the field of production, it’s still Kaizen.
For example, if you wanted to put things right on the working table, they stopped the 5S tool (about which it will be said later), and then, after an hour, they found out that cleaning up your method takes a lot of time. The most obvious way is to drop everything and turn to the old barefoot. And you can take a different path, analyze the causes of folding, put a smaller style, or start a special police to save papers. The hour for choosing has changed. Let's try to pick up the color marking of your documents, try not to drop the documents, and putting them in order is no longer necessary. And so it is possible to thoroughly clean up the work space, and at the same time from it, to the point of indistinctness. The philosophy of Kaizen will be especially for you. Aje vi steadily collapses forward, and skin quilt, stained for perfection, turn every hour by the year. The process of improvement is made up of the gradual introduction of a large number of small deposits, which create a strong effect.
On the way, they often will start a revolution. I am changing everything once again. How about taking care of small rights, if you can buy a fundamentally new possession and take the edge off?
But the general process, moreover, in any company, practically, it is folded over the top of current and systemic problems, as it does not involve the supply of equipment, syrovina, transport, partners and a lot of other factors. Itself in the war with these difficulties and pass the working day of the workers and workers. Ale, unfortunately, no matter how hard the robot works, there are no less problems. The in-line activity at the top of the head rarely allows you to spend an hour on the roll. The Japanese, vikoristovuyuchi Kaizen, guessed about the health of the mind and realized that it is easier, step by step developing the system, to get out of the zadannyam once and back, lower than the mother’s day on the right with the legacy. The Japanese have won. They knew for the solution of other problems in the same key. Tsej comprehension pіdhid otrimav the name of the philosophy of Kaizen.
Kіnets oznayuvalnogo fragment.
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Guidance cognizant fragment of the book Philosophy Lean. Lean Manufacturing at Home (Andrew Stein, 2014) gifts from our book partner -