STATE LIGHTING PATCH
GREAT PROFESSIONAL EDUCATION
TYUMEN REGION
"TYUMEN STATE INSTITUTE
SVITOVOY ECONOMY, MANAGEMENT AND RIGHTS»
Department of National Economy and Management
course work
from the discipline "Fundamentals of Management"
on the topic: "Pobudov's system of dbaylivy virobnitstv"
Vikonala: student
3 courses special MO, 571gr
Khodorivska T. I.
Revisited:
Serochudinov Y. WITH.
Tyumen 2010
INTRODUCTION…………………………………………………………………………..3
CHAPTER 1
1.1 The main idea is the principle of prudent virobnitstv…………………...5
1.2 Lean Manufacturing Tools………………………………….11
ON THE APPLICATION ORGANIZATION CJSC “UILAN”………………...20
2.1 Characteristics of the organization……………………………………………….…20
2.2 Implementation of the system of sustainable vibration at ZAT "Vilan" and assessment of vibration changes………………………………………………………...23
VISNOVOK…………………………………………………………………….27
LIST OF WIKORISTAN LITERATURE……………………………….29
The Daedals conquered the minds of fahivtsiv more widely the idea of sparing cultivation. This is a modern concept for management, focused on reducing costs, simplifying manufacturing procedures and speeding up the release of products. Particularly swear at the orientation on the uninterrupted thorough processes and the constant increase in the number of competitive advantages: the increase in economic efficiency and the cost of short-term expenses.
In translation from English "lean" means "singy, without fat, stringy". "Lean Production" ("Lean Manufacturing") - literally "production without fat", production, without excesses and costs. In the Russian version, the term Lin was translated as “sparing virobnitstvo”, “string virobnitstvo” or simply “Lin”.
Ideology Lіn mає іn uvazi organіzatsiyu prudent virobnitstvа, optimіzії ії business protsessіv z maximum oriєntatsiєyu na rієntatsієyu na rієntatsієyu mіnіntаtsієyu і vyrahuvannіm motivії ї dermal pratsyuyuchyogo. It is prudent to become the basis of a new philosophy and culture of management. This is a broad management concept, based on the adoption of costs and optimization of business processes: at the stage of product development, development and cooperation with post-employees and customers. Management of thrifty selection of the maximum orientation of the needs of the Ukrainian market and the creation of the maximum value of the client with the minimum amount of resources: human resources, adjustment, hour, production area and others.
The actuality of the chosen by those obumovlyuєєtsya simple principle, kakim cheruєtsya practi- cally kozhen pіdpriєmets - for the minimum amount of resources otrimati maximum results. And if you lie, if you use incorrect resources, then you will be led to find new ways to save on harvesting. The concept of Line, however, can be shown as a way of uninterrupted thorough organization processes to achieve the maximum possible economy of all business resources.
The object of the coursework is ZAT "Whelan" The subject is the system of careful selection.
The method of coursework is the encouragement of a system of prudent production at the enterprises of CJSC "Vilan". As the main tasks to speak:
Determine the main idea and principles of prudent virobnitstvu
· Detection tools for double-clicking
· Build a change of care when implementing a system of conscientious manufacturing at the enterprise.
CHAPTER 1. THEORETICAL FOUNDATIONS OF THE CONCEPT OF LINE
1.1 The basic idea and principles of lean manufacturing
The main point of sparing virobnitstva is a value for a spazhivacha. With a quick look, the goods (servants) are gaining a fair value less than once, if you need to process, prepare. To that, the heart of prudent virobnitstvo is the process of spending money, which is called “muda” in Japanese, which means spend, go out, so be as diyalnist, as you save resources, but don’t create values.
Apparently, up to the concept of sparing variability, the entire activity of business can be classified as follows: operations and processes that add value to products, that operation and processes that do not add value to products. Henceforth, everything that does not add value to a gentleman, with a look of sparing virobnits, is classified as spent, and may be sunk. For the final wrapping, let's look at the butt of the hand-folded shasi vantage on the folding line (div. Fig. 1).
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Rice. one. Spend on the warehouse line of vintage cars
The operator to work richly diy, ale deyakі from them to add value to the viroba, as an important gentleman. In times, only three operations were revealed, which add value. The low number of other operations is also necessary, although the stench does not create value. For example, the operator is guilty of stretching out his hand to take the tool. The head of the office in the fact that during the operation, in order not to add value to the robo, it took less than an hour. For this tool, the details of the responsibility should be given closer to the date of selection.
In the system of careful production, it was revealed that the main types of costs - diy or vitrate, which do not add value in the case of the development of virobnicheskih and business processes, as if re-invested lower. You can spend money on the production line, as well as product development, accepted by business.
1) Perevirobnitstvo: vyrobnytstvo robіv, on the yakі there was no need for a spell,
If you spend too much stock and generate so much, like too much workforce and warehouse space, as well as spend on transportation.
2) Ochіkuvannya (waste of time): robot workers, like guarding the robot of automatic possession, stand in the ochіkuvannі chergovoi robochoї operation, іnstrumentu, parts lean. or just sit without work through the daily details, zatrimok for an hour of work, simple possession of that inconvenience.
3) Zayve transportation or relocation: relocation to large roads, which generates inefficiency during transportation, as well as relocation of materials, parts and finished products to a warehouse and warehouse.
4) Application for processing: non-necessary operations for processing details. It is not efficient to work through a low quality of the tool, or an ill-conceived constructive solution, which pulls the damage along with it and leads to the appearance of defects. Spend, caused by the rise of the vimogi to the bitterness.
5) Too much stock: too much sourness, WIP, or more ready-made products will increase the hour of consummation, call out the morally old products, leading to the cost of ready-made products, raising the costs of transportation, saving, and calling. In addition, too much stock is responsible for the manifestation of such problems as the imbalance of production, blockages in deliveries, defects, downtime, and overhead.
6) Zayvі ruhi: all zayvi ruhi, yakі be brought to work by spіvrobіtnikam at the process of work: the search for what is needed, the need to reach for the tools, the details too. or take care of their packing. Syudi lie down walking.
7) Defects: the elimination of defective parts and the correction of defects. Repair, rework, repair, replacement of products and її re-verification lead up to an hour and effort.
On fig. 2. Time of presentation on simple coordinates for the process of casting, mechanical processing and folding of parts.
Sirovina Hour Ready details
The hour by which value is created
The hour, by which the value is not created, is given
Rice. 2. Spend an hour creating the added value
It can be seen on the little one that it’s even easier to process the work to the floor and stretch the flooring, that the hour, by stretching what is done, is added to the value, to become only an insignificant part of the total hour. Undoubtedly, irrationally, the time spent leading up to significant financial expenses for the ceramics worker and the company wasted.
But for an effective system of reasonable variability, it is not enough to spend and use them, the shards of the concept of Lin are directed not only to the elimination of mud, but also to the uninterrupted thorough organization of processes. At the link with the cym, 14 principles were hung, as if to become the "heart" of all thrifty manufacturing.
Grouping principles for category 4:
Section I: Philosophy of the pre-stroke perspective
Principle 1. Praise the management decisions for the improvement of the debt
perspectives, to inspire as a manager of short-term financial goals.
Rozdil II. The right process gives the right results
Principle 2. The process as a non-stop flow solves problems.
Principle 3
Principle 4 : practice like a turtle, not like a hare.
Principle 5
part of the virobnichoy culture, as a matter of fact, vimagaє akіst.
Principle 6
Principle 7 Victory visual control, so that any problem is not left unmarked.
Principle 8
Rozdil III. Add value to the organization, developing your practitioners
and partners
Principle 9. Succeed leaders, as they thoroughly know their rights, follow the philosophy of the company and can teach others.
Principle 10
Principle 11
the important thing is to help them get better.
Rozdil IV. A permanent solution to fundamental problems stimulates
uninterrupted training
Principle 12
Principle 13. Take decisions without haste on the basis of consensus, calling for all possible options; vodzhuyuchi yogo, do not call.
Principle 14
1.2 Double Vibration Tools
Following the Other World’s War, Toyota evoked the principle of “flow-based generation” inspired by Henry Ford and added a number of impersonal ideas, tools, and methods of efficiency, logistics, product planning, motivation, and leadership. As a result, regardless of the shortage of labor and financial resources, Toyota was able to promote products of higher quality with lesser variability than competitors.
The most popular tools and methods of gentle harvesting are:
1. Value Stream Mapping
2. Vityaguє streaming virobnitstvo
4. Kaizen - no interruption to perfection
5. System 5C - technology for creating an efficient workspace
6. SMED system - Schwidke changeover
7. TPM system (Total Productive Maintenance)
8. JIT (Just-In-Time) system
9. Visualization
10. U-like centers
Let's take a look at the report of skins from newcomers.
Value Stream Mapping
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 to improve.
Mapping the flow of value creation includes the following steps:
1. Documentation of the flow sheet
2. Analysis of the flow of production
3. Creation of a picture of the future
4. Development of the plan for the improvement
Vityaguє streaming virobnitstvo
Pull production (eng. pull production) - a scheme for organizing the production, if the production is obligatory for the skin production stage, it is determined exclusively by the needs of the upcoming stages (let - by the needs of the deputy).
The ideal is “single piece flow”, that is. a post-head (or an internal post-head), who is known more by the stream, does not do anything, while he is calm (or an internal post-head), 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.
Tse pokhіdne vіd dvoh ієroglіfіv - "change" and "good" - sound like "change on the best" 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 to be thorough
Kanban is a Japanese word that means "signal" or "card". This is the method that is victorious for drawing products and materials on a gentle selection line.
There are several options for Kanban in fallow due to zastosuvannya: forward process, which is launched, two-bunker (single-card), rich-card, one-time kanban and other.
Kanban allows you to optimize the planning of the production activities, starting from the forecast, the planning of the production tasks and the balancing/spreading of these tasks for the production efforts with the optimization of their engagement. Under optimization, it is understood “do not work for anything, do not work before the hour, tell about the need, what to blame, only if it is really necessary.” The Kanban system was developed and first implemented by the company "Toyota".
5C system - technology for creating an efficient workspace
Under zim znachennyam vіdoma system of putting things in order, cleanliness and zmіtsnennya discipline. System 5 includes five mutually dependent principles in the organization of the working area. 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: sorting out necessary items - tools, parts, materials, documents - from non-necessary ones, to clean up the rest.
2. Rationally rozashuvannya: rationally rozashuvat those that are left out, put the leather object in your place.
3. Tidy up: keep cleanliness and order.
4. Standardization: dotrimuvatisya accuracy for the regular count of the first three S.
5. Refinement: redirection to the icon of the established procedures of those refinements.
Shvidka perelagodzhennya (SMED - Single Minute Exchange of Die)
SMED literally translates as "Change the stamp for 1 whip". The concept was broken up by the Japanese author Sigeo Shingo and made a revolution in the way of re-equipment and re-equipment. As a result, the implementation of the SMED system to change any tool, that changeover can be done in just a few minutes, or in 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 - 30%
fixing and removing stamps and tools - 5%
centering and placement of the tool - 15%
trial and adjustment - 50%
As a result, the following principles were formulated, which allow you to spend an hour reloading dozens and repeat hundreds of times:
· Podіl vnutrishnіh and zovnіshnіh operations nalagodzhennya,
Reconstruction of internal affairs at the outside,
· Zastosuvannya functional zashkakіv or outside usunennya krіplennya,
· Vykoristannya dodatkovyh outbuildings.
TPM system (Total Productive Maintenance)
TPM - "the deep watch for the possessions", mainly to serve to improve the quality of the possession, focusing on the most efficient way to achieve 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. Zavdyaky to whom it is necessary to ensure the promotion of such an indicator, such as Povna Effektivnіst Statutory (in English Overall Equipment Effectiveness - OEE).
JIT (Just-In-Time) system
JIT (Just-In-Time) / Exactly at the same time - the material management system for the manufacturer, if the components from the front operation (or the front post worker) are delivered at the same time as the stench is needed, but from 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
Vіzualіzаtsіya - tse be-yaky zasіb, scho іnformuє about those, yak can vikonuvatsya robot. This is the distribution of tools, parts, packaging and other indicators I will become virobnitsva, with the skin at first glance I can understand the system’s standard - the standard of living.
The most common victorist methods of visualization:
1. Outlining
2. Color marking
3. Method of road signs
4. Marking farboi
5. "Bulo" - "became"
6. Graphical working instructions
1. Outlining is a good way to show where the responsibility for saving tools and storage attachments is. Contouring - means to outline the storage outbuildings and tools there, de stinks are guilty of saving up. If you want to turn the tool on the tool, the outline will show you the place to pick up the tool.
2. The color marking is shown, especially those other details, tools, attachments and molds. For example, as if the details are needed when making a singing viroba, stench can be brewed in the same color and change in the field of safety, dressed in the same color.
3. The method of road signs is the victorious principle of pointing at objects that are in front of you (WHO, DE and in a certain quantity). There are three main types of such signs:
· Indicators on objects, what they mean, de faulty objects are found
· Pokazhchiki on missions, yakі podomlyayat, yakі the very subjects of guilt are found here
· kazhchiki kіlkostі, scho podomlyayat, how many subjects in may buti in tsimu mіstsі
4. Marking with farboi is the same method, which is victorious for seeing the place of finding something on the ground or in the aisles.
Marking with a farboy is to be used to identify the different lines between working areas or transport passages.
5. "Bulo" - "Became"
The image of the working place / business / shop “before” and “after” the change clearly demonstrates the changes that we have made, promoting the motivation of practitioners and advancing the new standard.
6. Graphical work instructions in the simplest and most visual form describe work operations and how much on the skin work area. Graphical working instructions are known without intermediary on the working area and standardize the optimal way of working, ensuring the universalization of workers and the maintenance of standards.
U-like centers
Roztashuvannya possession in 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 takes place without a middle near the cob stage, that operator does not need to go far to begin the onset of the onset harvesting cycle. On fig. 3 nightly submissions of the butt of the contest on the undertaking of a U-like center
Rice. 3. Scheme of a U-shaped middle on the butt of the processing of parts.
CHAPTER 2
ON THE APPLICATION ORGANIZATION CJSC "UILAN"
2.1 Characteristics of the organization
TOV "Vilan" is a specialization enterprise, as of 1989, it has been engaged in the selection and processing of worn car tires and inputs of human engineering tires. For this type of activity in the enterprise, there is a license of the Federal Service for Ecological, Technological and Nuclear Supervision of the Russian Federation.
The enterprise is able to produce more than 500 tons of raw materials with a six-month production. The organization of the campaign was based on the idea of improving the ecological situation in the region, and as a result, we took into account the value of polymer syrovine - the humic acid of various fractions of 0.63 mm to 5 mm.
While constantly virobnitstvo, the company TOV "Uilan" from its inception was engaged in the uninterrupted modernization of the possession and the advanced technology of virobnitstva, carrying out the follow-up at the gallery of the modes of remanufacturing and reconditioning. The technological process was won by different installations of domestic and imported vibrating. In an hour of work, the richly finished construction, installation, and taxation, a team of highly qualified specialists was created. All this allowed us to take away the virobnitstvo, which inspires the present-day vimog.
In 2007, the distribution company of TOV "Vilan" gave the authorities a plant for the production of car tires, and, having issued shares, became a closed joint-stock partnership. Ninishna named the enterprise ZAT "Vilan"
For 3 years ZAT "Vilan" has been a rich business enterprise, as it specializes in the selection, production of human-technical chemicals and the possession of a gum-based product, and is also engaged in the production of car tires, selling products to the market.
Vyrobnichiy complex for the workshop with a selective installation with a total area of 70 square meters. m and a height of 10 meters, yak can recycle up to 22.5 tons of syrovin for production. In addition, the warehouse includes a warehouse for syroving (worn tires and plastics), a warehouse for the preparation of syrovins (tire processing for shmats), a warehouse for finished products: a warehouse for rare firewood, a warehouse for technical coal, a warehouse for storing metal brut (metal cord).
Sirovin in the reactor is laid out at a temperature of approximately 450 ° C, in the process of which the following products appear: gas, a low-temperature fraction, carbonaceous excess and metal cord. The gas is often turned into the furnace of the reactor to feed the process. Part of the gas, which is left out, is pumped through the pipe (behind the starry look and the amount of gas at the exit is equal to the flurries of the vantage). The carbonaceous excess after quenching and cooling is subjected to magnetic separation (or passed through a sieve) with the method of cutting the wire to the metal cord. Rarely pale, metal cord and carbon surplus are sent to the warehouse for further processing.
Otriman's cricht in the range of fractions of 0.63 mm to 5 mm. transported to the plant for further processing of ready-made gum products with an advanced coal-mining capacity of up to 12 tons, as a result, 2 times for extraction.
2.2 Implementation of a system of careful harvesting at CJSC "Uїlan"
that assessment of vibrational changes
The authority of the company ZAT "Vilan" has a workshop for the preparation of polymeric syrovin or gum krichty, which is located in the boundaries of the city, as well as a plant for the manufacture of gum tires, packing at the plant 90 km from the workshop. Today vantazhivka zdіysnyuє 2 viїzdi, delivering crychta with a haul of up to 50 tons at the place of processing. With such obligations of flexibility, transport costs can be large costs as material, and at the same time, having turned them on, you can increase the income of the business, as a result of the increase in the net income and let them go to the farther turnover of the court.
Until the change, you can watch for:
Palyvo, oily materials, electricity, rukhovy operations;
Technical maintenance and in-line repair of a dry warehouse (including spare parts and materials);
Salary payment for water transport (personnel who are directly involved in transportation);
Until the late vitrats, ring out:
Vitrati mannya virobnicho-technical base and infrastructure of various types of transport (rent);
Vytrati to pay for the cost of administrative and managerial staff;
Overlays and other stained glass.
Like any type of winding, transport winding can be minimised, but I’m working on a solution to the attack - I’ll take it by the way of transferring the shop from the production of gum krichti to the plant for the production of tires, and I myself will sell the shop and start the work of a new mill to the plant. So that this idea did not come up with an ill-advised, expansive mathematical development.
2) How hotly vicorous diesel fuel is, vitrata is as expensive as 32 liters per 100 km:
360 * 0,32 = 115,2
3) The average market price for diesel fuel is 23 rubles / l:
115,2 * 23 = 2649,6
4) For 22 working days we take:
2649,6 * 22 = 58291,2
Also, a total of less than 58,291.2 rubles was spent on fire for investment. On the river sum to become 699 494, 4 rubles.
5) It’s time to spend money on wages for rіk:
20000 * 12 \u003d 400,000 rubles.
6) A technical inspection of vintage cars costs 3600 rubles without window materials and spare parts.
7) An unrepaired breakdown can cause repairs to the amount of up to 75% of the cost of the investment, or close to 30,000 rubles.
8) Tire wear is due after a run of 50,000 km, then
360*22*12: 50000 = 1.9
For greater accuracy, we will enter all the omitted data in the table.
Table 1
1) Speed of vantage on the spot to be 30 km/year.
90:30 = 3 years
2) Multiply by 2 see back there
3*4 = 12 years
3) For 22 working days
12*22 = 264 years
4) For river
264 * 12 \u003d 3168 years.
Henceforth, by stretching the rock it was irrational to win time resources to establish 3168 years for 132 days. In order to protect that the income of the enterprise for 2009 was 187.5 million dollars, then with a 1-day repayment, 514,000 dollars will be taken. Multiplying by that hour, as an undertaking of stained glass for the transportation of materials for the river, and in itself 132 days it takes 67,848,000 $ or 2,171,136,000 rubles. The very style of business is wasting a lot of time, irrationally vicory timchas resources.
First judge, we will see how it will be for the implementation of this project, it is necessary to work for the windshields, as it will be carried out in the wake of the life of the new plant. Below is a table with data. (Table 2)
Table 2 Vitrati life of the new shop.
Zagalni vitrati on everyday life to the workshop to become close to the middle
It is more important to spend on the life of the workshop to establish in the average close to 5 million 100 thousand rubles for the construction of a new plant. we take 67848000. 5 million 100 thousand rubles, which 5 times outweigh the transport routes of business across the river. With the onslaught of the organization, you may need 5 years of winding up, incurring the life of the new workshop. It is also necessary to protect the fact that the power of the enterprise already has 2 working shops, one of them, and the old one itself, can be sold on average for 2 million rubles, .
One of the main pluses of the development of this project is the shortfall in material and time periods and the increase in the client base. SPVPRATSYA VITLALS “BEDARITS INBAGATO VIGIDNISHYA, SUCCILY PIDPRIMMIT - KLINTI WITH NOT TILKA ZDATATY SNISHI, ALE IT RIMATIA NOVIA in one MISTSIS, Scho to be permitted by tints.
WISNOVOK
Gentle virobnitstvo - tse technique, straightened out systematically fast vitrate. Її zavdannya polagaє in the design and development of the production line, building production of different kinds of products exactly for the hour, which is really necessary for that.
Lean Forest Virgins Vitriyty: Pirdvishchiti Ethnicity of the Vitri, Vitrati, Pivishchiti, Vybuduvati Gnobychka Vobrnitstoy, Shvidko ry without the back on the snake of the situation on the process of producing, creation of new products/services, increase the level of coordination between employees, supporters, increase the level of satisfaction of customers and others.
But, regardless of the significant positive side, it is essential to understand the difficulties of subsoiling, as it is necessary to fix it for the creation of a system of sustainable production in the enterprise, such as:
The need for significant organizational changes and readiness for staff to change them;
Possibly summaries of material evidence;
Personnel retraining;
The need for close cooperation with post-employees, deputies, the building of post-employees to supply the production of reliable quality at suvoro restorations of the hour;
Trivali terms zastosuvannya;
The day of sufficient sovereign support.
У другому розділі за допомогою нескладних математичних розрахунків вдалося довести ефективність впровадження виробничої системи Ліїн на підприємстві ЗАТ «Вілан» за допомогою принципу Канбан, який передбачає оптимізацію ланцюжка планування виробничих активностей, починаючи від прогнозу попиту, планування виробничих завдань та балансування/розподілу цих завдань за виробничим . tightness and optimization of their entanglement.
Як на прикладі даного підприємства, ідеї та методи ощадливого виробництва могли б відіграти вирішальну роль у трансформації окремих галузей російської промисловості та наближенні її до рівня сучасних розвинених країн, дозволити їм витримати посилення світової конкурентної боротьби за споживача та забезпечити успішний розвиток підприємств у жорстких умовах сучасної світової economy.
LIST OF WIKORISTAN LITERATURE
1) Womack James P., Jones Daniel T. Spacious versatility. How to get through the expenses and reach the prosperity of your company. -M.: Alpina Business Books, 2008.
2) Wumek James P., Jones Daniel T. The machine that changed the light.-M: Popuri, 2007.
3) Tayiti Vono. Virobnicha system of Toyota: unique mass virobnichestva. - M: Vidavnitstvo ІKSІ.
4) Pascal Dennis. Sirtaki Japanese: I’m not just talking about the Toyota system. - M. Vidavnitstvo ІKSІ, 2007.
5) Yasuhiro Monden. Toyota control system. - M. Vidavnitstvo ІKSІ, 2007.
6) Liker Jeffrey. Tao of Toyota: 14 principles for the management of a leading company in the world - M.: Alpina Business Books, 2008.
7) Hobbs, D.P., The Choice of Lean Manufacturing: A Practical Tool for Business Optimization. – Minsk: Grevtsov Publisher, 2007.
Іsnuyut different points of view to change the role of the concept of sparing virobnitstv. On the back of the beast to history, the term "sparing virobnitstvo" is blamed. On the cob of the 80s of the last century, Japanese passenger cars (mainly Toyota) invaded the domestic market of the United States and took up to 30% of the domestic automobile market for a few years. American automobilists began to investigate the reasons for such a development of the situation with a method to know how to get out of the situation. For whom a fund was created and a follow-up project was organized within the framework of the International Automotive Program of the Massachusetts Institute of Technology, on the basis of which James Wumek, D. T. Jones and D. Rus. Since the beginning of 1985, the project began to be quickly developed and for five years, practically the entire world car market was followed up. The research process introduced the term lean production, the author of which was John Krafchik, one of the participants in the project team, who introduced this term to the project's middle name, and then to another. Sub-bags for the project, for which five million dollars were spent, was published in the book of Wumeck, Jones and Russ in 1990. The authors of the book, obviously, realized that the new system is spiraling, first for everything, on the system of organization of labor, spread by the Toyota company. The new term is entirely necessary to reflect the fact that there is a lot more to be found, a specific system of variation and management of one of those great companies.
More for everything, proponuyuchi the term Lean production, John Krafchik mav on uvazі that situation, that in this new type of production there is nothing zavyvo, tim more sho middle idіom, po'yazanih zі word lean, є, zokrema, і taka: zdatny to vakkoї and effective work (lean and mean). Ale, the translation of examples with the word virobnitstvo is rotten, they blamed the problems with an adequate translation of this term. In official publications and translations, “sparing virobnitstvo”, “dbailive virobniktvo”, “strunke virobniktvo”, “synchronously virobniktvo”, “gnuchka virobniktvo”, “fine virobniktvo”, “low-cost virobniktvo” were mentioned. And the best way to drink in the rest of the years was to take out such an option as “Lean manufacturing”. Dali, conceivably, approached fakhivtsiv to daylight and change the concept of sparing virobnitstv.
O. G. Turovets respects that manufacturing is sparing - the current concept of organizing manufacturing is focused on reducing costs, simplifying manufacturing procedures and speeding up the release of products. Particularly supported is the orientation on the continuous improvement of processes and the constant increase in the number of competitive advantages; promotion of economic efficiency of production with additional cost savings.
E. Bashkakardin, a leading specialist of TOV "Center Orgprom", considers it better to use the term "Virobnicha System Line", less "sparingly virobnitstvo" to the fact that the wine is richer. On the other hand, virobnicha system Lіn - tse vityaguє system virobnіstva, sprámovannya raznyh vidіv vtrat, scho include such components, yak: kartvannya stream of creation of lower values, systems of rational organization of the work space; visual control; TPM, Kanban, changeover fee.
Fahіvtsі company "KIODA" vvazhayut, that in the basis of prudent virobnitstvom lie іdeya, іdpovіdno іkої be-yaki_ії ії ії ії ії ії ії ії ії ії ії ії іn't nієmіstvo іnebhіlії vzgljat z vіdkіl zlієnta: kіnnіє vіnіst і for ієnіntі chi nі. Lean manufacturing, in my opinion, according to philosophy, managerial and manufacturing technologies, to which one can see: a value creation flow map (VSM), a Kanban manufacturing management system, a system of organizing a workspace for a business “5S”, the principle of “5S” organization per hour "(JIT system), the system of global monitoring of possessions (TPM), security change of possessions; the system of permanent improvements "Kaizen", the system of visual, sound control and the fear of pardons.
The following should be taken into account, which, with the help of principles and methods in the concept of sparing viability, it is possible to reach the coming floods:
90% shortening of the hour of the prayer (an hour of the cycle);
increase the productivity of work by 30 - 50%;
short inventory of WIP by 80%;
increase in capacity by 50 - 80%;
short-term occupation of the area by 30-75%;
a short time for pardons and an hour for the completion of a prayer;
optimization of the work and the hour of customer service;
short time changeover at 2-4 times;
speed of turnover of the total cost by 70-80%;
fast consumption at the staff;
increase in the amount of payment for work;
fast payment of the possession that vitrate for renewal;
shortness of the number of exits in 2-3 times.
But, regardless of the significant positive aspects, it is essential to overcome the difficulties of the subsoiling, as it is necessary to fix the system of thrifty production in the enterprise, to overhaul the main ones:
the need for significant organizational changes and the readiness of the staff to these changes;
possible summaries of material evidence;
staff retraining;
the need for close cooperation with post-employees, substitutes, and the building of post-employees to supply the products of the reliance at the hour;
trivalі terms zastosuvannya;
the presence of a sufficient sovereign support.
Such a rank, vicoristy of the principles of the Otchadny Vobrobnitsa, can be primely at the wibration of the Vobroitza, the productive product, the productiveness of the mother, the Materiality of Vitrati, the speed of Viconnia Vikonn, the Pereododa, the competitive exposure of the competitive disclosure of the novelties of newborn vicinates. Ідеї та методи ощадливого виробництва могли б відіграти вирішальну роль у трансформації окремих галузей російської промисловості та наближенні її до рівня сучасних розвинених країн, дозволити їм витримати посилення світової конкурентної боротьби за споживача та забезпечити успішний розвиток підприємств у жорстких умовах сучасної світової економіки.
The Lean Manufacturing Sampling Algorithm by James Womeck
1. Find a change agent
2. Get the necessary knowledge according to the system of sparing selection
3. Know how to create a crisis
4. Don't overspend on strategic food
5. Encourage the cards of the streams of the creation of values
6. As soon as possible, start the work for the main directives (information about the results may be available to the staff of the organization)
7. Pragnuty take the result negatively
8. To improve without interruption after the Kaizen system
Wumek J., Jones D. Thriftfulness: How to spend money and achieve the prosperity of your company. - M.: Alpina Business Books, 2007. - (series "Models for the management of corporate corporations")
Prote, the implementation of the principles of "sparing virobnitstv" is not enough to determine the value of the product, it is necessary to think over the process of creating the value of the value. The process of creation of value is the succession of success, as it is necessary to grow, so that the song product goes through three important stages of production:
Problem solving (in terms of concept development and operational design before release and testing of the first prototypes);
Management of informational flows (vіd otrimannya zamovlennya vіd spozhivacha to storage graphіkіv zabezpechennya financial resources and material resources, detailed graphіka preparation and delivery of goods);
Physical transformation (depending on the materials of the doti, as if the savior is ready to show up).
The value of food for the company is strategic, because in today's minds not so good companies compete, like a bunch of values. Also, at the borders of the “genteel virobnitstva”, one can see a small number of equal streams of value creation: less on equal terms, more processes, more companies, more companies, less on equal terms, the creation of values. In order to take care of the result, the skin participant in the stream is guilty of playing in a wild game. This is necessary with the method of optimizing the flow in a rush, and not on a few plots.
When picking a product, there are two kinds of flow:
1. The information flow helps the skin process, what work, how much, how many have given the terms. Vіd spozhivacha to rіznih parts of the virobnicheskogo process іnformatsiyny poіk can collapse without hiccups;
2. Virobnichesky potik pov'yazanі z remіshchennyam materialiі v seredinі podprijemstva. Directly to the flow of the flow, go to the materials of the finished product. Prote, the exit point is to drink the calm.
In order to analyze the effectiveness of the creation of products from the post-employee, it is necessary to have a map of the flow of the creation of value, so that I can describe the choice of the product and the armchairs of “sparing selection”. Pobudova cards are created on the basis of the collection of information in the shops. From the beginning, there will be a map to the flow, then, after analysis, a map of the future flow.
As a point of “sparing virobnitstva” є spozhivcha cіnnіst, then in the process of creating a product it is necessary to use unproductive dії and operations. Leather production, materials, processes, functions are evaluated from the position: what is needed for the client?
For evaluation of the efficiency of entry, rozroblenih for the usunennya vtrat at the process of virobnitstva goods, you can order the indicator of KKD pіdpriєmstva. How such an indicator can act as an effective cycle of the process, which depends on the formula:
Efficiency of the cycle of warfare \u003d The hour of the creation of value / The hour of the day of the prayer * 100%
If you wake up the card of the stream, I will become a stream of the sumar hour of the semester, becoming 576 years old, but only 2.42 years were spent in the creation of value. Also, the efficiency of the cycle became 0.42%, and 238 years of expenditure fell on the skin value. After the recovery of all negative factors, the card of the future will become a stream. As a result, the hour of the creation of value was shortened to 0.32 years, and the total hour of the consummation of the prayer - up to 72 years. Tse allowed to increase the efficiency of the cycle up to 0.44%.
In this way, the map helps to show the actual reserves between the stages, by which the value is created with the usual hour of consecration. For help, you can expand your armchair by going in whenever you need to spend that short-term creation of value. And the map of the future flow may support the concept of “sparing viability”.
Also, in order to promote the efficiency of the activity of the organization, it is necessary to win the idea of the method of "sparing virobnitstv". To improve the final results of the activity, it is not necessary to purchase expensive equipment, new materials and technologies, computerization of virility, and the introduction of expensive information systems. Such results can be achieved by changing the management of business, schemes for mutual payments between subsidiaries and peers, the value system of orientation of practitioners. Vykoristovuyuchi principles of "sparing virobnitstva", you can increase the productivity of work, speed up spending and reduce the co-production of products. Tse allow to increase the competitiveness of the enterprise in the calm market.
Hobbs D.P. Lean Manufacturing Promotion: A Practical Tool for Business Optimization. – Minsk: Grevtsov Publisher, 2007.
Tire recycling business pays off in 6 months
People have been thinking about it for a long time, how to recycle worn car tires, so many more daedals. But today, from the total amount of all tires in the world, only about 20% are recycled, although ways to recycle tires are being developed today. You can earn money on some of them, obviously improving the environmental situation.
On the right, in the fact that tires are worn, it is necessary to add valuable polymeric syrovina: in 1 ton of tires there is about 700 kg of gum, so you can re-whikoristan for the production of firewood, gumotechnical chemicals and materials of budive recognition. At the same hour, if you burn 1 ton of worn tires, then 270 kg of soot and 450 kg of toxic gases are seen in the atmosphere.
It is difficult to finish the tire reconditioning economically viable on an industrial scale. Prote, like the vineyards for the disposal of waste, the government’s mini-factory from the processing of tires - the whole pributkovo vorobnitstvo.
Vyrobnichiy complex with a selective installation with a total area of 17.5 square meters. m and a height of 10 meters, yak can recycle up to 5 tons of syrovin for production. In addition, the warehouse includes a warehouse for syroving (worn tires and plastics), a warehouse for the preparation of syrovins (tire processing for shmats), a warehouse for finished products: a warehouse for rare firewood, a warehouse for technical coal, a warehouse for storing metal brut (metal cord).
Tire Recycling Business: Recycling Process
Tires that have served their own are picked up and transported by road to the tire warehouse. Dali autogum look back at the presence of metal disks, the ring and straight to the work. After processing, the syrovin is fed into the primary bunker of the reactor.
Sirovin in the reactor is placed at a temperature of approximately 450 ° C, in the process of which the following products are used: gas, a low-temperature fraction, a carbon-containing excess and a metal cord. The gas is often turned into the furnace of the reactor to feed the process. Part of the gas, which is left out, is pumped through the pipe (behind the starry look and the amount of gas at the exit is equal to the flurries of the vantage). The carbonaceous excess after quenching and cooling is subjected to magnetic separation (or passed through a sieve) with the method of cutting the wire to the metal cord. Rіdke palevo, metal cord and surplus charcoal are sent to the warehouse for further exploration of spozhivachevі.
Tire Recycling Business: Ownership Description
Productivity of the installation (for extraction) to become: for rare fire - 2 tons / extraction; for hard coal surplus - 1.5 tons / min; for metal cord - 0.5 tons / dobu; for gas - 1 ton / production.
Saving sirovini - 5 tons / dobu. Tse means that when you leave a rare paliva to become 40% of the mass of the interested gumi.
The installation works without interruption, vicorist gas, which vibrates during the process of reconditioning car tires. Resting on open Maidan.
Dimensions: height - 10 m; width - 3.5 m; dozhina - 5 m.
Energy saving - 14.5 kW/year (installation - 7 kW/year and cutters - 7.5 kW/year).
Serve 2 individuals.
Tire recycling business: start-up capital
Vartist installation to become approximately 1,100,000 rubles. (without delivery). In addition, tanks are needed for storing fuel oil, which is taken from the refining process. To get a bigger profit in the period of price decline, it is recommended to accumulate fire in tanks and sell the accumulated products during the period of price increase. 60-ton tanks can be delivered at a price of 20 - 25 thousand rubles per 1 piece. Six tanks will be enough.
Plus storage facilities, tools, overalls - at least 100 thousand rubles. In this rank, vitrati on the possession of the rent of the territory and the accommodation, delivery, installation and other weather becomes no less than 1.5 million rubles.
Window staining
For work, two people need four workers. Salary of dermal -
close to 10 thousand carbs per month. We also need an office for accounting and, as a minimum, two more workers, one of which organizes the supply of syrovin, and the other - the production of finished products. Zagalom - no less than 70,000 rubles per month for the salary of hired practitioners, plus taxes and rent of office space.
Electricity savings to become 14.5 kW/year, tobto 10,440 kW/mіs.
The cost of spending on the daily work of the business is about 100 thousand rubles.
Tire recycling business: Income
The advantage of the project is that the syrovina is actually cost-free. More than that, you can earn money from some kinds of activities while choosing yoga.
For example, industrial enterprises to pay for the disposal of car tires, tk. autogum is not accepted in the city. In different places, the price is different. Tse is discussed at the contract with the undertaking. Chelyabinsk, for example, pays 2,000 rubles for the disposal of 1 ton of car tires, while Krasnodar pays 3,500 rubles.
Metal brook is accepted by enterprises for utilization at a price of about 4,000 rubles per ton. The price of low-acid coal will be close to 3,000 rubles per ton. Vuglets vykoristovuyut for the preparation of various pokrittiv.
Thus, the total income from the installation for a month is 375,000 rubles (2? 3,000 (fuel oil) + 1.5? 3,000 (coal) + 0.5? 4,000 (scrap metal) = 12,500 rubles / Dobu). Household bills: 100,000 (salaries for employees and offices) + 14,616 (electricity) = 114,616 rubles. From the same time, the term of installation payback becomes close to 6 months from the moment of the start of virobnitstv.
Tire recycling business: Water stone
In the first place, there are no free villagers - the whole earth is already divided under the forgetful dwelling houses. In a different way, it’s not easy to pick up such a house from the dwelling houses, but not less than 300 meters. It is even more important to pass the examination. Plus, a huge thought - people don’t want to, so that they would have a new undertaking under the hood, and there will be more reworking of smittya.
It is much easier to organize such a virobnitstvo on the territory of essential enterprises and organizations. It's no secret that a lot of maidan maidans don't spawn at once. And now the territory may have all the necessary ecological visnovka and the weather. If you don’t have to deal with the business itself, it’s much easier to make arrangements with the landlord, less with ecologists, firefighters and other authorities.
Another important moment. In order to zabrudnennya navkolishny middle ground with such a waste, better for everything, you have to bathe a special clean-up installation, so that the purchase can be done at a more expensive cost, the same waste.
So, in the opinion of experts, there will be one small plant for processing, which specializes in one type of product is not enough. It is necessary to process the processing of the largest number of products: warehouse, plastic, metal, gum, paper too.
The project has not been given over to the impersonal non-transferring vitrates, like, singsongly, to blame the preparation process and the total activity of the production. There will be problems with ecologists, firefighters. For example, to save fuel oil from old tanks, one fire shield is not enough. Here, a number of steps are necessary to ensure safety: from hoses, which flow like hot gas, to instructions for staff.
And ecologists, so you are jealously placed before the monuments and factories for processing. Prychepitisi zavzhdy є to what, and vitrati on vikonannya all could make more than one hundred thousand rubles.
TOV "Region Ecology" was organized in 2007. for the solution of the acute environmental problem in the region - the number of worn car tires that are growing. Through a few days of licensed services for the disposal of the mind, millions of worn car tires are transported to the places where they bury themselves or burn themselves, straying into the middle of the wrong environment.
The mission of TOV "Region Ecology" is to improve the environmental situation in our region, protect against negative impact on the life of people and enterprises, resource conservation, improvement of the place. Our activities are aimed at advancing the level of environmental safety and the health of the citizens of our region.
Our meta is the promotion of ecological culture in our region. It's not a secret for anyone that the processing of solid butovyh inputs is necessary. At the same time, few people can see that reworking allows not only to clean up the territory, but also to save natural resources.
The main type of activity of TOV "Region Ecology":
Selecting and further processing of remanufactured car tires and other RTIs.
TOV "Region Ecology" since 2007 promote services for the disposal of used car tires. License No. OT-53-002197 (63), seen by the Federal Service for ecological, technological and atomic vision. In its activity, there is a victorious ECOLOGICAL-CLEAN method of reprocessing used car tires - the method of mechanical crushing. The main product of our manufacturing is Hum's kricht, one of the most important and wear-resistant materials.
Variable pressures of DC "Region Ekologiya" allow to recycle up to 5 thousand tons of tires per river. In this manner, our undertaking of construction will again solve the problem of utilization of the colums in the city. The acceptance of worn tires and human-technological tests is carried out on our maidanchik near Togliatti city.
TOV "Region Ekologiya" actively arranges contracts for the disposal of used tires with undertakings. We also work with private individuals, accepting passenger tires for recycling on a free basis.
Contract for the disposal of used tires
License for the operation of picking, winning, savings, transportation, accommodation of non-safety entrances:
Description of tire recycling technology:
The shop is divided into three zones:
Sirovina warehouse.
Virobnicha zone.
Warehouse of gum krichti (tire processing product). 50 tons
1.3 Algorithm for zastosuvannya sparing virobnitstvu and yakі vinikayutsya when
problem management
Algorithm for scheduling Lean manufacturing with Dennis Hobbs
STAGE 1. Initialization and launch of the project
Meta: start a project from a project
Formulate the goals of the project and the goals of the future production. Designate a warehouse of teams and teach participants. Fold plan diy. Designate the repetition of the commands of those tasks. Find out the information about the processes and products required for the design of a lean line of the Kanban system.
STEP 2. Understanding products, processes and materials
Meta: document all manufacturing processes and products.
Determine the productivity of processes by improving variability, reprocessing and output. Designate product families based on similar processes. Document the progression points and the recurrence of the Kanban components. Install the lanyards of the vityaguvannya and the hour of replenishment. Designate the components of the Kanban system.
STEP 3. Confirmation of data for a conciliatory line
Meta: complete the selection of information and confirm the data for the creation of a conciliatory line.
Achieve consensus and confirm by the core committee the decision on the choice of products, obliging the release of the amount of available working hours on a reasonable line. Complete the documentation of the sequence of steps, the trivality of the processes, and the ability to excel. It remains to choose the components for the Kanban system and the lanyards for the target zone. Vikonati rozrahunok necessary resources for the lines that are being designed.
STEP 4. Modeling of vaping pressures and development of a gentle line design
Purpose: create a layout of a sparing line.
Expand the paper layout of a sparing line on the basis of the allocated amount of resources. Decide which kanban location to run the forward process (IPK) and the RIP folder. Develop a report plan for the implementation of the Kanban system. Decide how much to train operators. Expand the schedule of technological and organizational transformation lines.
STEP 5. Commissioning of the conservatory line
Meta: put the robot on a sparing line.
Reconsider the balance of the line and the building of operators to remerge. Reconcile with the correctness rozpodil zavdan on work tasks and reverify the ergonomics of planning. Perekonaytes, scho all IPK is well visible to operators. Equip a two-bunker kanban system with inventories. Reconsider that all the necessary training has been carried out. Develop a plan for the step by step stock of unfinished production. Ensure the victorious mechanism of the post-improvement process.
STEP 6
Meta: reconsider the robot line and evaluate the effectiveness of lean manufacturing methods.
Decide on the improvement and development of the correction strategy. Look over the rozpodіl obov'yazkіv and modify the strategy and procedures to improve the management of dbaylivim virobnitstvom. Review the presence of all systems necessary for the management of a thrifty line and the KANBAN system.
Promotion problems
On the skin side of the 6 stages of stosuvannya, some problems can be blamed, for the skin side, they have their own way.
Stage 1. Initialization and launch of the lean manufacturing project.
Problems. Preparatory work for the project is slipping through underestimation of the status. Seems like the director doesn't take special care of the vykonavtsy.
The effect on the status of the project is being created, as the initialization of a savvy business is being created by the manager of the enterprise. The authority and power of the director's functions automatically promote the importance of the project among the practitioners. In addition, there is only the right to assign additional functions to other top managers of the enterprise.
Stage 2. Understanding products, processes, materials in terms of formalization and analysis of the basic transport and technological scheme.
Problems. A group is selected that does not tie in with each other behind the structure and the material, which is impossible to work out.
The effect of the systemic nature of the project is being created, as the function of the project initiator is gradually growing into the function of the coordinator. Top-managers of the enterprise are appointed as the main supporters of the project (leaders for directing). Leadership is expected to have a functional character, based on the essence of the finished product. In a prudent selection of wines, the unity of three components: first, the selection processes, which include robotic technologies; in a different way, material warehouse; thirdly, the financial security of the manufacturing processes and the zbutu. Obviously, there are 3 direct implementations of sparing virobnitstvo, skin with its leader.
The lead engineer becomes the leader of the process group. We are engaged in manufacturing, as a service and maintenance of technological processes, product control.
Marketing director and became the leader of the material group. We are engaged in the purchase and transportation of raw materials and materials, sale and marketing, engineering design of new products, production planning.
The director of finance becomes the leader of the financial security group. Vin is engaged in financial incentives for vikonavtsiv; financing of the modernization of the manufacturing process for an optimized transport and technological scheme; financial security of instruments of dbaylivy virobnitstva.
Director - head coordinator - goiter at the short glider to hear the names of the best victories in the project. It is to ensure the steel systemic work and high status of the project.
Stage 3. Transformation and optimization of the transport and technological scheme, for the additional help of transformation to the PUSH system.
Problems. Formation of a non-viable data system with autonomous robots of specialists of the enterprise and the requested consultants.
The synergy effect of the project is due to the combined work of consultants from a consulting company and fahivtsiv business. It is not possible to pay for those that the consultants after a small number of labors bring ready and new life solutions. Only the practitioners of the business are well aware of the manufacturing processes and products. However, their weakness is lacking knowledge of how to organize a charitable production. Decisions about how to blame the project are discussed and accepted in full. Practical knowledge of recruiters, supported by scientific knowledge of consultants, to ensure the necessary result, otherwise it seems to be the cause of a synergistic effect.
Stage 4. Planning the manufacturing process for an optimized transport and technological scheme.
Problems. A large number of unprepared practitioners were hired for the implementation of the project for entrepreneurship.
The effect of ostentation is formed for the apparent success of the first steps of the project implementation. One (pilot) technological line is tested to create the effect of precision. The process of її transformation into a prudently looks like a show. Therefore, in the new may be the core of the participants in the project, and the director of the enterprise and the top managers are the leaders of the functional directives. The visible success of the building reconciliation of skeptics and enthusiasts. Naygolovnіshe, leaders of the group, krіm dosvіdu, owe nabouti innocence at the correctness of the chosen path.
Stage 5. Introduction of optimized vaping strains into operation.
Problems. Navіt practitioners, as they took part in the design of a long-term production, are not always ready to change to a new organization of practice. Other practitioners often look at sparingly as a way to sweat. Negative thoughts are blamed on them: we will improve timely pictorial displays, and the stoners will speed up tsim and see prices. At a glance, the problem can be eliminated by a forward transition to the annual payment of the cost of the standardized task. Protemasova vіdmova vіd vіdryadnoї payment prіtі basic period zіvnyuє zarobіtok robobіtok rіznої ї nіfіfіkаtsії. The productivity of the practice for business will change.
Парето-ефективність проекту, що свідчить про взаємному інтересі менеджменту та робітників виявиться, якщо у процесі навчання працівників буде переконливо доведено, що при зростанні продуктивності інтенсивність праці лише знижується за рахунок усунення зайвих трудових прийомів та дій, а середній рівень зарплати безпосередньо пов'язаний із productivity of work.
Stage 6. Newly mastered the tools for the mechanism of dbayly virobnitstv.
Problems. If you do not support the activity of the workers, it will calm down, and the project will become obsolete.
The effect of non-returnability of the project creates a critical mass of victors, as I take part in the launch of the project of vicious viability. Sufficient and necessary mental effect of irreversibility - 2 mind: the reach of compassion on a pilot line; the reaction of top managers to whether or not the proposition of the teams is natural. First, I create a virtuous base of admission for the preparation of practitioners to win the mechanism of double selection. Others will be morally satisfied with participation in the project.
http://www.ifsrussia.ru/publsch7.htm
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 past century, and then they were fully implemented in Japan. At the company "Toyota" a system was created, meta yakoї - speed or liquidity diyalnіst, that saves resources and does not add vartіst, so that you don't have to pay for yaku.
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 additional (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 signatures of the chiefs, the ability to quickly get hold of the possessions, telephone calls, and the supply of materials from the posts of the chiefs is too short.
Analyze, yakі signatures on the documents with the right necessary, liquidate all applications and standardize the new procedure;
- learn spіvrobіtnikіv mіzhnyh profesіyam, schob stink could replace one of one;
- 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 claims (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;
- Significantly, if the signatures on the documents are definitively necessary, 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 and the reasons for the zayvih ruhіv vykonavtsіv - walking, stretching, thinning.
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-explore the already broken work, in such a defect, insanely, you can go to the category of waste, the shards of a robot 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. Responsible for the adoption of these expenses to save millions of dollars to these organizations, as they regularly evaluate their activities for the standards of double-dealing virobnitstv. Spend more money on the cost of 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 practical supply of tools for effective development 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 clogging - a waste of time. 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 herds, viklikayut vinikennia, it is hung up, and the formavnya systems - repeatedly, it is possible to know the same, in the absolute
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 urgently require a process description for 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, investments in the production 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.
Stage 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 responsible for a lot of time for understanding, that is why they contain detailed knowledge, little pictures, diagrams, photographs.
- 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 zabіv sobіv control over the camp to the product and zavantazhenіstyu obladnannya.
- 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 to improve.
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 and not to add tsіnіst), necessary, to make 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, the 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 remaining activities may be necessary and may not be used (for example, accounting), so they may be as optimized as possible, 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 on operators' possession.
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 to promote 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, petroleum chemistry, energy, the agricultural state, transport and communication, 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 minimum 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) variability" (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 who saw American backwaters and laid the foundation for the organization of the Toyota Motor company's manufacturing system.
T. Vono having developed a simple set of goals for encouraging the system of car selection: to make a car as quickly as possible, to do it negligently and not to save everyday industrial reserves. 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 vіd "shtovhaєє" system, scho create non-necessary stocks at all stages of production independently from drink and transition to "thick" 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, vydіlyayat dodatkovі vtrat, for example, "hibnu ekonomіyu", scho in the offensive actions: vikoristannya cheap and neakіsnoї 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 organization of the order, the improvement 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 vstanovih (standardized) methods, without spending money on the improvement of the hands of the practitioner (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. Reconciliation and management of the quality assurance process is carried out by the victorious operators, so that they are reconsidered, what products, what to go to the next stage of the process of necessary quality;
12. Storing the necessary items. Syrovina, details, information, tools, working standards and descriptions of procedures are there, de stink is needed;
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 stages:
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 "exactly 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 fahivtsіv it is noted that behind the zavdannya, zmіst 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 on an American warehouse, they create cars - and they worked much more efficiently here, lower in their homes - 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.Since 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 exclaim dissatisfaction with your employers, - guard Modi s Oracle Corporation. - Successful companies have learned the principles of "forgiveness" and 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 and the Pella Corporation love to tell, as through the river of the introduction of resource-saving methods, the director of IT, having asked him to prepare a call 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, which was a 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. - There is no price to pay."
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 with additional rescheduling, rescheduling 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 the cob of 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, the chips will require an analysis of a large number of factors. Before such officials are put: the structure of the commotion, the camp of the market, the productivity of the establishment, the schedule of robotic changes, then. 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 storage of materials and products for ensuring 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 ruhi can greet the ebullient diyalnist, and if you marvel at it, you can swear that the stench will saturate the creation of the value of 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);
It is brought to the hits, the methods of managing the Vobrinza is not enough in the same gallows I can’t do the pre -Opomogty of Army, Ale Riznitsy Mizh Organi Organi on the VPK I, the factory of the vicinity of the technician processes in the army and the sphere of services. Logistics, delivery, purchase, medical services, work with a personnel warehouse - why would these processes not be zdіysnyuvalis - in either place or in the zone of military dіy - the stench passes, in fact, however, and often sticks with those very foldings, which means, can rely on your own solutions. Techniques that are practiced in civilized galuzahs of craftsmanship, to bring profits to military galuzakhs, that was a confirmation.
USA
Today, the military forces of the United States, connected with them by the state structures and enterprises of the military-industrial complex, are going through, apparently, the most serious transformation of the decade. And there is no question of re-arrangement of cadres and reshuffles in the higher echelons of the military command. The new sickness that the army of all equals has stumbled upon, becoming Lin.
1.3 million people - this is the largest number of kaizen teams of US military forces. The concept that originated and developed within the framework of the automotive industry, today successfully serve for the benefit of the country, transforming army units, departments of the Ministry of Defense, enterprises of the military-industrial complex of the country.
Why did the current concept of the management of virobnitstvo zatsіkavili the US Department of Defense and how did it become such a streak of speech?
Viysk's promissory is due to the majestic vibrancy and vimagaє nayvishchoї yaskosti and arrogance of virobleny obladnannya. It is especially important for the US Army to carry out active military operations in different countries of the world. No less graciously provide financial support to the literate distribution of the state budget, in which case there are no large sums of money.
Michael Kirby, the intercessor of the Minister of Nutrition for the Modernization of the Army, said that at the singing moment it became clear: the need for modernization could not be overestimated. "The US Army is an ultra-modern, highly efficient military machine, but our practices of conducting internal processes were stuck in the middle of the 20th century," Kirby said.
To solve the main problems, within the framework of the ministry, a team was formed to search for the optimal development path. Most of the time it was omitted from benchmarking.
“We began to analyze how processes are organized in various organizations, in enterprises of various profiles, and we showed that we can zastosuvat low practices in ourselves,” Lieutenant General Ross Thompson, responsible for supply, logistics and technology, said. - For example, the Warner Robins Center for Surveillance Logistics has successfully implemented Lin. We have a butt in front of our eyes, like saying: so, tse pratsyuvateme. We have assessed the stagnation of lin-instruments in the management of defences”.
Having looked at the low concept, the US Department of Defense laid down the concept of Six Sigma as its main principles. Being developed in Motorola Corporation and popularized by General Electric's success stories, the concept is stagnant and for Russian structures, shards of scaling different processes and is directly based on increasing the quality of outputs of any of them, minimizing defects in and on standardization of production.
Мета програми Лін та Шість сигм, що залучає як військовослужбовців та співробітників міністерства оборони та відповідних структур, так і працівників підприємств та підрядників, полягає в тому, «щоб зробити виробництво, постачання, діловодство такими ж ефективними, як військові операції», - розповідає Рональд Rezek. , a special assistant to the US Minister of Defense.
The first promotion of Lin was the establishment of the RedRiver army warehouse in Texas, one of the centers for the repair and technical support. The current name success is already at the first stages of launching a system of uninterrupted improvements, becoming a butt for other developments.
Massive expansion of Six Sigma in the American army rose like the year 2005 for US Secretary of the Army Francis Harvey. The very same team from the first months of work took up the revision of the processes that are taking place in the army and ministries. Lt Colonel Marko Nikityuk became the yogo intercessor for the formation of the Shist Sіgm and Lіn promotion program.
Speaking about the scale of Lin's larceny in the army, it is necessary to understand what the US army is like:
Formed: 1775 rіk
Number (including the reserve and the National Guard): 1.3 million
Number of operations in the whole world: 4100
Presence at: 120 countries of the world
Budget (for 2006):$175.8 billion
The start of the project in 2005 was the piloting of the command, army and ministerial servicemen, working enterprises of the military-industrial complex about those, with some processes they blamed the most problems, such as the stench of bachat їх virishennya. “So we wanted to bring out the most cautious, enterprising and ready to learn people,” Nikityuk explains.
A group of consultants was requested for the training of specialists, and a significant vote was made for the preparation of local lin-trainers. The trainings started in 2006; In 2008, the number of trained coaches reached 446 points, with the leaders of the groups being blamed, the number of them increased to 1240 points.
Six Sigma program, 2008
Start: 2005 rіk
Number of top coaches:
- Pochatkіvtsі - 1240
- Certificates - 446
- Maistri Shіst Sіgm - 15
Number of projects: 1069 completions, 1681 in progress
Amount of savings: 2 billion dollars
The difference between the distribution of Lin and Six Sigma in enterprises and in state structures is really not so great. “They work for one model,” says Nikityuk. - Centralized planning and decentralized planning.
Just like in the industry, so it is in the structure of the Ministry of Defense - in the military districts, departments, enterprises of the military-industrial complex - Lіn pratsyuє on the formation of culture without interruption to improve, to ensure the speed of the loss of expenses, to carry out operations, to inefficient use of resources. Classical methods of charting the flow of value creation are successfully introduced into the “arsenal” of process management methods, speeding up the cycle to increase the efficiency of work, and to my state budget - it means saving money, as they can be channeled into other needs.
Є і vіdminnostі, і deyakі z them - pozitivnі. Let's say, in the army structures, prompted by the pretrial orders, the internal support for innovations appears to be richly weak, lower on the undertakings of civilians.
Another important aspect is the difference in scale. Today, to get the most business is impossible to compare with the Ukrainian complex of the country in all respects.
“We have won the best evidence of industrial undertakings to assess our progress and the formation of a further plan, - it seems Kirby, - but then we remembered that we had to rewrite the system of showings for ourselves, for organizing such a expansion, like the US military machine. Ale and tse zavdannya for a competent approach to the whole zdijsnenne.
Chinnim decision to become an internal portal - a single system for the exchange of information, the creation of bases of ideas, the collection of statistical data. The key indicators for any project were the reduction of cost savings, the reduction of the cycle time, the increase in the quality of the product and the process.
There are others who are doubtful about the possibility of zastosuvannya Lіn in the Viysk industry - the results seem to be for themselves:
- U.S. Navy-Marine Forces: savings for the first river in the sale - 450 million dollars; ROI - 4:1;
- Production of military-transport aircraft Lockheed C-130J: an hour of work at the stamping shop for one aircraft was shortened from 12 days to 3 minutes;
- Variety of electronic modules for military needs: speed of compatibility by 73%;
- Delta IV launch vehicle growth rate: 63% shortfall of breaking ground;
- Preparation of components for the General Dynamics F-16 Fighting Falcon vinischuvach: shortening the cycle time by 75%;
- JDAM versatility (equipment kit based on GPS technology, which transforms bombs, which can fall freely, and has all-weather corrected ammunition): 63% faster compatibility.
Lin in the US Army- ce modernization of enterprises, directing the shortfall in expenditures and the number of defects in the greater effective achievement of the state budget. Одночасно з переведенням підприємств на рейки нової економіки Лін почав впроваджуватися по всій мережі пов'язаних з обороною установ: від військових міністерств, відомств, військових академій та тренувальних таборів, що борються з бюрократією та нераціональним витратою ресурсів, до військових частин, міжнародних баз та підрозділів , which will lead to combat operations in hot spots. Here Lin-logistics, JIT, improvement of information flows become a guarantee for the order of life and success of operations, giving the opportunity to quickly improve the supply and apply the necessary support. With the improvement of military operations, which are carried out on decal lines, the price of success has never been so high.
Nіmechchina
As the United States speaks on Lin and Six Sigma in their classical mind, then Nimechchina promotes the efficiency of its processes behind an additional system of uninterrupted supply, or KVP. Practically, skin care is so much more likely to want the fate of your practitioners' losses, narrow areas, problem areas in virobnicheskih and non-virobnicheskikh processes. Undertakings of the military-industrial complex, military forces, departments and ministries are not to blame.
Here KVP is also not a big initiative, which is poking around in a lot of "solid" parts of business. Until the introduction of that conception, the ministry of defense of the city of Nemechchiny went systemically, with true pragmatism and schilnistyu to order.
In 2008, the statute was created, in which it was concluded Program of uninterrupted improvements in the Bundeswehr . It is necessary to take revenge on your own algorithm of filing, processing and implementation of propositions in a way that is improved, fixing the functions of the NPU consultant and other important issues, depending on the current nutrition, which is blamed on the process of work. Being an official document of the Ministry of Defence, the Statute has also become a kind of reminder for all those in trouble, to the extent that stench can rage in any nasty situation.
Programming without interruption was followed by a serious push on the most important level: practical papers and instructions were published, the internal border was expanded for the exchange of information, booklets and flyers were expanded, special visits were made, and a Bank of Ideas was formed. Participants of the program are rewarded with valuable prizes and prizes up to 25 thousand euros, and they can also take away a car.
Such a serious robot did not bother to bring results: savings for the first river in the cost of spending was close to 8 million euros. Today, the Bundeswehr receives 60% of the rationalizations that are given by all the federal services of the city. Nearly 2,000 propositions are being processed in bulk.
In Russia, Line, Six Sigma, Kaidzen, and other management concepts are being implemented most importantly at the enterprises of civilized galleys of industry - in metallurgy, machine and automobile production, energy, chemistry, food industry. Nevirobnichi galuzі, vіysk's promislovіst zalishayutsya practi- cally unborrowed tsimi zminami, like the United States and Germany form a new look at the process.
For example, the State Corporation "Rostec", which promotes the production of high-tech products of civil and military recognition, began to promote Lean manufacturing at its enterprises. For example, in 2012, she created the Center for Optimization of Virobnicheskikh Systems, which developed the methods of dbailivy virobnizstva leading lighting companies. Ale, in the right way of Russia, today there is no systemic approach, which is supported on the most equal level.
The need for change has been long overdue. For days, the intercessor of the Minister of Defense of the Russian Federation, Ruslan Tsalikov, has declared that there are three whales on which the defense of the country is built. The first one is the development of that military technique. The other is the infrastructure. The third is personnel and a block of social nutrition. In the presence of the skin segments, it will inevitably weaken the strength of the veins. LIN allowed Opersovati all three by the same: Pydvichychi yakosti, the worship of the sorceressed funeral, like Ozbrinnya, rosovychi, the form of the form in the SPIVBITYVIVIVIVIVIVIMSITS TA MINISTRICTIONS, at the same civil services, the culture of active areas are spent in the nurses.
By launching the program of modernization of the country's military-industrial complex, the President of the Order of the Russian Federation directs the development of billions of rubles. Prote pennies vyrishyuyut not all. The military-industrial complex itself, its enterprises and structures, have a majestic potential, which, for a proper development, allows not only to spare millions, but also to send mail to the “updating” at the sumizhny galuzy, tied to the security of the military-industrial complex.
Prepared by Nataliya Konoshenko
STRATEGY AND TACTICS OF PROVIDING LEAN PRODUCTION
WHY DO YOU START?
It is permissible, you understand, that your company can become sparing. Let's just repeat the cost, you don't pass more tests, the culture is far from equal to Toyota. The system of leaders every day, there are no effective working groups, the functional ones spend most of the time at the confrontation station, the methods of solving problems are superficial and inconsequential. Wanting to try some tools of sparing virobnitstva on the okremih dalyankah and navіt otrimali bad short-line results, no success was achieved.
We kindly ask you to reality, in the same way you will change more companies in the world. Navit Toyota to be brought to practice tirelessly, pіdtremuyuchi its Tao. The widened dao posture of Japan is given to the company in a richly folded way. Tse is incomprehensible, important worker.
Why start? Let's talk about strategy and tactics. Starting with the help of dbaylive virobnitstvo, you need to virishite on what to concentrate zusilla. Otherwise, we need a plan. Maє buti rich work, and є impersonal ways її vikonati.
It is my belief that all the equal parts of the Toyota model – philosophy, process, partners and partners and the solution of problems – intertwine with each other in the most complicated way. The whole system. Ale z chogos all the same to happen to fix it. Navitija vy kіlka rokіv ineffectually occupies itself with the development of dbaylivogo virobnitstv, you need a starting point to give the process a new impetus. You have at least a couple of options:
1. Philosophy. It is possible to develop the concept of reorganization of the company on a savvy enterprise.
2. Process. It is possible to understand from the introduction of thrifty virobnitstv through the creation of connected streams in the creation of value, which is found in part III of the book.
3. Spivrobitniki. It is possible to start teaching people a new way of thinking - the philosophy of conscientious thinking - and in such a rite to give a post-reformation of culture.
4. The solution to the problems. You can teach people the methodology of solving problems, give them the opportunity to choose at once and analyze real situations.
All the times come and go by fate to be zastosovuyutsya different companies with changing success. In the next world, you will be able to win the leather of them. Alternately, it is necessary to choose directly for the concentration of zusil, if the process can be done, then the cost will be short.
LEAN PRODUCTION, STRATEGIES AND INSTRUMENTS
Structuring the plan of stosuvannya prudent virobnitstva can be іnakshe, having broken the organization of kіlka rivnіv 24 . Number of equals - in the form of an expanded business that unites all organizations and companies that value your products, to a specific process - presented in Table 19-1. Let's take a look at some of them, starting from the bottom, from the process.
| Table 19-1. Strategies and tools for promoting lean manufacturing | ||
|---|---|---|
| Rіven v provadzhennya | Strategy | Apply tools |
| Expanded business | Supply chain management | Contracts, alliances, determination of the target price, logistics, analysis of the quarter indicators / functional and quarterly analysis, training of post-employees, associations of post-employees |
| At the scale of undertaking | Genuine versatility in the office and design work | All tools and tools are suitable for careful manufacturing, adapted to manufacturing processes and processes of service |
| On the verge | Conceptual models, training programs, attestations of double-deep viability, demonstrations of double-degree viability, helpers of standard procedures | |
| Do scale factory | Tools to get in touch with the scale of the plant | 5S, standard work, kanban, middling, shift change, team leaders, TPM, early pardon |
| Actual projects | Analysis of obmezheniya, analysis of vitrates and results, be-like tools for dbaylivy virobnitstv | |
| The Potik of Creation of Value | Zrazkova line | Folding maps for the flow of value creation, tools for careful selection, necessary for the implementation of the concept of future life |
| Improvement of the process | Kaizen project | Practical seminar on kaizen, kaizen project, strength groups, work group, tools for the development of a specific purpose |
| Six Sigma Project | Six Sigma Tools |
Improvement of the process
Process - tse those, scho rob a specific practitioner on the typist or manually: tse stamping or zvaryuvannya parts, picking, mixing farby, receiving calls in the information and development service, introducing data then. To improve this process, you can follow a specific method - reduce the number of defects by 20%, increase productivity by speeding up the hour of the cycle by 20%, reduce the stock of work in progress by 50%, reduce downtime from 10 to 2% less.
For the completion of processes, as a strategy for mastering sparing manufacturing, such a tool is widely promoted, as is the current practical seminar on kaizen. The structure of the practical workshop on kaizen (whether the workshop on accelerated completion or the practical workshop on fast-paced virobnizstva) is as follows:
1. Early preparation. Two-chotiri tizhnі front
preparations, at the hour when the scale of the problem and the warehouse of the team are determined, data are collected about the current situation, the necessary tools are selected for careful selection and the nutrition for the safety of the seminar is selected. At a number of vipadkivs, it is necessary to go through the purchase of tools, materials and possessions in advance, as it is impossible to start the next hour of the seminar.
2. Conducting a seminar:
Monday. The participants will take into account the general awareness of the sparing choice and specific tools that will be used during the half hour of the seminar. On the day, the collection of data about the in-line mill of the process begins.
Second. Participants complete the analysis of the flow mill, collect data, map the flow of the process, depict the trajectory of the operator's movement on the work station planning scheme, expand the table of standardized work, etc. she develops ideas that succumb to the future. Until the end of the day, you can tell the details of the future camp (plan).
Wednesday. Pochatkov vikoristannya (robi). It can be a pilot project, which allows you to try out a proposed solution, or a large-scale implementation. Sometimes the production begins with the dismantling of the possessions and the furnishing of the workshop, after which it is necessary to arrange it appropriately before the new planning.
Thursday. Evaluation of the process (verify), refine (inject), away from the cycle “plan - work - reconsider - inject” (PDCA), until the overriding method is vibrated.
Friday. Preparing a presentation for management. presentation. The urochist is closed. (The seminar often ends with a Christmas reunion.)
3. Step in. Those who have not been able to work through the day are included in the list of domestic work, which is sometimes called the “Kaizen Newsletter”. At the course of the winter seminar, a plan is formed, in which it is indicated, if and to whom it is necessary to work, to bring it to the end.
In rich schools, practical kaizen seminars have gotten a bad reputation. Jim Womack slyly calls them "kayden kamikaze"
abo "kaiden by way". Vіn maє on vіvі, scho, strіmko spіkuvavshi down, viz vyrіshuєte a number of problems and so very quickly zlіtaє into the sky. On the right, not in the fact that practical seminars on kaizen are bad on their own, but in the fact that in rich companies, mastering a thrifty way of working is carried out to a series of such seminars, with which a special training is created, which is engaged in training, administration, and control. Some practical seminars from kaizen are included in the list of the most important shows in the organization. Such a pіdhіd mає kіlka serioznyh vad (div. fig. 19-1).
1. Practical seminars on kaizen focus on local improvement of the environmental process. For the appearance of a broad concept, it is impossible to secure a flow at the scale of business.
2. A practical seminar on kaizen will end with the folding of distant entries (homework). Most of the time, this work is overwhelmed with nevikonana, shards on the job do not have a right master of the process.
3. Wanting the staff at the work station to take part in the seminary and convocations at the same time to enthusiasm, after a while everything is forgotten and in more vipadkiv turns back to normal.
4. Most of the practical seminars on kaizen can only be judged by a short-line reduction in turnover, as it stimulates the right changes of a systemic nature.
5. There are no permanent changes in culture.
It does not mean that the company, as it seems to be up to the mastery of the careful production of everything, is not guilty of victorious practical seminars for kaizen as one of the tools. Seminars with kaizen mayut row advantages:
1. Tse hvilyuyucha pod_ya all participants. Intensive analysis and thorough analysis of each other's feelings, like giving a robot in a team, building a change of sight of people. The stench will start to poke and waste it, what you can do, if the stench is sunken.
2. Managers bachat, as soon as possible zusil vede until the result is achieved. Tsіlespryamovanіst dіy and vikoristannya system is important when rozpodіlі resources allow you to work wonders.
3. People are given a lot of things to learn. Intensive promotion of informing the staff of a wide range of opportunities, like, sounding, during the traditional classroom teaching.
4. Call for the seminars to see a penny and other necessary resources, including encouragement to management, as well as other support. With a stretch of the day, you can create a transformation, like in other minds, waking up for a long time of drinking, that mind is strong.
5. Most of the time, you can be smart about your own bik of skeptics. When instructed in the audience, a skeptic can ask for a word and start explaining why, in the light of a sympathetic choice, there is nothing to be cleared up. At the seminars of wines, with your own hands, bring yoga into life, talking about the pasture.
The butt of the Teppeso company from Smithville, Tennessee, illustrating the experience of a short period of practical seminars with kaizen. In this case, a radical reworking of seminars and kaizen took place once every two days, and they completely changed the look of the plant. For the help of kaizen, about 40% of the staff were sent away. Over the course of the year, the plant’s practitioners managed to hold such seminars at all virobnicheskih yards, moving hundreds of individuals and creating new terminals and acquiring virobivs near the zones of their virobistannya, after which the plant simply pretending to be. Surprisingly lowering the investment turned the respect of the company and spurred the general director to large-scale investments in the company's production. It should be noted that the seminars are far from being successful. At the Teppeso plant in Smithville, the work of practical kaizen workshops was co-ordinated by a veteran of gentle manufacturing, an informed trainer, who oriented the participants and the entire plant on a serious transformation. At the same time, seminars with kaizen are often held by coordinators, such as rejection of evidence, indifference and skill in kaizen with similar visits. For such minds, the seminar often did not go far beyond the 5S system.
Six sigma programs, which are designed to complete the process, may be about the same as the shortcomings that practical kaizen seminars are. Sound the project of six sigma may be great trivality (for example, a few months), you will be amazed by the “black belt” teachings, and the robot itself, in a significant world, revolves around statistical methods and vimiri. The Six Sigma Method is a development of quality-based management (TQM), six sigma principles are solidifying that Six Sigma is complementary with a focus on financial performance. It is important that the Six Sigma project can be awarded $100,000 for the company. A lot of companies are right to see the savings in Six Sigma projects and tell the numbers to stock market analysts. Teach a thousand people to win projects in two hundred thousand dollars, and in two seconds you will achieve enormous savings. If you want to use statistical tools in Six Sigma projects, which can be even more effective in the right hands and at the right time, the method may have low serious shortcomings.
1. The six sigma method gives such value to data analysis, choice different statistical procedures, reversing the statistical characteristics of data and the creation of new and reconciled links, which the analyst can use to check the project and pay respect to gemba.
2. Designed with the Six Sigma method, “green belts” or “black belts” are in the organization on special regulations. If you want such experts to be good at analyses, don’t stink to be sure about the process, which will be perfected.
3. "Black Belts" should often work on their own investigation and turn the robot into an engineering and technical project, which may not lead to the participation of other specialists.
4. In the midst of uninterrupted vikonavtsiv, it is often not possible to meet the “lord”, as a result, the recommended change is not to be tried for an hour.
5. The Six Sigma program does not have a philosophical basis, but the principle is to know, to die, to use a variation and to reward more pennies.
Such a pіdkhіd - to know, to understand, to analyze and correct the camp, to save pennies - often leads to local kaizen and for an hour seriously supersedes the principles of lean manufacturing. They gave suggestions for projects, as if they secured a reduction in the cost per unit of production, and at the same time they gave the organization a prudent choice, and with a sanction they brought it to the promotion of high prices:
Decrease in the hour of changeover, declaration of savings in labor costs due to the increase in changes in the party’s office and change (div. “Specific situation: reduction of trivality and changeover by the six sigma method”),
Decreased costs for transportation for the cost of managing the latest costs at a fast delivery frequency and increasing the level of stocks at the plant.
Short workforce for the cost of moving materials and remuneration entrusted to operators in the middle. Through the war, the pressure on the workers, who took on additional value, grew up with additional work, as they did not add value.
The method of "savvy versatility + six sigma" is taken from both systems more and more beautifully, the prote "sustainable" warehouse is often interpreted in a narrow way and reduced to technical tools, for example, the creation of a standard description of a standardized work. The result is local kaizen, for which tools like six sigma are used, as well as gentle vibrating. The creation of the flow of that change of culture, like the necessary support for the transformation in the development of sparing virobnitstv, is not. Such a mindset may be short, powerful optimization of the process for additional seminars on kaizen and six sigma tools.
Specific situation:
Tenneco, Smithville. Radical kaizen, 1st stage
Tenneco Automotive opened an exhaust system manufacturing plant near Smithville, Tennessee in 1994. The first customer was Toyota, later Nissan, Saturn, Honda and Corvette came before it. In 1996, the plant passed ISO 9000 certification, and then - QS 9000 standards. Everything went miraculously. It's a pity that the plant's work spun on the concept of "process forces" traditional for Tenneco, as it transferred the grouping of functions behind the functions - punching presses, pipe-forming machines, and manufacturing equipment. Everywhere lay a store of syrovini that unfinished work, the material was turned into great batches, so that it could pass a lot of changeovers. Calls at the factory went faster, lowered, and it was given, there was no need to change anything. The profitability of the plant was more than predicted, and the best of the company's sight - the allowance for the actual fund to pay for the work of the normative - the plan was changed by a million dollars.
However, in 2000 roci, anxiety symptoms began to appear, the surplus decreased. Although the quality of products dominated Toyota, the discipline of supply was cunning, which, according to the words of representatives of Toyota, became menacing. It went to the point that, due to some problems, Tenneco had a chance to pay the terms for the delivery of components by air from Japan, which cost 30 thousand. USD It became clear that the situation needs to be changed, otherwise in the future the company does not take away the desired promise - and Toyota's promises have taken care of half of the work for the plant. It's time for the new vice president to nominate Joe Czarniecki, who is oriented towards showing off something else. Vіn having declared that if the plant is profitable, for yogo rozrakhunkami, the profit margin can be increased by 20%. Vіn having analyzed the effectiveness of the work of auxiliary workers, investigating the above-standard work and stocks and revealing that all these indications are far from quiet, that having taken into account the correct wines. Nissan wanted to reduce prices by 20%, and Toyota launched a hell of a price reduction program. The need for transformation has become critical.
Recently, Tenneco asked for an expert on lean milling, Pasquale Digirolamo, who, after 8-12 months, could dedicate all his time to the plant and look at it as a pilot project for the development of lean milling at Tenneco. Dijirolamo and director of the plant Glenn Drodge talked three times a day - at a rankovy glider, at the middle of that day for example. Didzhirolamo engaged in coaching, but at the same time he was more daring and naive. Vіn bachiv, that the high level of discipline at the factory is low, and often repeating: You accept those with whom you are ready to accept.
The Japanese consulting company Shingijutsu taught Dijirolamo to conduct practical kaizen seminars aimed at radical transformation. Vіn vlashtovuvav such seminars kozhnі two tizhnі, at іlshostі vipadkіv for tizhden the seminar was created tsiliy vyrobnichiy seredok. For the first time, all operations for the preparation of warehouse nodes began to be fixed at the center. For the next six months, all operations from the residual folding were reorganized into the middle. The plant was practically created anew, the planning was changed again, it was possible to relocate 450 units of possession. The new terminals were closer to the production areas. Such a transformation has become an opportunity for practical kaizen workshops aimed at radical transformation. In fact, it’s not kaizen (without interruption to perfection), but kaikaku (radical transformation).
At the process of preparation to the fundamental reorganization of the plant, for some kind of boom, a river is needed, Dijirolamo rozrahuvav, which was too much workforce to become 40%. Vіn having pleased the speed of staff to the cob of Kaizen. Nasampered was a lot of timchasovyh pratsіvnіkіv, oskelki plant actively vykoristav їhnyu pratsyu. For the most part, it was proponated to the standard leave to help Teppeso, and a lot of those who waited a while to drink on their minds. In the wake of which, the primus line of practitioners with annual payment disappeared. Zvіlnennya bumped and majstrіv - we're quiet in front of us, who doesn't have managerial skills, necessary for new minds of sparing virobnitstv. As a matter of fact, the ownership of the plant by the director of the plant and Digerolamo essentially meant that the kermo ownership of the plant was transferred into the hands of Digerolamo.
Subsumkovy results were clear. Didzhirolamo appeared at the plant like a sensei at the fall of the leaves 2000 year. This is the hour of pishov for the victory of food stabilization. At the beginning of 2001, a charitable slander began to grow up, like a very coordinating committee at Smithville. Until Thursday, the situation had significantly improved, and the plant had begun to show off its planned shows, and the directors of other Teppeso plants began to chirp, which is seen at Smithville. During the first year, the cost of working on labor force decreased by 39%, the efficiency of the labor force of workers increased by 92%, the overall productivity of the workforce increased by 56%, the total reserves of the pennies decreased by half, which allowed for the transfer of 5 million dollars. cooking. The number of parts with major defects has decreased from 638 to 44 per million, and the hour of repair has shortened twice. In 2002, the plant first took off Toyota's reputation in the city for the high quality of its products and services.
As a way to beat the terminology, I will give a description of the approaches to the transformation, the plant near Smithville, with the first fate, staging a radical version of the kaizen projects. These projects went on without interruption, one by one. When to create-
wavy potik, wanting more vipadkіv vіn surrounded by okremim middles. Before the beginning of the fate of radical transformations, a sprinkling of kanban systems was introduced, and the main respect of Dijirolamo was added to the stability and creation of the core. Yogo pіdkhіd vіdrіznyаl orientatsija on podії. The main transformations were carried out quickly, opir skeptics, as well as at Smithville, and at other Teppeso factories. The results were obvious. A short glance at the reach should be directed at the table 19-2. In addition, the success of the plant has turned the respect of the general director of the company, which has become one of the priority directions. At that very hour, as if guessing about the spiral of uninterrupted thoroughness (the cycle, indications in Fig. 3-4, chapter 3), the robot, vikon on the scale of the plant, - stabilization, alignment with the flow, standardization - was only part of one turn. To create at the factory, I will build the Toyota system, it is necessary to work even more richly.
| Table 19-2. Mastering lean manufacturing at Smithville, the results of the 2001 turnaround | |
|---|---|
| Total number of staff | -39% |
| Salary personnel | -12% |
| Efficiency of the practice of virobnicheskih robotnikiv | +92% |
| Global productivity of work | +56% |
| Prepared stock, in pennies | -48% |
| Koshti, vivilnenі z with the help of a fast obligation of stocks | $5 millionadditional |
| The area of selection premises (for the total area of 200 TOV sq. ft.) | Vivilneno 8% |
| Number of major defects per million | From 638 to 44 (-93%) |
| The Hour of the Wisconsin | 50% |
| Quality and discipline of deliveries | Toyota's honors in 2002 |
As it will be told further in this division, stretching the coming three fates, the plant did not stick out much in the mastery of the sparing production, a number of creation systems fell into oblivion. The first ones at the factory took up the full flow of the folding of values, having opened up the folding of the folding line. The map of the in-line mill process, as it protected all the transformations, the growth of the kaizen seminars, showed that the insulated production centers are engaged in vishtovhuvanni production, which generates a great amount of stocks. The map of the future camp was broken up. After the entry vital one more streak was smashed to improve efficiency. Although radical changes in the course of practical seminars for kaizen have reshaped the plant and allowed significant improvement in efficiency, the stench has not ensured the change in culture and the creation of a connected flow.
Kaizen projects are used to select a number of tools for careful selection, which are used to complete specific tasks in a thorough process. A lot of methods for solving the problems described in section 13, with approaches to the thorough process. We told each other that we should develop methods for solving small, medium and great problems. The problems of the middle scale sound like they are behind the help of practical seminars on kaizen or six sigma projects (beyond Toyota), as shown in fig. 13-2. Tables 13-1, 13-2, 13-3 present a wide range of approaches that can be applied to Toyota for a thorough process. The middle of the tsikh went to the interfunctional teams, groups of agility, work groups, chosen by the leaders of the group and іn. Select methods to deposit according to the nature of the project. It may be an official project, which is transferred to the interfunctional team. The robot can be entrusted to an engineer, who will choose a special team. You can organize a kaizen seminar, which a working group can do for a small amount of positive encouragement.
All you see is the improvement of the process in Toyota may have low sleepiness:
1. As a rule, the director of a specific business is assigned the goals of hosin canri (politics) for the business, with which the goal is thoroughly on all levels, right up to the president of the company, poov'yazan_ himself.
2. Design to thoroughly process the steps described in Sections 13-17. In the residual view, it is possible to file for the AZ format, to which Chapter 18 is assigned. Regardless of whether or not such a star is presented - on the wall, on the doshtsi, or on the arch paper to the AZ format - it is inevitable to place those warehouses themselves. (Formulation of the problem, detailed task, looking at alternatives, choosing alternatives, rounding, results, further diї).
3. The robot is victorious up to the cycle “plan - work - revise - pour in”.
4. The work to serve as a part of the process of training the organization in the whole, and the most important knowledge and knowledge become the foundation of the organization.
Critical projects
When vikonanna be-like robots, they sometimes blame the painful problems that seem to be a nega- tive virishennia, and the one who dares to suck them out becomes a hero. Mova can go about the operation, as it is a narrow space and constantly changing the schedule. Tse mozhe buti important possession, like lamaetsya at an inopportune moment. It is possible, on the right, in the problems of yakіstyu, through yakі tsili groups of practitioners of confusion, to be engaged in less inspections and rework.
Gentle thoughts and the beginnings of the solution of problems allow you to quickly run into similar inaccuracies. As a method that allows you to quickly solve problems of this kind, companies win practical seminars with kaizen. On fig. 19-2 stars put together the strengths and weaknesses of the focus on critical projects.
| Characteristics of rice | | |
| Invisibility: to know the term | Active companies win practical |
| s crisis | kaizen seminars |
| One pokanik | |
| Reading zavdannya thoroughly | |
| Polishing of insulation processes | |
| Strengths Highly motivated/active supportive Resources, as a rule, available pasta The presence of a large-scale enterprise / a single strategy The presence of a system that ensures the stability of the transformation Risks of a return There is no “lord”, as an initiative for the idea of a functional support | |
Rice. 19-2. Strengths and weaknesses of the critical project method
We have consulted companies, the management of which has leaned to the point of thrifty variance with frequent skepticism, despite the confirmation of its effectiveness. Admitting that the gentle potential of the singing potential and varto try yoga in practice, the cerivniki vychikuval, wondering, chi zastosovuєtsya out to their work and the sum of their culture. In such moods, we sometimes feed: “What bothers you especially? What problems keep you awake at night?” Calling out vіdpovіdі allows you to reveal a number of miraculous possibilities for the negainous transformations, the results of which are to confuse the curiosity of simply spending language. Until then, as you have taken on a project, which is important for kerіvnitstva, imovіrno, you will be helped to fix it up, be it a change, grant access to resources and, for the need, give the strongman a boost. If the camp miraculously grows, the management begins to believe in new developments.
And to the one who walks with a sword, you can die from the sword. If managers are working, how to develop technologies, they are violating critical problems, the stench is starting to want more. "Let's move on to this village, there is a serious problem here." Abo: “Hi, it’s better to take care of this accursed workbench. As soon as I showed up, I saw some inaccuracies. It’s okay to go all the way to the bottomless low of local kaizen, like during practical seminars. It's all the same to give a drug addict a high-yielding drug. Wait a minute, what will be the result?
Too many Six Sigma projects are "critical". Vіd "black belts" vymagayut, schobi be-any project obov'yazkovo giving great savings. The easiest way to get there is to know the critical project. The purpose of this is to show the pointing lower butt of the short-term trivality of the changeover using the six sigma method. The task of which project was supposed to be in a narrow place in the process of littya under the pressure, speeding up the reloading period. The project turned out to be successful and saved up to 30 thousand rubles. USD on r_k for rahunok skorochennya vytrat on working force in the process of retraining. It's a pity, in view of the prudent production of this project, it called for the expansion of the parties and the obligation to stockpile molded parts and the growth of scorched stains. The six sigma method, with all its subtlety, allowed to reduce the hour of changeover to only 1.2 years, which is far from the level of light.
Tse does not mean that next time and next time you should move in the direction of the emphasis on critical projects. In the first place, such projects allow you to quickly achieve good results and take away the right to engage in more thoughtful molding of a system of careful manufacturing, focusing on a long-term perspective, and also, a penny deposit in a bank. In a different way, work on such projects is carried out by those who are engaged in the development of double-dealing virobnitstva to finish the trival hour. If the main systems of gentle variation have been formed, the basic level of stability of security has been created, the variation has been developed, and people are practicing in teams that may have developed the ability to solve problems, practice over important problems often. The same problem is oriented to kaizen. However, such projects are only part of the organic kaizen process, and they cannot be driven by the force of the transition to lean manufacturing.
A specific situation: fast trivality changeover using the six sigma method for the adoption of a high school 25
At the plant, which produces auto components, including headlights, a young woman-engineer was preparing to win the title of "black belt". Like a project, she chose an important problem, like she started a long life at the plant. The problem seemed to lie in the fact that the transcendental amount of time and resources was spent on the remanufacturing of machines for casting plastic under a vice. In Trivale, the change of remuneration robbed of the littya under the vise of a narrow hand.
Report data were collected. The hour of changeover is the hour of the transition to a different type of virobiv in the average, becoming 3.5 years old. Changeover of leather from 34 machines was carried out three times a day. The amount of time spent in the county was 357 years for a day. Bulo was appointed as a measure of trivality changeover - 2.5 years. More than three times the change was considered as a defect. The basic goal of the project was that half of the turnovers were less than 2.5 years old, and also, the number of defects was reduced by a small amount. Bulo was set and overplanned task - to ensure that 90% of the changeover was completed in 2.5 years and less.
In order to determine the rozpodіl ymovіrnostі for re-adjustment, the significance of the data was analyzed. The analysis allowed to reveal statistically significant data for various changes, machines and molds. The system of vimіryuvannya trevalnosti renagodzhennya and the stability of the process was also reconsidered for the help of statistical methods, after which the report map of the reimplementation process was expanded. The robots were victorious with various statistical tools, Student's test, Weibull's test, block diagrams ("boxes with whiskers"), and the graph under the ymovirnosti. In the Crimea, more traditional tools of sparing virobnitsva were zastosovulysya, so as a folded transfer of steps in the process and subdivision of the operation to change to the outside and internal. Operations with ovn_shnyoї changeover can be done, the docking machine goes through repair, internal changeover can be done with teeth. All the vidi dialnosti were ranked fallow at the hour of the night. Bula folded causal-inheritance diagram "rib'yachy skeleton", in a kakіy buli vіdobrazhenі factori, scho reduce the efficiency of reloading, po'yazanі z materials, ob-
ruduvannyam, people, methods, vimirami and navkolishnim middle ground. Two most important reasons were revealed - the cost of the changeover and the process of heating the mold, which was 38% of the total changeover hour, or 1.3 years. In addition, it was revealed that 12 out of 22 operations can be vacated while the machine continues to work (external operations).
The engineer, who was preparing to become a black belt, adopted the brainstorming method to generate perfect ideas. Before that, the workers were trained in the workshop. As a result, it was possible to implement the following ideas:
Fold the schedule for changing the molds so that the given procedure falls on the lunch break. It is not allowed to warm up the molds for an hour of lunch (we spent on the front heating of the molds being untruthful).
Add an additional visa.
The deputy of that schob to hand over the retraining to the operators, to see a special team for the work, as it is possible to save a part of the operation from the old retraining, while the machine continues to work.
The results turned the whole display. Were selected report data, which were put on the charts and analyzed. The results showed a significant improvement in the situation, which accounted for 98% - 2828 defects per million (the defect was cited as a changeover over 2.5 years). Now, the average changeover took 1.2 years, which is significantly less than a 2.5 year old. An analysis of the economy, which vrakhovuvav vrakhovuva us ahead of short labor costs for re-taxing, showing that the won was worth 300 yew. USD on river In fact, the number of changeovers per day exceeded the mortgage at the koshtoris, and in parallel, work was carried out to stabilize the schedule and the shortness of the number of changeovers. Vinikli superechki, chi need to evaluate the savings of labor resources for the project's salary at the current moment, or to improve the speed of their number in the future.
Otzhe, the project turned out to be successful? What can you doubt? Let's think about what's wrong here:
1. A few months went to work. For more than an hour it was spent on collapsible statistical analysis and preparation of presentation materials. Yakby for a similar work, having taken up the knowledge of fakhivets from a dbayly virobnitstv, everything could be done by stretching one week's seminar for kaizen.
2. Engineer vikonala most of the work itself. Vaughn didn’t get to the point of participation the staff of the virobnichos’ house, and she didn’t slander.
3. The engineer underestimated the least important ideas. For example, she came up with the idea of early heating of molds, as if playing a vital role. Yakby agent was changed by a certified virobnik, respect would be attached to the idea itself.
4. Tsіl'ovy pokaznik 2.5 years is not foldable, which requires effort, and navіt 1.2 years for the changeover of possession for littya under the yoke - too long for "serious" meti. An acceptable planned indicator can become 15-20 quilins, and overplanning - 5 quilins. The very same hour borrows a change of salary at the factories that have mastered the dbaylive manufacturing. Fifteen days of reworking allowed to increase the number of changeovers, to reduce. Expanding the party and with whom it is significant to speed up labor.
5. Become less thrifty in the process of creating value. The map of the flow of value creation did not develop. The map, folded after the fact, showed that the short-term changeover for the details had been lying for five days. The short period of change, now timed until the break for lunch, in the future, with further changes in the number of change times, has led to the fact that now the stock of parts has been adjusted for a little more work for a little more days, which means that the trivality of the brewing cycle has grown. Folding the map to the flow of the creation of value could lead to the idea that the meta of the short-term change of time - to increase the frequency, to speed up the storage.
Plant-wide production of tools for large-scale production
The brother of critical projects is the method that can be called "critical tools". Quite often, within the framework of short courses, it is evident from the double variance that the main goals of the participants are to get the tools to work, so that they can get stuck in the robot. The very tools seem to people to be special, which can bring real mischief. Theories are good, but the tools are bad.
There is nothing nasty in such a relationship to the tools of a powerful tool. Teslyari, musicians, athletes, engineers and professionals in any other area, insanely, are responsible for the masters of their craft. Who has no spare sums. Nutrition in the other: chi on the cob of mastering the sparing virobnitstva orientate the main rank of the next training on the tools of that yogo last vykoristannya at the scale of business.
Such a subsequent selection of tools at the scale of the plant may have additional moments, which are indicated in fig. 19-3. If the warehouse of the company has a small number of enterprises, you can win all of them. So, you can use the tools of a dbaylivy virobnitstva, including a standardized robot, a blatant eye for possessions, 5S, a changeover, a midpoint, a kanban, an early pardon, six sigma and a new work group. Tsej pіdkhіd є vіdno svydkoy, clumsy and inexpensive way, which allows you to learn a lot of things, reach global recognition, develop standard models of production and lay the foundation for a distant molding of the system of thrifty manufacturing. At branch 4, one speaks of the importance of ensuring stability before the flow. Why not start implementing on a scale of organization the instruments of security of stability, for example, a wild eye for the possession of that standardized work? ^
In razdіlі 3 it was said that linking two operations to create a flow between them would ensure the basic stability of the process. We talked about those that dbayliv virobnitstvo - tse system and koristuvatisya її the results of the whole world allow more creation to the stream. Tse can be seen, if the system dіє. You can take care of the fates of stabilizing the robots of the okremy workers, making connections between the streams and allowing yourself the opportunity to be recognized, which can be done sparingly. How to balance stability from the foundation, go out, you are laying one foundation after the other, and you won’t reach the building on the right.
Understanding the booth is more important to the one who mutually replaces one of the other. For example, in order to match the flow of the necessary stable processes, the process reduces the water flow and helps to achieve stability. It’s easy to run the pot, but it’s still vibrating with strength, occupied day by day with preventive maintenance of the possession, the grain of which does not flow into the offensive process, which one can you stock up? Well, if the breakage of the workbench interrupts the attacking process and the faults are fixed, the repair of the workbench and preventive maintenance become unavoidable.
Instruments of sparing virobnitstv, pokkanі priyati susunennyu vtrat - not vіdіrvaniya vіd іnshih zasіb. The main positive result of a short changeover is the ability to change the time of change more often and lower the party's size, and at the same time, at your own pace, spriya virіvnyuvannu vrobnitstva. Tim is no less, we have worked with a lot of companies, as if they were victorious in reducing the changeover as an autonomous tool for the sake of turning more details and processing the material in even larger batches. This is more obvious than the idea being created.
Vlasna virobnicha system
Now let's take a closer look - to talk about the organization as a whole. Let's assume that the vice-president of virobnitstva virishiv seriously engages in the development of dbailivy virobnitstva. Having learned about this idea through books or through other companies' benchmarking, and perhaps through successful seminars from kayden or through critical projects, the representative of the greater ceramics industry declares: "We need a proper system of careful selection." It's wonderful, the very setting up to a sparing virobnitstvom we do it.
We helped to build the power system in several companies. One of the biggest projects was the creation of the Ford vibration system in the middle of the 1990s, although here, sing-songly, we can talk more about the creation, the TPS splinted on the Ford system. The history of skin care of such projects is shown in full in fig. 19-4. The consultants are engaged in the “workings” of the system, working with representatives of the administrative staff of the enterprise, as they encourage the selection of lean manufacturing, and hiring other employees to work. If you want the basis of such a system to be TPS, it is possible to have differences in terminology, specific intent (Ford, for example, vicorist model, where five mutually dependent components are included) and other principles, such as to lie in the company's characteristics. It’s time for me to go to the vibration of the movie and the creation of the image. In order to take advantage of the greatest curiosity, to write a lot of documents and work a large number of presentations.
Various parameters of standard working procedures are purchased in addition. Conducted an audit of the dbaylivy virobnitstva. The company is aware that the system of indications is based on stimulating models of the behavior of mass vigilance. Vaughn is initiating a system of showings of thrifty
the first time: the hour of the prayer, the first time, the efficiency of the possession. The morale of the practitioners is due for help. For example, Ford has developed a complex of the most important indications for five skin components.
The development of a new manufacturing system (sometimes called an “operating system”) is the process of learning that learning: learning - cultivating the basic concepts of gentle manufacturing, and learning - mastering the specific features of the operating system. For example, the Ford company, having found a rich day's rate due to the establishment of a new system of ostentatious bribery, shards of leather from factories, smelting from the whole world, is guilty of more or less zvіtuvati for new oscars. The main respect should be given to a single brewing system, standard for all brewing businesses. So pratsyuє Toyota, and tse dієviy pіdhіd. Vіn daє I can easily exchange a forwarding dosvіdom.
The development of that implementation of a single operating system may have a lot of positive results. In the organization there is an individual image, which is identified with the operating system. A common language is being created, as it allows the exchange of information about the movement in advance. The system of pokaznikіv prudent virobnitstvu priyaє stabilizatsії and shaping the flow that does not want to nadvirobnitstvo.
What are the shortcomings of the approach, why can there be such obvious advances? Naygolovnіshe - do not put vіz in front of the horse. Tao Toyota spiraєtsya on diї that navchannya on vlasnomu dosvidі. Such a pidhіd conveys that the help of a reasonable philanthropy comes only once, if people have the ability to try a thrifty variance like a system. Otherwise, it is left with just an abstract idea, as you can understand smartly, but not try it on the dot. Having acquired її theoretically, you can no longer philosophize about it. In fact, you face three problems:
1. How can I create a virobnichi system, without looking at a deep type of new manifestation of sparing virobnitstvo?
2. This process is often related to the consensus of the consensus, and it should be known that the company knows well what is such a thrifty production, otherwise it is known daily.
From the book Marketing war author Rice El From the book Exhibition. Technique and technology success author Zakharenko GennadyStrategy and tactics Yak was appointed, the work of the stand is to blame for the assignment of appointments by order of the orders of the stand's keeper. Vіn carry personal vidpovіdalnіst for the camp stand, yoga security, staff. Ker_vnik stand v_dpov_daє for vikonannya
From books Advertising activities of newspapers and magazines author Nazaikin Oleksandr 3 books Marketing. Course of lectures author Basovsky Leonid YukhimovichStrategy and tactic of price setting The company will set a new price, and then we will correct the various factors that are needed in the middle. Set prices for new goods. The strategic approach of the company to the problem of pricing is often deposited in
Books Marionettes to business author Sharipkina Marina5.4. Strategy and tactics of negotiation With the inevitable approach of partnerships, negotiations. Negotiate - the whole process, in which the mutually acceptable positions of the parties are vibrated. So that the negotiations were successful, i.e. all parties
From the books of Enkodi: How to make home with Kim for sure, that about it for sure author Khodorich OleksiyROZDIL 4 Strategy and tactics of effective conflict
3 Books Advertising: Cheat Sheet author Author of nevidomiya From the book Break through the business! 14 best master classes for ceramics author Parabelum Andriy Oleksiyovich From the book Sales of goods and services for the method of lean manufacturing by Womack JamesWar strategy, battle tactics Project management and process management are not like a seen egg, so there is no clear mark. If the project is ruining you one step ahead of you until the end of the planned mission, you will be strategic.
From the book Dosit pay for everything! Company's cost reduction author Gagarsky Vladislav From the book Universum. The global theory of management author Maslikov Vladislav Ivanovich From the book Ways of Caterpillar [Lessons of leadership, growth and struggle for leadership] by Bouchard Craig 3 books by the author4.2.1. Strategy, tactics and operational tasks A classic description of the military operations Vikoristov understands the strategy, tactics and specific, operational tasks. All of them fit into the universal model (Fig. 4.2). Let's look at the visionary U-potik that starts from
gentler virobnitstvo (Lіn) (eng. lean production, lean manufacturing vіd lean - “thin, stringy”) - a system of simple solutions, zavdyaki how you can achieve an increase in efficiency and a decrease in wattage.
On this day, a greater number of enterprises stand on a gentle path to development, which allows for additional organizational inputs to increase the productivity of practice from 20 to 400% for a long time. By speeding up one of the tools of sparing virobnitstv - changing the flows of the movement of virobivs, for two years you can increase the productivity of work by 30%. Thus, the General Director of the Kaluzsky plant of automobile electric power was charged. Now the plant is to set ambitious plans for increasing productivity - by 50%.
The technologies of thrifty manufacturing just give results, the stench is necessary for businesses. About tse and timetsya far.
8 Principles of Lean Manufacturing to Drive Business Efficiency
The robots of our company follow the principles of lin-management, in the basis of any kind of exercise, without hiccups, release in the required quantities only goods that are not accumulating stocks in warehouses. When completing the package, we try to give uniqueness to the product, to add value to the product. For example, saving non-essential stocks, ordering processing and moving products in the middle of the warehouse. I'll give you some ideas, how we managed to implement them. The descriptions made it possible to reduce staff rotation, improve the ergonomics of the work process, and improve safety. Productivity on all the plots of the processing plant increased by 20% for six or seven months.
1. Vag control
. One of the ways to eliminate costs at the logistics center is the control of ready-made orders. Vin allows you to know the pardon before him, as if you were going to spend it before the client, which will reduce the number of claims. So, if the vaga of the box is actually not sealed, then it is not glued, but corrected for re-checking and, if necessary, on additional folding.2. Conveyor system for vicorous tare
. The conveyor is laid through the harvesting station and automatically delivers corrugated cardboard to the pressing station, de horizontal press machine without the participation of the operator sees the pile of pressed cardboard. Tse minіmіzuє roboti, pov'yazanі z vikoristanoї tare, that zmenshuє obsyag paper saw. As a result, the rіven zabrudnennya navkolishny middle is reduced, the possession is more likely to get out of tune. Pressed cardboard is sold to companies for processing.3. Vіdbir according to the world. Behind the conveyor with an area of 9.2 yew. sq. boxes are collapsing, and the workers at the warehouse stations deposit their products for the additional pick by light system. Therefore, the productivity of the collection of the promise from our center by 50% exceeded the productivity of the other centers of the collection of the Oriflame from Russia. In addition, the line of selection was inspired by the principle of ABC, which allows minimizing the number of stations of selection and optimizing the cost per unit of production. Axis how to expand the product:
- zone A - the most common storage zone, here close to 20% of goods are placed, and they consume up to more than 80% of goods;
- zone B - here come close to 30% of the goods (or tenth leather box);
- zone C - here they consume over 1.5 yew. name from the least popular (or leather 50th promotion).
Technology pick by light(Engl., Vіdbіr po svіtu) vikoristovuєtsya for the collection of zamovlen at the working station. On the scoreboard, placed under the middle window, a light signal was sent. The Komirnik chooses the middle product and puts it in the box from the instructions that fall along the conveyor line. Then we press the button on the scoreboard, confirming the completion of the operation.
4. Visualization. Most of the elements of visualization (markings, different signals) were made in such a way that it is easy to comprehend a new mind of your senses. So, the layout of the logs helps to improve the order of the working zones of the conveyor, it shows that there are more and more materials, and they are fenced. For the help of additional signs (photographs, stencil images) you can accurately indicate how they can stand or what type of material can be used on a specific site. Tse shortly an hour to search for the possession of that material, to help prepare newcomers. For the help of portable plates, you can trade with streams of products in a fenced space, which is more scary in small warehouses.
5. Orthopedic kilim
. Complete sets, like putting piece goods in boxes, are constantly rebuying from Russia, and until the end of the change, productivity drops. We had such a working space with a special orthopedic kilim. Due to the soft, springy structure of the veins, the burden on the legs and back of a person when moving around the station is reduced, similar to running shoes for running. And the anti-coagulant surface prevents the risk of injuries and helps to improve the flexibility of folding.6. The principle of "everything is at hand"
. What is the most popular product, we are closer to the complete set of veneers. Products with a high werewolf are put on the vіdstanі of the venerable hand, the comrades, like they say, are farther away. For the speedy hour at the top of the middle, on the working areas, metal puffs were installed, as they allow the guards to easily reach the top police.7. Work productivity monitor
. In the real time mode, it shows the speed of folding the system of the lines and other stations. So we can evaluate the work of the skin picker, moreover, the spivrobitniks begin to heal one by one. The monitor successfully supplements the monetary motivation and makes the KPI system more transparent. In addition, such a system always allows pardons to be made at the skin station.8. Bali for an idea. The most important thing is to get the workers to the process of polishing. The very same among them may need ideas how to liquidate expenses. We try to achieve the goal of promoting the philosophy of conscientious versatility among specialists of specialists, training scientists and specialists in the algorithm of minor changes following the PDCA principle (Eng.
Narazі doopratsiovuєmo the system of motivation of practitioners in a fallow way from an individual deposit to a hard process. Chastkovo is a new system for the logistics center in Budapest. Sensation lies in the fact that for a skin idea the spivrobitnik takes balls, as if they can be exchanged for prizes, moreover, whether ideas are assessed, to bring those that are not suitable for implementation.
7 “smart” ideas that 100% of companies use
The editorial office of the magazine "General Director" together with the support of "Rostsilmash" held a workshop "Virobnicha system: operational efficiency in business". On the back they listened to the speech of the speakers, and at the other half of the day they went on a tour of the workshops. You will know ideas of lean manufacturing, as a whole you can sell it to any company.
Possible reasons for spending on enterprises
1. Necessary relocation of workers
.- irrational organization of work functions - through the unmanageable placement of work stations, the possession of that one;
- pracіvniki zmushenі robiti zayvі ruhi, schob know vіdpovіdne equipping, іnstrument іn.
How to get lost? The timing of one of the working areas is checked by stretching the change. Next time to spend an hour of practice for walking to the place of knowledge of tools, components, accessories, their search - at once we multiply by the total number of workers in the change and the number of changes by the end of the year. Zavdyaki tsomu mozhlivy rozrahunok vtrat pіdpriєmstva protyazh rock through unnecessarily moving their spіvrobіtnikіv.
An example of usunenny vtrat. The robots of one of the car dealers had all the tools in their bedroom wardrobe. Pratsіvniki took one tool on the cob of change, then it was necessary to change it for another. Operators in total had to spend close to 10-15% of their hour for return trips to the office and back to work. It was a shame for him to see his instrument cabinet for the skin specialist. Zavdyaki komu farted to speed up all the movements, ensuring efficient and rational work space - increasing the productivity of the work of our workers by 15%.
2. Unprimed transport of materials
. The category includes the movement of materials, which ensures additional value for the product. Possible reasons for spending on business:- I mean to see between the workshops, among them to carry out the transportation of products;
- ineffective planning of their premises.
Rozrahunok vtrat. For the butt - it is necessary to show the preparation that I have put into the warehouse. Then let's think over the algorithm, which is given to prepare to go through all the technological stages of manufacturing. It will be necessary to invest, I will need to relocate for the skilki meters, I will need to relocate the skids, the skils will be raised and delivered, which resources will be collected for which one is necessary, the skils of value on the output will be spent or will be added (inodі such a relocation will be made). Spend multiplied by the number of blanks that go through the manufacturing process to support rock.
Yak pozbutis vtrat? The large-sized body part was moved to the truck loading bay at the trucking facility. The hull was welded, then the veins turned on a large space, in order to refinish the surface - and again it was necessary to repair it for brewing (for welding a storage unit) and again at the weekend. As a result, they blamed a serious waste of time to move the details and clear the navantazhuvach. To reduce the cost of the time, the cost of the cost of production is in the order of electric power and mechanical processing. We managed to save an hour 409 min. shomisyatsya. Enough for the construction of 2 more buildings appeared during the guarded hour.
3. Unusable processing
. Blame similar losses on the situation, if the power of the product does not make it harsh for the deputy. Including:- Necessary to purchase the functions of the products that are supplied.
- Unprimed foldable construction of screeds that are released.
- Road packaging products.
Rozrahunok vtrat. Follow up to the purchase (deputy) for clarification - how to win victorious products of your enterprise. As you specialize in the release of parts, it is necessary to familiarize yourself with the installation process and subsequent operations with your partner. It is necessary to put together a mix of constructive elements and the power of materials in your products, as it does not matter to the mind. It is also necessary to clarify with the deputy - how many commodities are in vvzhaє sobі obіbnіbnimi chi other row. It is necessary to evaluate your own wines, as they were previously necessary for such inappropriate qualities.
An example from practice. At one of the enterprises for the release of buses, all surfaces were farbulated for the highest class of accuracy. We conducted an experiment on our companions and installed them - they don’t need such faring to the accuracy of farbing. To that, changes were made to their technical process - for the invisible on top of the class, the accuracy was reduced. Away from the reach of lowering costs for hundreds of thousands of rubles shomisyatsya.
4. Hour of recovery
. The reason for these losses is a hundred simple possessions, machines, spіvrobіtnikіv in ochіkuvannі offensive chi front operations, nadkhodzhennia іnformatsії chi materials. Viklikana similar situation may be due to such factors:- Vyhid obladnannya і out of tune.
- Problems with the supply of alcoholic beverages, syrovini.
- Ochіkuvannya order of kerіvnikіv.
- Vіdsutnіst nebkhіdnoї dokumentії.
- Problems with robotic software security.
Rozrahunok vtrat. It is necessary to keep a time-keeping of the processes, or the idleness of one’s spivrobitniks, as well as the work (or idle time) of having a change. It is necessary to determine how long the workers are standing idle, the skils are not very possessed. An hour of simple spіvrobіtnikіv that possession multiply by the number of practitioners (one possess) that amount of change on the river - on the way out you will spend heavily.
An example from practice. In one of the workshops of our automotive manufacturing, it was quite easy to get through parts of a breakdown. To reduce downtime, a repair and maintenance center was organized in the workshop itself. At the exit of our workforce, it was enough for the worker to turn around to the repairmen, so that the stench immediately sank the problem. At the same time, the master worked on an application for a review by the head mechanic. Such a pіdkhіd allowed us to reduce the hour of idle time of spіvrobіtnikіv that possession by 26 man-years shomіsyatsya.
5. Prikhovanі vtrati vіd nadzherbnitstvom. It is important to use the most safe type of expenses, the shards provoke other types of expenses. However, it is customary in practice for wealthy companies to respect the normal situation, if they produce more products, less is necessary for the deputy. Losses in the form of overdose can be caused by such reasons:
- Robot from great batches of products.
- Planuvannya re-engagement of their workforce that possession.
- Variety of unsolicited products.
- Encourage the release of products to transfer the drink of the environment.
- Duplication of robots.
Rozrahunok their expenses. It is necessary to unpack a quantity of unclaimed products in the warehouses of the enterprise for a month, a quarter of a year. Variety of these goods and delivery to frozen capital. It is also necessary to clear the necessary expenses for the use of your warehouse premises and area. How many products are collected from the process of saving? Allowing for the summation of tsikh pokaznikіv to allow you to spend your money on the inheritance of overkill.
An example from practice. Automotive production from the release of spare parts and auto components was carried out between opportunities from regular promotions. Prote in the warehouses was gradually depleted of a part of the products. Behind the results of the training, I will take a drink of comfort and relief from the dermal appearance of the goods, I was able to understand - rather, turn on your choice of singing positions, and the tightness, which you have noticed, should be sent for the selection of the requested details. The company was able to spend more money in its practice in the field of overwork, achieving an increase in profits of tens of millions of rubles.
6. Get stock. There are excesses in the situation, if the necessary materials and syrovina are bought in reserve. As a result, the company is brought to close with the following expenses:
- payment for workers at the warehouse;
- spend on renting storage facilities;
- unfinished production;
- Trivale savings negatively affects the authority of materials.
Rozrahunok vtrat. It is necessary to determine the amount of stocks that are stored in the warehouse, not requested earlier than in the next day - as required for storage. It is also necessary to insure the amount of materials in the warehouse, as you do not need for picking - and skils of zipped materials. Now it is necessary to understand, like the bones are frozen, the zipped materials have poured into the bag.
An example from practice. Incomplete work on the receipt of buses from the release of buses took 16 days. The number of the most important components when folded was superficial, but other names were regularly insufficient. Therefore, they organized the delivery of the necessary details of the day at the required quantity.
7. Defects and їх usunennya. Spent viklikana reworking your products, eliminating defects, which were blamed for an hour of work.
Rozrahunok vtrat. Sliding away the number of defective goods from your catalog for a month and a half. Yakі vitrati znadoblyaetsya for the utilization of products. What resources are invested in processing defective products? It is necessary to vrakhovuvati - tі vіtrati do not rely on the zamovnika, oskolki yogo pennies direct for the purchase of non-domestic products.
butt. At the production site, a high number of defective goods - baked goods for cakes did not pass the aesthetic standards. There were some changes made to the viability and different methods of quality control at the stage of preparation. As if there were malfunctions, having spratsovuvav and zupinyavsya the whole process - for a nega vyshennya problem. Such a change allowed to reduce the incidence of defective products by approximately 80%.
Implementation of lean manufacturing for business
In the activity of our undertaking in the month of 2008, actual methods of dbailing virobnitsv will be provided. In the Urals region of the past fate, the money will definitely be spent on the purchase of profitrolls. For the growing market, significant commitments are needed. But at that period, our order had only one alternative line, so we thought about increasing productivity for the smallest strains. For yourself, for whom and if you need a method of sparing virobnitstv.
Product layout diagram. At the 1st stage, the VSM technique was victorious - a small scheme, demonstrating the skin stage of the flow of information and materials. It is necessary to see the beginning, which is necessary to take into account the results of this process and to designate the first step for reaching the goal. Then we will need to induce the necessary lances to move from the first stage to the offensive stage. It is indicated on your map the trivality of the skin stage and the necessary hour for the transfer of materials and information from one stage to the onset. The scheme can be placed on one sheet - with the method of assessment of the mutual modality of all elements. After the analysis of the scheme, we will image a thoroughly detailed map, demonstrating the already completed process with the corrections made.
Liquidation of expenses. The beginning of the analysis of the card can be understood at a high time during the collection of profitroles. Among the problems were the inefficient use of personnel, the galvanization of their reserves, the non-optimal distribution of the possessions. In order to avoid expenses, the bula vikoristana 5C system for optimizing the distribution of possessions - conveying five basic rules. And for yourself - get in order, sort, standardize, refine, and improve in purity.
For the cob - bringing the fret. They marked the possession of that material with a red marker, as if they did not win for a month. It turned out that more than 4 out of 15 tickets were needed, the non-necessary ones were sent to the warehouse.
The next stage is the standardization of the distribution of one's possession. Clearly marked the interdermal object of virobnitstva - with additional markings on the underside. We have designated with a red color the place of significance of unsafe units, which vikoristovyvavsya for another possession. They hung all the instruments on a special stand, for skin care they also indicated a place with a rose mark.
The coming task is the standardization of the robotic practitioners of the zavdyaki method of visualization. On the walls, there were placements of stands with images of the algorithm of working operations and methods of vikonnannya. Zavdyaki tsіy schemі pracіvnik instantly easily orientate at the process. There are also photographs of standard and defective products on the stands. When the pipeline is revealed, it is carried out until the reasons are fixed, directing the production of non-standard products for processing.
Dali - modeling the process, reducing the cost of transportation, moving and clearing. Zokrema, éclairs and profiteroles in a rotary oven were previously boiled in the last batches (a bunch of 10 éclairs, then ten profiteroles). If profitrolls ended in a simple injection machine and manufacturers. They speeded up batches of profiteroles up to three vizkiv and éclairs - up to 7. The marking of vizkiv for éclairs was made in blue color, for profiteroles - yellow. We have created a signaling system - when you need a yellow vіzk, you need to start picking up additional vіzok profitroles. This is the very principle of victorism for éclairs.
So, it was done in the same way that it was not victorious, it was made new - in addition, the injection machine and the additional string conveyor.
Zavdyaky prudent virobnitstvu far away to reduce the number of workers in the virobnicho line to 11 spіvrobіtnіv zamіst 15 - having reached the increase in virobіtku to 9000 sets of zamіst kolishnіh 6000 per change. The increase in the number of workers from the rozrahunka for one spivrobitnik made up 818 sets and 400 deputies. Three spivrobitniks were transferred to a more qualified work. Totally, it was possible to reach an increase in productivity by 35-37%. Also, the buv organizations maydanchik for training their spivrobitnikiv new methods of organizing virobnitstv.
Having failed the system of thrifty virobnits, we took care of warehouse stocks
Tetyana Bertova, certifier of the regional distribution center of the company "TechnoNikol", Ryazan
Olena Yasinetska, HR Director, TechnoNikol, MoscowCaregivers of the business nearly 8 years ago realized that victorious management does not provide the necessary effect. Todі vyrishili vikoristati sparing virobnitstvo. If they made a difference, they didn’t need a lot of money, but at the same time they allowed them to achieve a solid economic effect. I would like to turn my attention to the axis on what.
- In order to speed up the process of reviewing the finished product, we installed number indicators for flyovers, as well as maps for directions on the territory of our enterprise. It has become easier for the waters to orient themselves on the territory, and they know more about the area of \u200b\u200bvantage, less hovering at the factory - far away to reach significant savings for an hour.
- Re-planning of storage areas and harvesting areas - in order to save more than 30% of harvesting areas.
In total, we were able to achieve a 55% increase in productivity with an increase in the turnover of two persons - to shorten the staff by 2 units. In a rozrahunka of one practitioner, the vibration increased over, below 200%.
Successful completion urged us to think about the best practices of these methods for other developments.
What needs to be done, so that the implementation of "friendly" processes will be effective
The main reason for optimization is the lack of harvesting areas. A pilot project for them directly - the reduction of the manufacturing process and the release of heat exchangers for air conditioning systems. The group of gentle manufacturing specialists included representatives of manufacturing, supply services, technology bureau, head engineer service and quality service.
Superficially corisna at the cob stage helped experts side by side. If you want the stench to once vomit - be it propositions that a thorough selection process can be found in a working group, experts may be less likely to help in project management. Also, the employees of the company took part in the work on the project - evaluating the results of the work and confirming the goals of the project itself. On our own, let's look at the main factors that contribute to the success of the integration of methods of gentle selection:
Orientation to the deputy. It is necessary to look at the skin scarg from the side of the client with the organization of an internal investigation. Live, come in and try to direct yourself to the prevention of such shortcomings, give a start to the process. Also, the next important aspect is to protect another significant aspect - the first hour of taking care of the skin, the gentleman is guilty of taking away the responsibility of the superior spivpracis for his own and the most victorious of his prayers.
Received by the staff. The vikoristannya system of sparing virobnitstva is impossible without irradiation of spіvrobіtnikіv. Ale for zaluchenny spіvrobіtnіkіv to uchіbі, chnobly stаlіїї їхніхіхініціав schodo dоskonalennya virobnichesіv protsіv іz zaspechennyami komfortable minds pratsі. At the enterprise, we regularly carry out tests to collect data on brainwashing, the availability of the necessary documentation, the organization of working places and other. Then we get used to the necessary visits for the full completion of all processes with the help of the interpretive ray of the interviewers. As if the initiatives of the practitioners were unreasonable, then the reasons for the change are correctly explained in the team gathering.
Accuracy. Obov'yazkovoy umovoy for dbaylivy virobnitstva becomes a system of visual management. Zavdyaki nіy mozhlivy control of the course of virobnitstva be-yakoy mіtі. On the walls, the premises were recently laid out schemes of objects - you can understand that, you can know it at once, from a quick joke of a necessary business. All dealerships have stands that show the equivalence of the release of goods to our plans and cause delays. It is necessary to reconsider the holidays, and not just cause the problems without a middle, which are blamed. For example, a defect in the brewing plant, causing a broken graphics - the other reason may be the weak quality of the details or the insufficient quality of the brewing plant.
Virivnyuvannya vantazhennya. It is seen as a plan for equal profitability of the equal stocks, but also for smoothing the spitting of a dead drink. It is necessary to work together with purchases, so that the stench will understand - it is not possible to bring the vanity to negative consequences for them.
Vimiryuvannya improve. Spivrobitniki and shareholders are responsible for the understanding - making changes may have a positive effect on corporate and financial performance. Nebhіdno, schob system zahochen spіvrobіtnіkіv stale in the activity of the entire team, but also in appearance and individual reach. For example, the beginnings of a pilot project with a merger of groups of labs and a decrease in stocks of an unfinished lab were able to prevent the onset of the effect:
- shortness of virobnic cycles in 2.5-7 times;
- The working hour was more efficient up to 85% and the total amount was 50%. And itself - the release of products is spent 85% of the working hour;
- udvіchі quickly obsyag vrobіv in unfinished vіrobnіstvі;
- shortness of the total turnover of the virobe in the process of virobnizstva by 40%;
- 50% reduction in hourly pay.
Prote smut to reach a sparing yield on the premises - the strain of strain increased by 25% without capital expenditures and expansion of the area.
Thrifty virobnitstvo vryatuvala Toyota
Be-yakі zmіni - tse way, more expensive. Only 10% of people know that the stench has broken on the road. The stench is good to work everything, to heal this way. More do not understand, now you need to change. The stench is just a posterigach. Another 10% were able to rely on the need to change. The stink roam ahead. As you see the need for change, you will determine who of your helpers are oarsmen, who are guardians, and who are opponents of change. And then help the oarmen and don’t turn your back on the skittles; And, as you have taken the right path, they will help you in an hour.
Morals of a Japanese parable, buv ker_vnik of one American machine-building enterprise. The plant, leaning in a crisis (in such a situation, there are a lot of Russian enterprises), it faced a number of problems:
- marriage to the hour, an emergency mode of warfare, which allows for the implementation of new management decisions;
- inadequacy of processes: most of the operations did not fit into the cycle, the management processes did not follow the next;
- unstable work of possession;
- availability of clear standards (for personnel, processes, possessions, materials, work areas);
- responsiveness to visual management, immediate response to problems;
- the lack of involvement of workers in the process of making a decision;
- the system of appearance is confused.
All this led to the fact that the plant, having let out a day for twenty cars less, was planned lower, the possession was constantly breaking down, and all workshops had problems with oil. Before the General Director, a serious choice was made: please allow the Vlasniks to close the plant and try to renew yoga. The company's "Toyota" management was taken for granted. The following goals were set:
- increase by 20% indicators of safety technology, quality, delivery and speed of recovery by 20%;
- speed up to 25% vitrati, caused by violations of the principles of ergonomics.
It was even more difficult for the General Director to change the strategy and get to the process of changing both the core workers of the city and the Middle Lanka, and the robot workers and master brigades. Axis of the main decision, which helped to turn the plant:
- the creation of an atmosphere of uninterrupted thoroughness, or pidkhіd kaizen (translating having guessed the Greek dance of sirtaki from the title of the book, which better conveys the essence of this process - the process’s enchantment and zatsіkavlenіst of all participants);
- seeing working groups to solve problems;
- vyyavlennya vyyavlennya vyzkyh mіsts for the help of the shchennoy analysis of products and the appearance of the in-line production mill;
- vikoristannya visual management;
- organization of permanent training and rotation of practitioners;
- standardization of manufacturing processes;
- prevention of the appearance of defects;
- putting things in order in the working area and watching over the possessions;
- vikoristannya so-called vityagyuchoї system of virobnitstv (virobnitstvo is only necessary when necessary).
Copying the material without a deadline is acceptable for the presence of dofollow-sending to the right side