• • • • •
Examples: Manually cleaning product because of the dirt introduced in the preceding operations 100% visual inspection at end-of-line to catch and prevent “escaping defects” Rework or repair or debug areas Materials awaiting decision and disposition
Waiting
Waiting for… man, machine, materials, information, etc. • Unbalanced workload • Unleveled scheduling • Unplanned downtime • Increases cycle time • Uncouples manufacturing flow Solutions: • Product absorbs more costs while waiting but receive no value • 5S Workplace Organization, Install Pull System, Reduce batch size to 1 • Shrink the Footprint • Employ Quick Changeover 6
Overproduction*
Making more-earlier-faster than the next process or customer needs it. • Just in case logic • Unbalanced workload • Unleveled scheduling • Waste information systems and people resources to keep track Examples: • Prod Planning – scheduling machines to run maximum capacity • Long Prod runs – avoiding frequent changeovers to maximize machine efficiencies • Batch production/Maximizing Machine Utilization– Producing in batches • WIP Inventory building up look at preceding workstation Solutions: • Make to Customer Order • Rate = TAKT, Make 1 Move 1 • Reduce Setup Time 7
Transportation
Inefficient movement of people, materials and information in the organization • Poor layout • Inefficient “flow” • Carrying large inventories • Exposes product to potential damage/loss during transportation • Increases cost to hire resources to ferry
• Examples: • Looking for tools to repair machines • Wait for Information Systems to complete transactions (reporting production) • First piece waiting for entire production batch to finish • People idle at workstations because of no materials to work on • Process waiting for instructions before proceeding • No material flow velocity
*Overproduction is considered the worst waste in TPS << It leads to all other kinds of wastes >>
Over processing 不必要的过程
不必要的过程
过程超出客户(内部或外部)要求 • 对产品规格,客户要求不了解 • 工作方法不一致(非标准化) • 沟通无效 • 批准过多 • 信息及复印件过多 举例: • 用手清除产品的灰尘 • 线末100%目使检查 • 重做或修复或调试区域 • 材料等待决定及部署 • 解决方法: • 在源头做好自检 • 错误检查
• Anywhere sequential operations are uncoupled • Where material storage is not adjacent to point-of-usage • Abundance of material handling equipments: conveyors, forklifts, pallet trucks, etc. • Deviation from straight-through material flow process Solutions: • “Shrink the footprint” - eliminate spaghetti flows via proper line design • Use Kanban pull systems • Eliminate or reduce WIP Inventory storage locations • Introduce Cellular Manufacturing 3
解决方法:
• 5S Workplace Organization • Point-of-Usage Storage •工作站设计
Motion
Unnecessary movement of people, parts or machines within the process • Poor layout • Inefficient Workplace Organization • Lack of Standardization, inconsistent work methods • Increase operator fatigue leading to other wastes e.g. defects • Ergonomic issues causing health e.g. repetitive motion injuries, etc. Examples: • Time spent away from workplace looking for items, etc. • Extraordinary movements • Materials and workstations not designed to appropriate level of reach Solutions: • 5S Workplace Organization • Point-of-Usage Storage (POUS) • Workstation Design 5
4
Motion 动作
动作 : 生产过程中不必要的荣誉,工作或机器的移动
• • • • • 工厂布局差 工作场所缺乏组织性 缺乏标准化,工作方法不一致 增加作业员疲劳导致其他浪费,如:缺陷 工效问题对健康的影响,如:重复性动作伤害,等 举例: • 浪费时间寻找物品,等 • 额外动作 • 材料与工作站设计不合理
Overproduction 过量生产
• • • •
过量生产 : 在下一工序及客户要求之前进行生产
以防万一逻辑 工作量不平衡 安排不合理 为保持原有路线浪费信息系统及人力资源 举例: • 生产计划-设定设备以达到最大量生产 • 长期生产运行-避免频繁转换以提高设备效率 • 批量生产/提高设备利用率-批量生产 • 建立WIP目录-看先前的工作站 解决方法: • 按客户要求生产 • 速度=TAKT,做一个拿一个 • 减少安装时间 *在TPS中,过量生产是最大的浪费 • 不同型号序列生产 <它导致了其他的浪费> • 安装一个拉动系统
-Examples: • Finished Good Inventory • Work In Process Inventory • Supplies Inventory • Staged or “kitted” Inventory Solutions: • Make to Customer Order • Kanban Pull System • Eliminate Inventory Storage Areas • Stop Planning for Unnecessary Inventory
Waiting 等待
• • • • •
•
等待 : 等待……合理 停机时间无计划 增加循环时间 生产流程不连贯
等待时生产成本增加,但价值并无增加
举例: • 寻找工具维护设备 • 等待系统完成信息处理(生产报告) • 第一件等待整批完成 • 因为缺料造成的人员空闲 • 生产前等待指示 • 无材料流程率 解决方法: • 5S,安装拉动系统,最大化减少批量 • 减少不必要的生产步骤 • 加速生产型号转换
八大浪费介绍
——与浪费开战
Prepared by Fisher Chan Oct.31,2007
Flextronics Manufacturing System (FMS)
7 Types of Waste 七大浪费
Transportation 运输
Inventory 库存