-精益思维, Womack & Jones
Whatever You Call It 不管你称呼它什么
Lean Manufacturing Flow Manufacturing Continuous Flow Demand Pull Demand Flow Technology Toyota Production System _____ Production System etc?..
市场竞争及全球化
Marketing Competition and Globalization
Shorter lead time and on time delivery
快速并准时交货 Grow the mix，special configurations 需求品种增加，特殊定制 Maintain / improve quality and reduce price 不断改进质量及降低销售价格 Total life cycle of product becoming shorter and shorter 产品的生命周期越来越短 No boundary，business globalize village 无国界，业务“地球村”
精益生产 流动制造 连续流 需求拉动 需求流动技术 丰田制造系统 ______ 制造系统 等等…...
Lean Manufacturing - Key Characteristics 精益制造 - 关键特性
Focus on SPEED and SIMPLIFICATION Pull materials through the process Balanced operations based on customer demand Minimal build unless tied to customer order Extend to Supplier Base 着眼于速度和过程简化 在生产过程中“拉动”材料 根据客户的需求平衡操作 除非受订单的限制，否则最小批量生产 延伸至供应商
1997 IWeek Survey of 2,900 manufacturers 1998 IWeek Survey of 2,100 additional manufacturers
Benchmark Results 定标结果
60% 50% 40% 30%
15
5年内生产周期时间的改进
35
交付周期时间 (天)
60000 40000 20000 0 1970
1980
1990
2000
Life Cycle Cost In Different System 不同系统中的成本
大规模生产模式下的 精益生产系统之产品
产品生命周期成本
生命周期成本
$/ piece
销售价格
$/piece
销售价格
V
产量
V
产量
The Cost / Lean Relationship 精益生产与成本的关系
catching on in the mid – 80’s in the reminder of the industrial world, Lean Manufacturing has become a key strategy for manufacturers
起源于20世纪50年代丰田汽车公司，而在80年代中
按时交货
98% 96% 94% 92% 90% 88% 86% 84% 82% 80%
Electronic & Electrical Industrial Equipment Handtools and Hardware Controls & Measuring
12 10 8 6
库存周转
40%的提高
丰田系统是建立在准时化观念上的拉动 式生产模式，以应付小订单多品种的挑战
Key Points for Manufacturing System 制造系统要点
Craft 手工生产
• Low volume • Customized • 低产量 • 个性化
Mass 大规模生产
Synchronous 同步生产
55%的改进
30 25 20
40%的提高
20% 10% 0%
Electronic & Electrical Industrial Equipment Handtools and Hardware Controls & Measuring
10 5 0
Electronic & Electrical Industrial Equipment Handtools and Hardware Controls & Measuring
The amount of human effort, time, space, tools, and inventories can typically be cut in half very quickly, and steady progress can be maintained from this point onward to cut inputs in half again within a few years.
• Large batches of • Focused on total elimination similar products of waste • Inflexible • Ongoing efforts machinery to improve • Manufacture of Quality, goods by process Productivity, and • 大批量少品种 Responsiveness • 工序式生产 • Recognition of • 设备大难组合 employee abilities • 消除浪费 • 不断改进 • 员工参与
直接员工
ቤተ መጻሕፍቲ ባይዱ产品生命周期成本
投资
精益的通俗定义
LEAN
本 成
间接员工 质量
质量 间接员工
灵巧的双手
全自动
What Is Lean?
lean adj. 1a: lacking or deficient in flesh b: containing little or no fat 2: lacking richness 3: deficient in an essential or important quality or ingredient 4: characterized by economy of style or expression syn. thin, skinny, lanky, scrawny, gaunt, bony, emaciated, svelte, lank ant. fat, fleshy, overweight, flabby, obese, plump, chunky, corpulent, soft
市场竞争及全球化
Marketing Competition and Globalization
Life Cycle Change/产品生命周期
Life Cycle in year
30 25 20 15 10 5 0 化装品 玩具 机床 食品 药品
50 年前 现在
Product Styles In Supermarket ¬ ´ Í ¡ ® É « ­ ± ¹ Ç ± Ó Æ Ã Ó ½
Lean 精益生产组织 • Builds on synchronous manufacturing • Emphasize on lead time reduction • Improve asset utilization • Built to customer demand • 在同步生产的基 础上，强调缩短 生产周期 • 提高资源利用率 • 需求驱动
Agile 敏捷生产组织
• Remove constraints to respond to customer demand through the entire supply pipeline (supplier-customer) • Capable plants linked to lean concepts • 改善整个价值链 • 节点上连着精益工 厂
期被欧美企业纷纷采用。随着微利时代的来临， 精益生产模式成为企业竞争的有力武器
Manufacturing Evolution 制造系统演化史
Henry Ford • Assembly line mass production • Produce in high volume with low variety • Single skill
福特首创的装配线是大规模低品种生产方式的代表， 工人被当成工作的机器
Toyota Production System (TPS) • Just-In-Time Production (produce only what is needed) • Pull System • High variety to meet customers wants
Benchmark：The Average Of Top 10% 标杆：前10%最好工厂平均

按时交货 - 98% 交付周期时间 - 10 天 缩短交付周期时间 (5年) - 56% 缩短生产周期时间 (5年) - 60% 生产周期时间 - 3 天 执行比率 - 3/10 = .30 库存周转 - 12.0 库存减少 (5年) - 35% 在制品周转 - 80 使用精益生产的工厂 - 96%
44%的提高
4 2 0
Electronic & Electrical Industrial Equipment Handtools and Hardware Controls & Measuring