精益的7+1浪费：消除低效率的指南

Did you know that a company’s inventory waste might lock away 30-40% of its cash? This is just one issue in lean manufacturing. It’s part of seven types of waste that hurt profits and efficiency. These ideas come from Taiichi Ohno’s 丰田生产方式. They include Transport, Inventory, Motion, Waiting, Overproduction, Overprocessing, Defects, and 8th more recent one, Unused Employee Potential. The goal is to find and remove activities that don’t add value in manufacturing.

Lean manufacturing aims to cut waste and boost sustainable, efficient production. Every waste type uses resources and creates costs that don’t help the product or service much. By tackling these wastes, companies can greatly improve how they operate. They can reduce expenses and boost production quality.

关键要点

• Inventory waste can tie up as much as 30-40% of a company’s working capital.
• Waiting times in production can lead to up to 90% of the total production time being non-value-added.
• Overproduction can account for roughly 15-30% of all production costs in a manufacturing setting.
• Defects can result in rework costs up to 5-20% of total sales in a given industry.
• Unused employee potential can cause a productivity loss ranging from 10-30% depending on the industry.

Introduction to Lean Manufacturing and Waste

Lean manufacturing aims to cut lean process waste while keeping production high. It started with the 丰田 Production System (TPS), thanks to Shigeo Shingo and Taiichi Ohno. The focus is on making processes better all the time, a concept known as ‘Kaizen’.

It’s all about getting rid of waste, making quality better, cutting costs, and saving time. This makes manufacturing more efficient.

What is Lean Manufacturing?

Lean manufacturing is about making quality products and getting rid of waste. Japanese companies, like Toyota, lead the way. John Krafcik made the term “lean manufacturing” popular in 1988. James Womack, Daniel T. Jones, and Daniel Roos talked more about it in their 1990 book.

The main goal is to streamline processes. This increases value while using fewer resources like manpower, materials, and time.

Understanding Waste in Lean Manufacturing

Waste, or “muda”, is anything that doesn’t bring value to the customer. According to the Toyota Production System, there are seven waste types: transport, inventory, motion, waiting, overproduction, overprocessing, and defects. Each one ups costs and cuts efficiency. For example:

1. Transport Waste: Moving materials more than needed adds to production time and costs.
2. Inventory Waste: Too much stock uses up money and space without adding value.
3. Motion Waste: Workers moving inefficiently can slow down production.
4. Waiting Waste: When things aren’t ready, everything stops.
5. 生产过剩: Making too much means extra inventory and higher storage costs.
6. Overprocessing: Extra features that customers don’t want raise production costs without adding value.
7. 缺陷: Faulty products need fixing or throwing away, which costs more in materials and labor.

By tackling these lean waste management issues, companies can make their operations smoother, cheaper, and more efficient.

Transport Waste in Lean Manufacturing

Transport waste in lean manufacturing is about moving products and materials unnecessarily within a facility. These movements don’t add value. This type of waste happens often, making production slower and less efficient.

Examples of Transport Waste

There are many examples of transport waste. One is using forklifts to move pallets of products. Another is trucks moving products between different work sites. In services, it can look like sending paper forms for signatures through interoffice mail.

Healthcare sees it when patients are moved too much between rooms. These movements are costly and don’t help create value. Thus, they lead to waste in lean production practices.

Strategies to Reduce Transport Waste

To cut down waste, companies need smart strategies. They can make their facility layouts more efficient, reducing the distance between stations. Better material handling, like using conveyors or automated vehicles, helps too.

Also, adopting “5S” practices can spot and remove smaller wastes. This improves productivity greatly. Such steps make processes smoother and faster, benefiting the whole production line.

Inventory Waste: The Hidden Cost

Inventory waste often goes unnoticed in lean waste analysis. It is the excessive stock, materials, or work-in-progress that uses space and money needlessly. It happens in physical business areas and in digital spaces like email or cloud storage. Cutting down on inventory waste is key to improving a business’s efficiency and finances.

it extremely frequent, and a natural behavior to have operators saying: “I currently have a bit of spare time, i will assemble additional products and stock them ASIDE FOR LATER”

Impact of Excess Inventory on Business

Having too much inventory hurts a business in many ways:

• It ties up a lot of working capital that could be used for growth.
• It leads to warehousing costs, including space, insurance, and handling fees.
• It causes stock items to lose value through depreciation or expiration.
• It can result in having to write off or dispose of outdated inventory.

“Inventory is money sitting around in a different form.” – Rhonda Adams

But it’s not just physical goods that can create waste. Digital storage and management costs can also add up. Managing data efficiently is crucial to avoid these extra expenses. So, using lean waste reduction strategies is essential.

Methods to Manage and Reduce Inventory Waste

To tackle inventory waste, lean waste analysis pinpoints where it occurs. Here are some ways to deal with it:

1. Just-In-Time (JIT) Production: Order materials only when necessary, minimizing unused raw materials and products.
2. Value Stream Mapping (VSM): This tool visualizes waste in the production process to eliminate unnecessary stock.
3. Engagement of Frontline Workers: Getting suggestions from workers can find new ways to cut inventory waste.

Using these strategies helps cut costs and streamline business operations. Reducing excess inventory lowers both internal and external expenses. This leads to a more profitable and sustainable business.

Reducing Waste in Lean: Motion

In lean manufacturing, motion waste means unnecessary employee movements. These movements can happen because workspaces are set up poorly. Fixing this boosts productivity by cutting down on wasted action.

The main goal in...

常见问题