On the most easy to ignore waste in lean improvement ------- stale waste
Summary of content: In lean production, the value of the enterprise is reflected in the company's products, and the value of the company's products depends on the actual waste of the production process. Usually waste refers to any equipment, materials, space and labor that exceed customer demand and production needs Activities that consume resources without adding value. From a practical point of view, the "seven wastes" proposed by Toyota's famous expert Naoichi Ohno: waiting waste, waste of handling, waste of defective products, waste of movement, waste of processing, waste of inventory, waste of overproduction, and the eighth largest emerged later. Waste: Management waste. In addition, in the field practice work, I found that there is a potential waste that can be easily ignored-the ninth largest waste: obsolete waste.
The so-called obsolete waste is caused by someone who buys a machine and has not used it for a long time due to factors such as low usage or frequent failures, poor operability, etc., resulting in rusting and aging of the machine without generating more product value. waste. It has been found through factory site practice that many companies have similar waste. This old waste usually includes the following three aspects:
1> Outdated thoughts (management methods, conservation awareness, stubborn and rotten thoughts)
In some factories, the quality and level of management personnel are not uniform. When problems and subordinates are encountered, they often adopt mandatory and command management. As long as the production does not teach causality and methods, the same problems frequently occur among employees and the same products are scrapped and remanufactured. . However, managers have never reflected on or changed their "untimely" management methods.
When it comes to entering the factory to work, it seems to have become synonymous with wage earners. In their respective positions, some employees are self-locating only as part-time workers. Even if they find waste, they may have this or other ideas: 1> Anyway, waste is owned by the boss, not mine; 2> Waste is wasted, and savings are not Reward; 3> I'm not the boss, it has nothing to do with me. This idea seems "reasonable", but it reflects a sense of work and quality, an old idea.
Every job will have different work habits. Good work habits are conducive to normal work, while bad work habits can hinder work. It is often found that some employees do not perform operations according to requirements and are independent. They do their own thing and unknowingly make a problem product without even knowing it. Eventually re-examination, re-work processing, time-consuming and labor-intensive. Stubborn ideas like this are the obstacles to management and improvement.
2> Outdated equipment (waste water / electricity, poor environmental protection, reprocessing)
Manufacturing products cannot be separated from production equipment. With the advancement of technology, the equipment has also been continuously improved and upgraded, and its functions are more powerful, rationalized, scientific and environmentally friendly.
Some companies have short-term difficulties or shortages in capital turnover. In order to save costs and lack long-term considerations, some old-fashioned second-hand equipment or old machines are purchased. There are some design or functional problems that lead to large water consumption, large power consumption, and sewage disposal. The effect is poor, or there is no treatment device at all.
The lack of environmental protection in waste disposal leads to additional waste water treatment in the company's environment and the industrial sector; the exhaust gas affects the working environment of the workshop. In addition, the old-fashioned second-hand equipment or old machines produce relatively low product qualification rates, either resulting in scrap or rework. , Naturally increased production costs, resulting in some manufacturing waste, even because of production problems, many products, frequent failures, so some factory managers simply stop for a long time, the machine is idle, rusting and aging, until three or five years after it becomes unusable and Scrap treatment, the cost of purchasing old used equipment or old machines also becomes an idle aging waste. To avoid such waste, equipment evaluation and design need to understand and consider the shortcomings and disadvantages of old used equipment or old machines, and whether they meet the current needs , Make a comprehensive decision before making a decision.
3> Outdated (old) technology (waste human, material and cost)
Good process technology can optimize product manufacturing, simplify production steps, and reduce unnecessary manpower and material resources. Outdated process technology not only limits the quality of the products produced, but also has poor operability, which is not conducive to monitoring parameter requirements, etc., and it is difficult to improve production efficiency. Some manual operations are prone to operational errors, improper manual handling, poor results, and increased repair or rework costs. Improving backward technology is the solution to prevent some waste.
Obsolete waste is not only reflected in general employees, but also the managers who play a leading role in improving activities are more prominent. They are one-sided in pursuit of employee improvement, but often ignore their old ideological changes and the improvement of technical level. Such waste has strong concealment, long-term, high depreciation, and it is difficult to attract attention. Only by fully understanding these nine wastes and paying attention to them, and exerting personal initiative, can we reduce more waste and create more value for the company.