How to reduce the cost of lean production? What works?

1. Kanban production mode.

A large amount of inventory will not only make the cost high, the company's capital turnover difficult, but also difficult to see where the problem is. Kanban management is the use of the essence of lean production. Kanban management starts production from the customer's contract order, so it is not easy to cause a backlog of products, and the production process is completely centered on the real and effective output.

2. TPM full production and maintenance.

Frequent occurrence of various failures in the production workshop will lead to a decrease in production efficiency and high maintenance costs, for such phenomena can be prevented by TPM full production and maintenance, TPM full production and maintenance can reduce the downtime caused by equipment failure, and can improve production efficiency and reduce maintenance and production costs.

3. Streamlined production.

Streamlined production can be arranged in order according to the different product categories, which is conducive to shortening the handling distance, reducing the number of work-in-progress, shortening the production cycle, and reducing the production space. On the contrary, the production is not synchronized, which is easy to cause problems such as inventory backlog, unsmooth production, and long production cycle in the intermediate process, and the synchronous production of the assembly line is conducive to improving the overall efficiency and reducing waste. The equipment operation and operation methods are more standardized, so that any operator can simply operate multiple equipment, which can achieve less manpower operation, reduce the difficulty of personnel deployment, and help improve the overall efficiency.

4. Reduce waste and loss.

The so-called waste is that useful things are discarded as useless. Scientific management can effectively reduce loss and waste. When the enterprise is producing, whether the waste materials and leftovers are fully utilized, and whether the equipment is fully used directly affects the production cost.

In the past, I had participated in the information construction of a copper plate production and processing enterprise in Japan, and they could minimize the waste of each roll of copper plate cutting through a computer software system, and basically there was no waste loss.

Controlling production costs has always been a problem faced by our factory, which not only includes the cost of raw material purchase, but also the labor and time we spend on analyzing and managing various material inputs. It is very effective in reducing production costs.

Sudden 1: Raise awareness and strengthen organizational leadership.

The key to implementing lean manufacturing is to bring the role of employees into play. Strengthen the education and training of lean management awareness for all employees, and the participants must be from the bosses and vice presidents of the management level to the general workers at the operational level. The training includes:

Competitive situation, waste concept, incentive production, 5S, team improvement, full set of equipment management, quality management, etc., in order to promote the concept and concept change of all employees of the enterprise, enhance the awareness and initiative to implement lean production methods. Establish a leadership and implementation organization specifically responsible for the implementation of lean production methods, which is responsible for the general manager and the participation of the heads of relevant business management departments, clarify responsibilities and tasks, formulate lean production work plans, and promote the implementation of lean production methods. Lean production methods in the enterprise.

Step 2: Establish the project leader and project execution team.

This step is to establish a lean manufacturing organization. This is also a necessary step for many companies to implement lean manufacturing. Some companies refer to the group as the "Lean Manufacturing Committee," while others refer to it as the Kaizen Organization.

In general, the general manager should be the head of the lean organization. Some companies also list the deputy general manager of the factory as the person in charge. The organization should include the production management department, the manufacturing department, the production technology department, the quality department and other related departments.

The supervisor should establish the improvement responsibility of the person in charge.

Step 3: Establish a demonstration production line and determine the management model.

Three to six months after the implementation of lean production methods, when the initial results of 5S are achieved, a production line should be selected as a demonstration to promote continuous improvement. To improve the content, make the most of lean tools, while paying attention to the selection of the assembly line and clearly improving the previous status, such as: finished goods and parts lists, flow charts of current objects and information, time surveys for each item, inventory surveys on the side of the production line, and frequency and quantity of deliveries.

Improvement must adhere to the principle of gradual progress, implement the person in charge, and pay attention to the use of brainstorming method to pool the wisdom of all personnel. Improvements must be posted in a timely manner to ensure that improvements are implemented and collaborated smoothly at the same time. At the same time, the person in charge of the improvement demonstration line must confirm the progress of the improvement on a daily basis.

Step 4: Field improvement from 5s.

5S Management (Organize, Correct, Clean, Clean, Finish). To implement lean manufacturing methods, we must first improve the on-site environment, clean up unnecessary items and reduce space occupancy; Place items on site in an orderly manner; After cleaning, keep the site clean and maintain the equipment maintenance in time: After inspection and rectification, employees will develop good habits to maintain a good site environment, thereby improving the company's production efficiency and product quality.

Finally, through the 5S activities, the orderly management of the site was realized, the waste was reduced, and the production management level of all employees was improved.

Improvement proposal system with the participation of all employees. Many people may feel more familiar, and many people will say that we have ah, we have a proposal system. However, the improvement proposal here is different from the proposal improvement, rationalization proposal, etc., the improvement proposal is to improve first and then propose, that is, to do it first, to improve first, and then to propose, which is completely different from our original proposal system.

The improvement proposal system is the basis for all employees to participate in continuous improvement. Start by reducing waste by all employees.

Improvement system for issues at the grassroots level. It is most appropriate for middle-level cadres who understand the situation of the production site to put forward improvement suggestions for on-site management and production processes, and formulate improvement plans.

Presentation system for all employees. Whether it is an improvement proposal or a major improvement issue, the results should be announced as a way to evaluate the results. The way of publication is not only a report, but also a live demonstration.

The results of the improvement will be displayed on the spot, and the participants in the presentation will share the improvement journey.

All staff training on relevant improvement tools. Through training, employees at all levels of the factory enterprise can master the relevant improvement tools, which is the basis for the continuous implementation of lean production management. If you don't master the improvement tools, you can't improve, and even if you do, you can't do it.

Therefore, training in improving tools is mandatory. It includes training at all levels from newcomers to veteran employees, to promoters, from grassroots to leadership.

Around 1980, FAW belonged to the First Machinery Department, and at that time, it carried out the selection of the honorary title of quality trustworthy team, which I think was the predecessor of lean production. I remember that at that time, what we pursued was never satisfied with qualification, but had to achieve the best! This is undoubtedly a huge test of your operating skills and sense of responsibility, looking back, we are worthy of the country, worthy of the meager wages to support the family, worthy of conscience!

We use VIOOVI's ECRS man-hour analysis software, which can solve the problem of over-processing in the machining process, reducing the unnecessary processes, because these redundant processes will waste man-hours and affect production, and the implementation of lean production must not be low in the first place.

The easiest way to do this is to look for waste. Find the eight waste points and analyze them one by one. Find the significant factors at each waste point, the main factors and the results of the waste. Look at the ones that waste the most money, and focus on the analysis.

1. Kanban production mode.

The large amount of inventory not only makes it costly and difficult to cash over, but also makes it impossible to see the real problem. The Kanban production method embodies the essence of lean thinking. Since it is started by the customer's contract order, the product produced does not cause a backlog, and the production process is carried out exclusively for a truly efficient output.

2. TPM full production and maintenance.

The frequent occurrence of various faults will make the maintenance cost of the enterprise too high and the production efficiency will be reduced, Huatianmou enterprise management can prevent the failure of the company through TPM full production and maintenance methods, reduce the downtime caused by equipment failure, improve production efficiency, reduce maintenance costs and production costs.

3. Streamlined production.

Streamlined production can be arranged in sequence according to the product category according to the processing order, which is conducive to shortening the handling distance, making the number of work-in-progress low, the production cycle short, and the production space small. The production is not synchronized, which is easy to cause problems such as backlog in the intermediate warehouse, unsmooth production, and long production cycle, and Huatianmou Enterprise Management believes that synchronous production is conducive to improving overall efficiency and reducing waste. Standardize equipment operation and operation methods, so that any operator can simply operate multiple equipment, which can achieve less manpower operation, reduce personnel deployment difficulties, and help improve overall efficiency.

4. Reduce waste and loss.

The so-called waste is to discard useful things as useless. Reducing waste and loss is needed to rely on scientific management to achieve, enterprise production, the full use of waste materials, leftovers, and the full use of equipment can reduce the cost of production. In the past, I have participated in the informatization construction of a copper plate production and processing enterprise in Japan, and they can minimize the waste of each roll of copper plate cutting through a computer software system, and there is basically no waste loss.

1. Lean production reduces all kinds of waste to improve production efficiency.

The waste of operation always exists in our work, if we can find out these wastes and improve them is the key, to find out the waste around us can only be more comprehensive with the participation of all employees. To really reduce all kinds of waste still need to do a lot of work, it takes a lot of manpower to do it, so we do a good job of publicity, mobilize all employees to actively participate in order to reduce all kinds of waste, to achieve the purpose of improving production efficiency.

s management. 5S management is to carry out comprehensive management of the workshop site, maintain a clean and efficient work site, so that workers can maintain good working habits. In the intelligent manufacturing environment, the methods and processes of 5S management are tooled through the MES system, such as the real-time display of the 5S layout standard of the station on the on-site terminal, so as to realize the paperless operation on the site, and automatically call according to the production task in the terminal, so as to avoid the existence of a large number of paper documents that are not easy to manage on site.

3. Lean production can produce on time.

Just-in-time emphasizes production synchronization and equalization, and the realization of both is to transmit instructions through pull kanban management. In automotive OEMs, material pull demand management is carried out directly from the first-class business workshop through Kanban.

Lean production mode is the thorough pursuit of production rationality, high efficiency, can flexibly produce to meet the needs of high-quality products of production technology and management technology, its basic principles and many trembling methods, has a positive significance for the manufacturing industry. The core of lean production, that is, the basic ideas of production planning and control and inventory management, also plays an important role in enriching and developing modern production management theory. Moreover, lean production management requires "zero switchover, zero inventory, zero waste, zero defects, zero failures, zero stagnation, zero accidents" and so on.

Lean production saves materials, improves the value of the commodity itself, so the cost is further reduced, lean production is really important to the manufacturing industry, you like the previous traditional manufacturing industry in the production process because of not enough refinement, resulting in a large number of defective products, not to mention the quality, the cost loss alone is not a few, plus with the development of the times, the manufacturing industry is relatively not so much, the traditional manufacturing industry wants to train a qualified skilled workers need to spend time and materials, Coupled with the improvement of people's living standards, there are higher requirements for the quality of goods, so lean production is an urgent thing for the manufacturing industry.

In order to do a good job in lean production, many enterprises have begun to carry out intelligent transformation, but some enterprises have not been applied in practice after the transformation, one is that workers are not used to it, and the other is the electricity cost and labor cost that are consumed, so many enterprises have begun to struggle with whether the manufacturing industry should carry out intelligent transformation. The emergence of the silent transformation of Rongshang World has resolved these problems, and the intelligent transformation of the factory has been carried out in the way of non-stop work and production, so that employees can learn to use and like to use it.

Therefore, if the manufacturing industry wants to lean production, it is necessary to keep pace with the times, and at the same time, choose the right direction and use the right way, so as to accompany the divination which half the result is doubled.

Conclusion: Lean production cannot reduce costs without sacrificing quality.

Why: Lean manufacturing is a production management approach that emphasizes maximizing value while minimizing waste.

However, it is very difficult to reduce costs while maintaining product quality.

Because the best way to reduce costs may lead to the manufacture of materials that reduce costs, reduce the number of employees, etc., which may lead to a decrease in the production efficiency of the production line, a decrease in the quality of the material, and thus a decrease in product quality.

Content extension: Although lean manufacturing cannot reduce costs, it can increase value by reducing unnecessary waste and improving production efficiency, thereby improving the economic efficiency of enterprises.

Businesses can reduce waste costs and waste by improving workflows and reducing unnecessary operations.

Through these poor sock key measures, lean production can help enterprises improve the quality of products, increase competitive advantages, and improve profit levels.