What are the misunderstandings of reducing costs in lean manufacturing?

There are 7 misunderstandings about cost reduction in lean manufacturing industry:

Myth 1:Taking advantage of the strong position of the buyer's market, the price of procurement costs is blindly reduced, resulting in a decline in the quality of raw materials.

Myth 2:The cost advantage is regarded as a simple reduction in production costs.

Myth 3:Think of cost reduction as the lowest cost in all links of the entire chain.

Myth 4:Interpret cost reduction as a sign of the drive to reform by drastic reductions in institutions, manpower, and welfare.

Myth 5:The important impact of product development and technology research and development on the design of product cost is ignored.

Myth 6:Lack of a dynamic, comprehensive cost analysis perspective and planning.

Myth 7:Contradictory and cross-cutting influences of cost reduction factors.

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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.

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. 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 by the customer's contract order, so it is not easy to cause a backlog of products, and the production process is completely centered around and emptied to be truly effective.

2. TPM production and maintenance of all employees.

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 deficit 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.

Lean production method summarizes a series of lean techniques, such as: "synchronous production line layout", "one flow production operation", "balanced production (planning) organization", "mixed line operation and rapid production change", "standard operation of personnel", "kanban production logistics system", "inventory management to adapt to changes in demand", TQM, TPM, etc.; And it has been disseminated in enterprises through various **. However, after the practice of many domestic enterprises, the effect is not very prominent, and the result is half the effort; The main reason is that the production system does not clearly adopt a certain production organization model, blindly using one or several lean technology props and methods (such as:

Kanban production) to be improved. In the implementation process of lean production, first of all, we should refer to a certain production organization model in combination with the current situation of the enterprise to form a production organization model and logistics rules with its own characteristics; Then flexibly use the props and methods of lean technology to determine the direction and gradually achieve improvement.

The basic state of the elements of the lean production site:

Production line (equipment) layout: equipment type configuration according to the process flow; Reasonable allocation of equipment according to the needs of production cycle; The equipment layout type is "U" shape as the preferred scheme, the operation direction should be unified, and the equipment spacing should be reduced as much as possible.

Logistics storage of work-in-progress between processes: the storage site is concentrated at the production site in principle; Clarify the maximum storage quantity and minimum order quantity of work-in-progress; Realize the fixed management of "5S"; Clarify the storage method and configure the corresponding logistics equipment.

Logistics storage of in-process products: the principle of "single piece (small batch), one stream transfer" is implemented; Clarify the storage location and storage amount; Configure the corresponding logistics equipment.

Production line materials (parts)**: Adopt the principle of "multi-frequency, small batch, and just-in-time system" to determine the supply storage area, storage volume, and supply logistics rules, and set up supply logistics equipment.

Production operation mode: according to the production rhythm of the implementation of "one person more sequence" rhythm production.

Staffing: Implement the principle of man-machine operation time separation, the operation cycle time should be constant, and the operation content should be repetitive operation.

Production plan: indicate the production volume and progress according to the production capacity and production cycle of each process; Under the premise of integrating sales planning and production planning, the principle of "levelization" is implemented.

Reduce costs, save resources, make more money, and give more money to anyone, and it is best for workers.

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.

Lean manufacturing is a production method that pursues high efficiency and low cost, but this does not mean that product quality can be sacrificed at the expense of reducing costs. Lean manufacturing emphasizes improving efficiency and reducing costs by optimizing production processes and reducing waste, rather than reducing product quality to achieve cost control.

In the lean production model, quality is a very important factor. This is because if the quality of the products in the production hall is not good, it will not only affect the customer experience, but also lead to additional costs such as after-sales problems, returns, and compensation, which will ultimately increase the cost of the enterprise. Therefore, lean manufacturing should focus on quality, rather than sacrificing quality to reduce costs.

In addition, in lean manufacturing processes, the main way to reduce costs is achieved by reducing waste and increasing efficiency. This package includes ways to reduce inventory, reduce processes, and optimize production lines. These methods are based on cost control under the premise of ensuring product quality.

Therefore, lean production and quality jujube consumption control are complementary to each other, and cost control needs to be carried out on the premise of ensuring product quality.

Lean production is a production automation model that pursues maximum value and minimum waste, and aims to provide high-quality, low-cost, and short-lead products and services. Although lean manufacturing can help to save costs, it should not only aim at cost savings, but should pursue maximum value on the basis of quality assurance. In the case of the company, if the company abandons quality standards in order to reduce costs in the process of pursuing lean production, then the quality of its products will be greatly reduced, which may lead to consumer complaints and a decline in market share, which will also cause the company to suffer.

Therefore, in the process of lean production, we should reduce costs by optimizing the process, reducing unnecessary waste, improving product quality and other measures, and not pursuing cost savings at the expense of reducing quality.