What methods does lean production management include?

Lean production management includes the following 11 methods:

1. 5S and visual control

"5S" means sorting (Seiri), rectification ( "5S", the abbreviation of the five words Seiton, Seiso, Seikeetsu and Shitsuke, originated in Japan. 5S is the process and method of creating and maintaining an organized, clean and efficient workspace. It can educate, inspire and develop good "human" habits. Visual management can identify normal and abnormal conditions in an instant, and can deliver them quickly and correctly. message.

2. Just-in-time production (JIT)

The just-in-time production method originated from Toyota Motor Company in Japan. Its basic idea is to "produce everything only when it is needed and in the required amount." products you need”. The core of this production method is the pursuit of a stock-free production system, or a production system that minimizes stock.

3. Kanban management (Kanban)

Kanban is a Japanese noun, which refers to a label or card that is hung or attached to a container or a batch of parts, or each item on the assembly line. Color lights, TV images, etc. Kanban can be used as a means of communicating production management information within the factory. Kanban cards contain quite a bit of information and can be used over and over again. There are two commonly used kanban boards: production kanban boards and shipping kanban boards.

4. Zero inventory management

Factory inventory management is a link in the supply chain and the most basic link. As far as the manufacturing industry is concerned, strengthening inventory management can shorten and gradually eliminate the detention time of raw materials, semi-finished products, and finished products, reduce ineffective operations and waiting time, prevent shortages, and improve customers' awareness of the three major elements of "quality, cost, and delivery time." Satisfaction.

5. Total Productive Maintenance (TPM)

TPM originated in Japan. It uses the participation of all employees to create well-designed equipment systems and improve the utilization of existing equipment. Achieve safety and high quality and prevent failures, thereby enabling companies to reduce costs and improve overall production efficiency.

6. Use value stream mapping to identify waste

The production process is full of staggering waste. Value Stream Mapping is a way to implement a lean system and eliminate process waste. the basis and key points.

7. Production line balance design

Due to the unreasonable layout of the assembly line, production workers move needlessly, thereby reducing production efficiency; due to unreasonable movement arrangements and unreasonable process routes, workers move over and over again. Pick up or put down the work piece.

8. Pulling system and supplementary pulling system

The so-called pull production uses kanban management as a means and adopts the "material taking system", that is, the subsequent processes are produced according to the needs of the "market". For the shortage of WIP in this process, the same WIP quantity is taken from the previous process, thereby forming a pull control system for the entire process, and never producing more than one product. JIT needs to be based on pull production, and pull system operation is a typical feature of lean production. The zero inventory pursued by lean is mainly achieved through the pull system operation method.

9. Setup Reduction

In order to minimize the waste of line shutdown and waiting, the process of shortening the setup time is to gradually remove and reduce all non-value-added operations, and Turn it into a process that is done during off-line time. Lean production is achieved by continuously eliminating waste, reducing inventory, reducing defects, shortening manufacturing cycle time and other specific requirements. Reducing setup time is one of the key methods to help us achieve this goal.

10. Single-piece flow

JIT is the ultimate goal of lean production. It is achieved by continuously eliminating waste, reducing inventory, reducing defects, shortening manufacturing cycle time and other specific requirements. . One-piece flow is one of the key techniques that helps us achieve this goal.

11. Continuous improvement (Kaizen)

Kaizen is a Japanese noun, equivalent to CIP.

The magic starts to happen when you start pinpointing value, identifying value streams, making the various steps of creating value for a specific product flow continuously, and letting customers pull value from the business.