How do garment factories carry out lean production?

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Lean production implementation steps 1, and select key processes that need to be improved.

Lean production mode is not achieved overnight, it emphasizes continuous improvement. First of all, we should choose the key process and strive to establish it as a template line.

2. Draw a value flow chart.

Value stream diagram is a method to describe logistics and information flow. After drawing the value flow chart of the current state, you can draw the lean vision of the future. In this process, more icons are used to represent continuous processes, various types of pulling systems, balanced production and shortened tooling replacement time. The production cycle is subdivided into value-added time and non-value-added time.

3. Conduct a seminar on continuous improvement.

Lean vision must be put into practice, otherwise, no matter how cleverly planned the chart, it is just a piece of waste paper. What (what), when (what) and who are responsible for the implementation plan, and set up review nodes during the implementation process. In this way, all employees participate in the whole productive maintenance system. Under the guidance of value flow chart and lean vision chart, each independent improvement project in the process has been given a new meaning, which makes employees very clear about the significance of implementing the project. There are several ways to continuously improve the production process: eliminating quality inspection and rework; Eliminate unnecessary movement of parts; Eliminate inventory; Reasonable arrangement of production plan; Reduce production preparation time; Eliminate downtime; Improve the utilization rate of labor force.

4. Create corporate culture

Although the significant improvement of workshop site can bring a series of subsequent corporate culture changes, it is obviously unrealistic to assume that positive cultural changes can be automatically established and promoted because of the improvement of workshop layout and production and operation mode. Cultural change is more difficult than the improvement of production site, and the two must be completed at the same time and complement each other. The implementation experience of many projects proves that the key to the success of the project is that the company leaders should combine the improvement of production methods with the evolution of corporate culture.

The transformation from traditional enterprises to lean production can not be completed simply by adopting the corresponding "Kanban" tools and advanced production management technology, but must change the concept of all employees. Lean production was born in Japan, not the United States, precisely because the corporate cultures of the two countries are very different.

5. Promote to the whole enterprise.

Lean production uses various industrial engineering technologies to eliminate waste and pays attention to the whole production process, not just one or several processes. Therefore, the success of model line should be extended to the whole enterprise, which can shorten the operation process and push production system will be replaced by customer-oriented pull production system.

In a word, lean production is a never-ending process of pursuing perfection. It is committed to improving the production process and every working procedure in the process, eliminating all activities in the value chain that cannot add value as much as possible, improving the utilization rate of labor force, eliminating waste, and minimizing inventory while producing according to customer orders.

The transformation from traditional enterprises to lean enterprises cannot be achieved overnight, and it needs to pay a certain price, and sometimes unexpected problems may occur. However, as long as enterprises unswervingly follow the lean road, most of them can recover all the transformation costs within six months, and some even enjoy the benefits brought by lean production in less than three months.

Lean production tools 1, 6S and visual control

"6S" is the abbreviation of six words, Seiri, Seiton, Seiso, Seikeetsu, Shitsuke and safety, which originated in Japan. 6S is a process and method to create and maintain an organized, clean and efficient workplace, which can educate, motivate and cultivate good "human nature" habits. Visual management can identify normal and abnormal states in an instant and transmit information quickly and accurately. The two-day course can help students:

Understand why 6S should be done, and master the steps and methods of implementing 6S and visual management;

Understand the types of visual control tools, and learn how to create visual control tools and some basic new tools that can quickly improve all areas of work.

2. JIT production

Just-in-time production mode originated from Toyota Motor Corporation of Japan, and its basic idea is to "produce the required products only when needed and in the required quantity". The core of this mode of production is to pursue a production system without inventory, or a production system with minimum inventory. Through the study of this course, students can:

Understand value-added and non-value-added activities to reduce or eliminate non-value-added and waste;

Identify seven kinds of waste and finally eliminate it;

Learn to use various pulling methods to realize just-in-time production.

3. Kanban

Kanban is a Japanese noun, which means a label or card hung or pasted on a container or a batch of parts, or various color signal lights and TV images on an assembly line. Kanban can be used as a means to exchange production management information in factories. Kanban cards contain a lot of information and can be reused. There are two kinds of kanban commonly used: production kanban and transportation kanban. This course will enable students to:

This paper introduces the pull system kanban and visual kanban used in the management process, and their significance to production organization, standardized operation and continuous improvement. ;

The role of production kanban is to buy "funds". What you need to pay attention to is what to buy, when to buy and how much to buy in the production process.

4. Zero inventory management The inventory management of the factory is a part of the supply chain and the most basic part. As far as 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 invalid operation and waiting time, prevent out of stock, and improve customer satisfaction with the three elements of "quality, cost and delivery". Through the two-day study, participants can:

Understand the basic concepts of inventory management, master the methods of inventory analysis, and learn to choose the appropriate inventory system;

Learn and master the skills of managing inventory operation;

Master the skills of formulating and implementing inventory operation management forms and procedures.

5. Total Production Maintenance (TPM)

TPM originated in Japan, which is to create a well-designed equipment system with the participation of all employees, improve the utilization rate of existing equipment, achieve safety and high quality, and prevent failures, so as to reduce costs and improve overall production efficiency. We hope that students can pass this course:

Understand the relationship between 5S and TPM;

Master the calculation of OEE and how to improve OEE;

Master the method of implementing TPM;

How to establish and maintain the history of equipment and evaluate the current TPM level.

6. Use the value stream diagram to identify waste.

There are amazing waste phenomena everywhere in the production process, and value stream diagram is the basis and key point for implementing lean system and eliminating process waste. Through the study of this course, students can:

Find out where waste occurs in the process and identify opportunities for lean improvement;

Understand the composition and importance of value stream;

Master the ability to actually draw "value stream map";

Understand the application of data in value stream diagram, and improve the ranking of opportunities through data quantification.

7. line balance Design

Unreasonable assembly line layout leads to unnecessary flow of production workers, thus reducing production efficiency; Because of unreasonable action arrangement and process route, workers pick up or put down the workpiece again and again. Through the study of this course, we will learn:

Able to design and implement balanced production line;

Understand the problems in typical process environment and how to influence them;

Know when to maximize productivity.

8. Pull system and auxiliary pull system

The so-called pull production is based on Kanban management and adopts the "material-taking system", that is, the next process is produced according to the market demand, and the shortage of WIP in this process is taken from the previous process, thus forming a pull control system in the whole 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. Lean pursuit of zero inventory is mainly achieved through the operation of the system. Through the study of this course, students can:

Understand the definition of pull system and supplementary pull system;

Understand the key parameters and calculation methods of tension system;

How to apply the pull system to lean projects in a changeable environment;

Understand the difference between manufacturing pull system and purchasing pull system.

9. Reduce the Setup Reduction.

In order to minimize the waste of offline waiting, the process of shortening the setup time is the process of gradually removing and reducing all non-value-added operations and transforming them into non-offline time completion. Lean production is achieved by continuously eliminating waste, reducing inventory, reducing defects, shortening manufacturing cycle time and other specific requirements. Shortening the setup time is one of the key ways to help us achieve this goal. Through the study of this course, we will learn:

Understand how the preparation time affects the turnover efficiency of the process;

Learn four steps to reduce setup time;

Understand the necessary preparations to reduce the setup time.

10, one piece flow

JIT is the ultimate goal of lean production, which can be achieved by eliminating waste, reducing inventory, reducing defects and shortening manufacturing cycle time. One piece flow is one of the key means to help us achieve this goal. Through the study of this course, we will learn:

The fundamental difference between one piece flow and traditional homework;

Design how to realize one piece flow;

Through one piece flow, your enterprise will get the following benefits:

The conditions are not good. Obviously, it will be solved in time. ※:

Team drive will be formed, and operators will concentrate on it. ※:

Shorten the time to solve problems. ※:

The operator's working time increases, while the auxiliary time decreases. ※:

Reduce production area, reduce logistics handling and improve production efficiency. ※.

1 1, continuous improvement.

Kaizen is a Japanese noun, equivalent to CIP. When we began to accurately determine the value, identify the value flow, let the steps of creating value for a specific product flow continuously, and let customers pull value from the enterprise, the miracle began to appear [2]. This course will enable students to:

When to improve and how to apply the improvement;

Improve strategies, common tools and techniques.