精益概论 ASME Lean Overview.ppt

Lean ManufacturingOverview Benefits/Goals of Lean Manufacturing Best Quality Lowest Cost Shortest Lead Time Best Safety High (Employee) Morale Lean and your company Which one of the five goals is your company most interested in? Which of the five do you think would be the biggest competitive advantage to your company? As a mechanical engineer, which of the five do you think YOU could have the greatest impact on? Lean manufacturing was developed at the Toyota Motor Company of Japan… The term “lean manufacturing” came years later, from author James P. Womack. Toyota got some of its ideas for TPS from Henry Ford: Shortened production flow –physically locate each process on the shop floor adjacent to the process that came before it. Standardized work –standardize the parts, discover the most efficient way produce then standardize the production work. Reduced cycle times – Eliminate unnecessary movement required by workers (e.g., placed tools/parts in easy reach). As the customer buys an item, make another to replace it… Taiichi Ohno, Eiji Toyoda’s production genius, originated the concept of just-in-time manufacturing. In the supermarket he saw an incredibly efficient consumer-driven supply chain. Daily and weekly orders to suppliers made it possible to eliminate warehousing by the grocery store – no storage costs, no overproduction. Taiichi Ohno expanded “just-in-time” manufacturing into the factory… No part is made upstream in the manufacturing process until it was “pulled” (required) by a process downstream. This avoided overproduction (the worst kind of waste). Parts “flow” through the plant at a level pace, no batches lined up waiting for the next process. If parts stack up between processes (buffer or safety stock), it interrupts the continuous flow of manufacturing that is critical to the lean manufacturing process. Products that flow continuously through the production process are created much more efficiently than those that start and stop,