Industry Standard: What Are The Four Core Of Lean Production In Textile Workshop

To target the mode of production, at the same time, it is a concept, a culture. Most enterprises have realized the importance of lean production to enterprises.

　　 What is lean production?

Toyota Institute of Technology (MIT) is in urgent need of "lean production process" in Japan; Benefit means that all business activities should be beneficial, effective and economical.

Lean production is the best production organization system and mode in the current industry.

　　 Four characteristics of lean production

Lean production can improve the production efficiency of enterprises to a certain extent, and at the same time, it can also enhance the competitiveness of enterprises to a certain extent. However, many enterprises want to implement lean management, but they do not really understand a feature of lean production. What are the characteristics of lean production management?

1. Eliminate all waste and pursue excellence

The characteristic of lean production is to eliminate all waste, to pursue excellence and continuous improvement. In order to make the most rapid response to the market demand with the best quality, the lowest cost and the highest efficiency, we should eliminate all useless things in the production link and simplify all the work that does not produce added value in product development and design, production and management.

2. Emphasize the role of human beings and give full play to their potential

Lean production shifts the tasks and responsibilities to the workers who directly add value to the products. And the task is divided into groups, which are undertaken by the workers in the group. Therefore, workers are required to be proficient in various jobs, reduce the number of workers who do not directly add value, and increase workers' autonomy in production. When the production line breaks down, the workers have the right to decide to shut down, find out the causes and make decisions. Team cooperation makes the scope of workers' work expand, stimulate workers' interest in work and innovation spirit, which is more conducive to the implementation of lean production.

3. Zero waste target

Inventory is a curse: high inventory is one of the characteristics of mass production. Due to the instability of equipment operation, unreasonable process arrangement, high scrap rate and unbalanced production, the phenomenon of untimely supply often occurs. Inventory is regarded as an essential "buffer".

However, lean production thinks that inventory is the "disaster" of enterprises

Firstly, inventory increases the operating cost;

(2) inventory covers up the problems of the enterprise.

4. Pursue perfection and never be satisfied

Lean production takes "endless pursuit of perfection" as its business goal, and pursues continuous improvement in product quality, cost and service. The spirit of lean production is also an important feature of success. Just in time production (JIT) and continuous improvement process (CIP) are the thought embodiment of the pursuit of perfection in lean production. 　　

Lean production strives to pursue the rationality and efficiency of production and the production technology and management technology that can flexibly and diversely produce high-quality products to meet various needs. Its basic principles and methods are of positive significance to the manufacturing industry. 　

　 Six advantages of lean production

In view of the above characteristics and compared with the mass production mode, the advantages of lean production mode mainly lie in the following aspects:

1. Whether in product development, production system, or other departments of the enterprise, the required human resources can be reduced by half compared with enterprises under mass production mode;

2. The development cycle of new products can be reduced by more than half;

3. The WIP inventory in the production process can be reduced to one tenth of the general level under mass production mode;

4. The space occupied by enterprises can be reduced to half of that of enterprises adopting mass production mode;

5. The inventory of finished products can be reduced to one fourth of the average inventory level of enterprises with mass production mode;

6. The product quality can be increased three times.

　 Ten tools of lean production

1. Just in time production (JIT)

Just in time production (JIT) originated in Japan, and its basic idea is to "produce the required products according to the required quantity only when needed". The core of this mode of production is to pursue a production system without inventory or to minimize the inventory. We should work in strict accordance with the requirements of the standard in the production operation, according to the demand of production, on-site need to send as many materials, to prevent abnormal inventory.

2. 5S and visual management

5S (sorting, rectifying, cleaning, literacy) is an effective tool for on-site visual management, and it is also an effective tool for improving employees' quality. The key to the success of 5S is standardization. Through detailed site standards and clear responsibilities, employees can first maintain the cleanliness of the site and expose them at the same time, so as to solve the problems of the site and equipment, and then gradually develop standardized professional habits and good professional quality.

3. Kanban management

Kanban can be used as a means to exchange production management information in the factory. Kanban cards contain a lot of information and can be used repeatedly. There are two kinds of Kanban: Kanban and kanban. Kanban is more direct, obvious and easy to manage.

4. Standardized operation (SOP)

Standardization is the most effective management tool of high efficiency and high quality. After the value flow analysis of the production process, the text standard is formed according to the scientific technological process and operation procedure. The standard is not only the basis for judging the product quality, but also the basis for training the staff to operate normally. These standards include site visualization standards, equipment management standards, product production standards and product quality standards. The requirement of lean production is "everything must be standardized".

5. Total production maintenance (TPM)

In the way of full participation, we can create a well-designed equipment system, improve the utilization of existing equipment, achieve safety and high quality, and prevent failures, so as to reduce costs and improve overall production efficiency. It not only reflects 5S, but also job safety analysis and safety production management.

6. Use value flow chart to identify waste (VSM)

The production process is full of amazing waste. Value stream mapping is the basis and key point of implementing lean system and eliminating process waste

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

Recognize the components and importance of value stream;

Master the ability to draw "value stream map" in practice;

Recognize the application of data in value stream mapping and improve the order of opportunities through data quantification.

7. Balance design of production line

Due to the unreasonable layout of the assembly line, the production workers move unnecessarily, thus reducing the production efficiency; Due to the unreasonable action arrangement and unreasonable process route, the workers repeatedly pick up or put down the workpiece. Assessment is very important now, and so is site planning. Saving time and effort is the best. Only by doing twice with half the effort.

Pull (8 production)

The so-called pull production is to use Kanban management as a means to adopt the "material taking system", that is, the subsequent process will produce according to the "market" needs, and take the same WIP quantity from the previous process for the shortage of WIP in this process, so as to form the pull control system of the whole process, and never produce 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, mainly through the pull system operation mode.

9. Fast switching (smed)

The theoretical basis of fast switching is operations research technology and concurrent engineering, which aims to minimize equipment downtime through teamwork. In the process of product line change and equipment adjustment, the lead time can be minimized, and the effect of fast switching is very obvious.

In order to minimize the waste of line stop waiting, the process of shortening the setting time is to gradually remove and reduce all non value-added operations, and turn them into the process of completing non-stop time. Lean production is achieved by eliminating waste, reducing inventory, reducing defects and shortening manufacturing cycle time. Reducing setup time is one of the key methods to help us achieve this goal.

10. Kaizen

When we start to accurately determine the value, identify the value flow, make each step of the value created for a specific product flow continuously, and let customers pull the value from the enterprise, the miracle begins to appear.

　　 Implementation steps of lean production tools

The steps listed here are for reference only, because the implementation of lean production must be based on the actual situation of the site after the investigation and diagnosis of the enterprise site.

Step 1: on site 5S activities;

The second step: Kanban management;

The third step: value stream analysis;

Step 4: standardized operation;

Step 5: stimulate production;

Step 6: JIT production;

Step 7: balanced production;

Step 8: fast switching;

Step 9: TPM management;

Step 10: continuous improvement.

The four core ideas of lean production are as follows: standing in the perspective of value (value), continuous improvement (continuous improvement), customer-centered (customer-centered), and maximizing the company's interests (perfect).

(source: China Cotton Association)