The ultimate goal of lean production

“Zero waste” is the ultimate goal of lean production, which is reflected in seven aspects of PICQMDS. The goals are described as follows:
(1) “Zero” conversion time waste (Products• multi-variety mixed-flow production)
The variety switching of processing processes and the time waste of assembly line conversion are reduced to “zero” or close to “zero”. (2) “Zero” Inventory (reduced inventory)
Process and assembly are connected to streamline, eliminate intermediate inventory, change the market forecast production to order synchronous production, and reduce product inventory to zero.
(3) “Zero” waste (Cost• Total cost control)
Eliminate the waste of redundant manufacturing, handling and waiting to achieve zero waste.
(4) “Zero” bad (Quality• high quality)
Bad is not detected at the check point, but should be eliminated at the source of production, the pursuit of zero bad.
(5) “Zero” failure (Maintenance• improve operation rate)
Eliminate failure downtime of mechanical equipment and achieve zero failure.
(6) “Zero” stagnation (Delivery• Fast response, short delivery time)
Minimize Lead time. To this end, we must eliminate intermediate stagnation and achieve “zero” stagnation.
(7) “Zero” disaster (Safety• Safety first)
As a core management tool of lean production, Kanban can visually manage the production site. In the event of an anomaly, the relevant personnel can be notified at the first time and measures can be taken to remove the problem.
1) Master production plan: Kanban management theory does not involve how to prepare and maintain master production plan, it is a ready-made master production plan as a start. Therefore, enterprises that adopt just-in-time production methods need to rely on other systems to make master production plans.
2) Material requirements Planning: Although Kanban companies usually outsource the warehouse to suppliers, they still need to provide suppliers with a long-term, rough material requirements plan. The general practice is to obtain the planned amount of raw materials according to the sales plan of finished products for one year, sign a package order with the supplier, and the specific demand date and quantity are completely reflected by the Kanban.
3) Capacity demand planning: Kanban management does not participate in the formulation of the main production plan, and naturally does not participate in the production capacity demand planning. The enterprises that achieve Kanban management achieve the equilibrium of the production process by means of process design, equipment layout, personnel training, etc., thus greatly reducing the imbalance of capacity demand in the production process. Kanban management can quickly expose processes or equipment with excess or insufficient capacity, and then eliminate the problem through continuous improvement.
4) Warehouse management: In order to solve the problem of warehouse management, the method of outsourcing the warehouse to the supplier is often used, requiring the supplier to be able to provide the required materials at any time, and the transfer of material ownership occurs when the material is received on the production line. In essence, this is to throw the burden of inventory management to the supplier, and the supplier bears the risk of inventory capital occupation. The prerequisite for this is to sign a long-term package order with the supplier, and the supplier reduces the risk and expense of selling, and is willing to bear the risk of overstocking.
5) Production line work-in-process management: The number of work-in-process products in enterprises that achieve just-in-time production is controlled within the Kanban number, and the key is to determine a reasonable and effective Kanban number.
The above is an introduction to the lean production method, lean production is just a production method, if it needs to truly achieve its ultimate goal (the 7 “zeros” mentioned above). It is necessary to use some on-site management tools, such as Kanban, Andon system, etc., the use of these tools can do visual management, can take measures to remove the impact of the problem at the first time, so as to ensure that the entire production is in a normal state of production.
Choosing WJ-LEAN can help you better solve lean production problems.