This is a question that lean people like to ask. At least I often hear my friends ask, how do you define a large batch or a small batch? Is there a clear distinction between them? When should I use large batches and when should I use small batches? and many more. Let’s explore this topic today.
Comparison of Ford Method and Toyota Method
In fact, Mr. Ohno has also had such problems and thoughts. He also mentioned in his book: "Which of Ford Method and Toyota Method is more dominant? Because these two systems are used every day. To improve and reform, it is difficult for me to quickly answer this question. However, I am confident that the Toyota Production System is suitable for production in the low-growth period.
There is no doubt that the Ford Production System was in its environment at the time. It has indeed brought a revolutionary change in production methods, that is, from single-piece operation to mass production, creating the myth of high efficiency and low cost, and also allowing the rapid development of the US automobile industry. This is not only the progress of enterprises. It also brought cheap goods to the common people. It should be said that it is the progress of human industrial civilization. The
Toyota production method was born in another scene. Japan was short of resources after the war, and the domestic automobile demand was small, and the categories were diverse. For Toyota, which is just starting out, whether it is capital or manufacturing capacity, it faces many challenges. How to deal with it? Only when there is pressure can breakthroughs. From Toyota Kiichiro to Ohno Naiichi, they continue to learn, innovate and practice, and gradually form themselves. Unique production method, multi-variety and small-batch production. This can be said to open another industrial civilization, so that our manufacturing methods can better match the needs of human beings. The characteristics of
mass production and small batch production
mass production Features:
has a large production volume.
means a large number of batches of a product. For example, Ford builds one model of car in one assembly line and keeps doing it; or some companies do one product for one month; or there is one product for one week. . High-volume is a relative concept, defined according to the demand characteristics of the product.
less frequent switching
high-volume must pursue continuity and reduce switching. Because switching will bring time loss and cost. In fact, we are implementing lean In the process, I often encounter this question raised by production managers. Isn’t it a long time to stop production and change molds? Isn’t there a lot of unstable factors in frequent switching, which will increase the point of change? Therefore, the existence of mass production also has soil If you want to change old habits, you have to do it gradually. The characteristics of
small batch production
small production batch
small batch means that the production volume of a single model product is small each time, such as making the same product for 2 hours at a time, and you can make several different products a day Model. In this way, there will be relatively few semi-finished products at breakpoints on the production line, and of course the raw materials and finished products inventory will also drop a lot.
fast switching
The key to realizing small batches is to achieve fast switching, otherwise it will bring a lot of waste. It is not as good as mass production to save time and effort. Fast switching can effectively shorten the product switching time, and the best switching can achieve almost no waiting. For example, it takes about 10 seconds for F1 racing tires to change, and it takes only 3 minutes for Toyota to switch models.
How to choose and apply? z 1z
customer demand pulls
all the demand comes from customers, not for small batches. When the customer’s demand is in large quantities, and we are able to achieve single-piece flow well, large quantities are the best way; when the customer’s demand is more varieties and small batches, of course we have to produce in small batches, otherwise we will bring Come with a lot of inventory and all kinds of waste.
Combine your own manufacturing capabilities
You can do as much work as you have. For manufacturing plants, this is also the case. When our manufacturing conditions and capabilities do not yet have flexible production, we should not be swollen to fill the body, or honestly choose the production method that is most suitable for us at the moment. For example, due to the limitation of equipment, personnel, and raw material procurement, it is necessary to save large quantities of circulation, so just do it.
really realizes fast switchover
fast die change is the hard power of enterprises, in fact, it can be extended to fast switch. Quick switching is not only the switching of equipment and molds, but also the corresponding rapid response of logistics personnel, making the entire switching fast and smooth. For example, it is often seen that after the production has been changed, the mold is waiting for an order, the product is half switched and there is no material, and the product is debugged, and the technical parameters have changed. These are some logistical cooperation not in timeKeep up with the cause. Fast switching is not just a matter of the production department, at least it is a matter of the entire operating department, or even the entire company. The existence of
is reasonable, but reasonable is not necessarily optimal. While knowing how to apply large batches and small batches, you must also know how to continuously optimize.
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