1. Lean production theory system and core ideas
1. Lean production theory system
Lean production theory system includes punctual production, automation, unit production methods and multi-functional labor , Quick mold change SMED , on-site management, visual management and other parts, the realization of intelligent manufacturing also refers to the automation, rapid mold change, visual management and other modules.
2. Lean house
The way to realize the theoretical system of lean production is to build the enterprise's own lean house. The Lean House consists of four layers: target layer, criterion layer, method layer and operating environment.
The operating environment is the foundation of the lean house, including human, machine, material, method, environment, etc. The method layer is the brick and tile of the lean house, the criterion layer is the load-bearing beam of the lean house, and the method layer surrounds the four load-bearing The beams are built layer by layer to form the main body of the Lean House. The target layer is the roof of the Lean House. The ultimate profit can be maximized by reducing costs and maximizing cash flow.
3. The core idea of lean production
For example, process-oriented manufacturing or manufacturing companies that focus on planned production, but we can focus on the core ideas of lean production theory and select the essence to form a lean production method suitable for our own enterprises.
Eliminating all waste is the core idea of lean production. , the founder of TPS , Toichi Ohno once said that “a reduction of 10% of waste is equivalent to doubling sales”, and a fixed profit of 10% Under the premise of, if you want to double the profit, you must either double the base (that is, sales) or reduce the cost by 10% from 90% of the cost. A doubling of sales will lead to overcapacity and inventory backlog when the market is saturated, which is detrimental to the long-term development of the company.
cost structure contains most of the value-added activities, which are indispensable links in the production process. The premise for us to reduce the cost by 10% is to identify non-value-added activities, including waste and change that can be eliminated immediately Conditions can eliminate waste.
2. LP-based decision analysis platform architecture construction _strong link 4strong
_span 1. Open up the entire two-way data link in the span_strong Lean production theory, customer-oriented order-based production mode gradually replaces mass push production mode, raw material procurement management with the goal of zero inventory, and personalized manufacturing methods based on flexible production to eliminate handling The intelligent logistics system for the purpose of waiting for waste builds a horizontally integrated digital platform.
divides the data collection of all the above links into four levels,They are respectively at the sensor level, automation control level, manufacturing execution system level, and enterprise resource level to build a vertically integrated digital operation system.
2. IT implementation architecture
By building an open and shared digital platform, we can realize the information management of the whole process and improve the supply chain operation quality and management model with the "54321" collaborative management model Efficiency, to promote all-round innovation and improvement of management with information technology.
breaks through the data barriers between various business systems, and uses ETL tools to perform data extraction, cleaning, and conversion operations, and build the ODS layer (query business data with high immediacy, transfer business systems Query pressure) and DW layer (historical summary data warehouse for analysis topics).
3. LP-based data analysis model
1. Three elements of data analysis
includes three elements of lean data analysis and analysis methods for lean data analysis and analysis of dimensions. Sorting out the analysis structure according to the three elements will not only help us a lot in our later report production, but also deepen our understanding of business logic.
2. Data analysis pyramid model
uses a pyramid model to build an enterprise data analysis platform,According to the needs of users, it can be divided into enterprise-level leadership strategy cockpit, business management analysis of various business modules, and data query of basic business personnel. With a clear structure and clear responsibilities, you will get twice the result with half the effort when designing indicators and reports, avoiding conflicts caused by the same indicators that need to be seen by leaders and business personnel and the presentation styles they need are different.
3. Data analysis model based on LP
, production capacity and quality adjustment, focus on production planning, production capacity and quality planning, etc. It is in line with the idea of punctual production to complete the number of products that satisfy the customer at the time of the customer's demand; through the monitoring of the equipment, the maximum utilization of the equipment is achieved, avoiding idleness, and the production abnormality is realized through the equipment alarm to reduce the problem handling The waiting time reflects the idea of avoiding waste in lean production; the real-time monitoring of the production line through rate and defective products through the report cockpit reflects the visual management module in lean production.
Produces QCD cockpits for the director-level leaders, and feeds back information about the three elements of production, quality, cost, and delivery; the workshop management cockpit is made for the workshop director, which is convenient for real-time management of production line personnel and opening lines Situation, 7S, production situation, etc.; for the production of team arena between teams, create a benign competition system and realize self-management.
IV. LP-based data analysis application case
provides and supports multi-screen visualization application solutions, including large-screen display, desktop or notebook, tablet, mobile phone mobile application, data movement reminder, etc. ,The following introduces some data analysis report cases based on products.
1. Large screen application
Make a QCD cockpit, monitor the real-time situation of the production workshop, and pass equipment status, personnel efficiency, alarm information, production rate, etc. It is displayed clearly in the form of graphs, bar graphs, and broken line graphs, which improves the production management level and the timeliness of problem handling.
2. PC-side application
to track the finished goods stocking, the responsibility of the batch stocking plan and inventory turnover must be kept to people, and the dynamic threshold of inventory should be constantly reduced. , Improve inventory turnover rate, which reflects the management concept of PDCA problem closed loop and continuous improvement.
TQM quality control analysis, multi-layer drilling analysis of regions, workshops, production lines, products, and sections, quality problems are traced to the source, and the responsibility is to the individual.
3. Mobile application
directors and workshop directors directly open the mobile production line management report for work guidance during the inspection; Production status, on-site accountability for abnormal indicators; production managers on business trips,Real-time grasp of the first-line production situation.
V. Summary
The theory of lean production is limited. There are different application methods for different types of enterprises. Its core idea is to eliminate all waste, but it is applicable to all Enterprises, including non-manufacturing enterprises. The focus of the promotion and implementation of lean production theory is how to identify non-value-added activities in the enterprise and find a way to eliminate them.
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