Lean production and its tools. Lean production is ...

Lean production is a special scheme of company management. The main idea is a constant striving to exclude any kinds of costs. Lean production is a concept that involves involving every employee in the optimization process. This scheme is aimed at maximum orientation towards the consumer. Let's consider in more detail what the lean manufacturing system is.

History of occurrence

The introduction of lean manufacturing into the industry occurred in the 1950s at Toyota Corporation. The creator of such a management scheme was Taiichi Ono. A great contribution to the further development of both theory and practice was made by his colleague - Shigeo Shingo, who, among other things, created a method for rapid readjustment. Subsequently, American specialists examined the system and conceptualized it as lean manufacturing (lean production) - "lean production". At first the concept was applied first of all in the automotive industry. After a while the scheme was adapted to process production. Subsequently, tools of lean manufacturing began to be used in health care, communal services, services, trade, the armed forces, the government sector and other industries.

Main Aspects

Lean production at the enterprise involves an analysis of the value of the product, which is produced for the end user, at each stage of creation. The main goal of the concept is the formation of a continuous process of eliminating costs. In other words, lean manufacturing is the elimination of any action that consumes resources, but as a result, no value is created for the end user. For example, he does not need a finished product or its parts to be in stock. Under the traditional system, all costs associated with marriage, alteration, storage, and other indirect costs are shifted to the consumer. Lean production is the scheme by which all of the company's activities are divided into processes and operations that add and do not add value to the product. As the main task, thus, the planned reduction of the latter.

Lean production: losses

As a synonym for costs, in some cases the term muda is used. This concept means different expenses, garbage, waste and so on. Tahiti Ono identified seven types of costs. Losses result from:

• Expectations;
• Overproduction;
• Transportation;
• Superfluous stages of processing;
• Unnecessary displacements;
• Release of defective goods;
• Excess stocks.

The main type of loss Tayichi Ono considered overproduction. It is the factor that causes the rest of the costs. Another item was added to the list above. Jeffrey Laiker, who researched Toyota's experience, described the unrealized potential of employees as a loss. As sources of costs are called overload capacity, employees in the implementation of activities with increased intensity, as well as uneven execution of the operation (for example, an interrupted schedule due to fluctuating demand).

Principles

Lean production is presented as a process, divided into five stages:

1. Determining the value of a particular product.
2. Establish a flow of value creation for this product.
3. Ensure continuous flow.
4. Providing the consumer with the ability to pull the goods.
5. The pursuit of excellence.

Among other principles on which lean manufacturing is based, it should be noted:

1. Achieving excellent quality - delivery of goods from the first presentation, use of the "zero defects" scheme, identification and solution of problems at the earliest stages of their occurrence.
2. Formation of long-term interaction with the consumer through the division of information, costs and risks.
3. Flexibility.

The production system used in Toyota is based on two basic principles: autonomization and "just in time." The latter means that all the necessary elements for the assembly come to the line exactly at the moment when it is needed, strictly in a certain number for the particular process to reduce the stock.

Composite elements

Within the framework of the concept under consideration, various components have been identified - lean manufacturing methods. Some of them may themselves act as a control scheme. The main elements include the following:

• The flow of single goods.
• General maintenance of equipment.
• System 5S.
• Kaizen.
• Quick change-over.
• Prevention of errors.

Industry Options

Lean health is a concept of reducing the time costs of medical personnel, not directly related to helping people. Lin-logistics is a pull-out scheme that unites all the suppliers involved in the value stream. In this system, partial replenishment of stocks with small volumes occurs. As the main indicator in this scheme is the logistic total cost. Lean tools are used by the Post Office of Denmark. Within the framework of the concept, a large-scale standardization of the services was implemented. The objectives of the event were to increase productivity, accelerate shipments. "Flow-based value-creation cards" were introduced to control and identify services. Also, a system of motivating employees of the department was developed and implemented. In the construction of a special strategy, focused on improving the efficiency of the process of erecting structures at all stages. The principles of lin-production have been adapted for software development. In the city, state administration, the elements of the scheme in question are also used.

Kaizen

The idea was formulated in 1950 by Dr. Deming. The introduction of this principle has brought great profits to the companies of Japan. For this specialist was awarded the emperor a medal. After a while the Union of Science and Technology of Japan announced a prize for them. Deming for the quality of industrial goods.

Advantages of kaizen philosophy

The advantages of this system were evaluated in each industrial sector, where conditions were created to ensure the highest efficiency and productivity. Kaizen is considered a Japanese philosophy. It is to promote continuous change. The school of thought kaizen insists that constant transformations act as the only path to progress. The main emphasis is on improving performance by eliminating unnecessary and hard work. The definition itself is created by combining two words: "kai" - "change" ("transform"), and "zen" - "towards the best." The merits of the system quite clearly reflects the success of the Japanese economy. This is recognized not only by the Japanese themselves, but also by the experts of the world.

Goals of the kaizen concept

There are five main directions for the development of production. They include:

1. Reduction of waste.
2. Immediate troubleshooting.
3. Optimal use.
4. Teamwork.
5. Highest quality.

It should be said that most of the principles are based on common sense. The main components of the system are the improvement of the quality of the goods, the involvement of each employee in the process, the willingness to interact and change. All these activities do not require complex mathematical calculations or the search for scientific approaches.

Reduction of waste

The principles of kaizen philosophy are aimed at a significant reduction in losses at each stage (operations, process). One of the main advantages of the scheme is that it includes every employee. This, in turn, involves the development and subsequent implementation of proposals for improvement at each level of management. Such work helps minimize the loss of resources.

Immediate troubleshooting

Each employee in accordance with the concept of kaizen should counteract problems. This behavior contributes to the rapid resolution of issues. With immediate troubleshooting, the production cycle time does not increase. Immediate solution of problems allows to direct activity in an effective channel.

Optimal use

If you quickly solve problems, resources are released. They can be used to improve and achieve other goals. In complex, these measures allow to establish a continuous process of effective production.

Teamwork

Involvement of all employees to solve problems allows finding a way out faster. Successful overcoming of complexities strengthens the spirit and increases the self-esteem of the company's employees. Teamwork eliminates conflict situations, promotes the formation of trust between higher and lower-level employees.

Best quality

A quick and effective solution to the problems contributes to coordinated work in the team, creating a large amount of resources. This, in turn, will ensure an improvement in the quality of products. All this will allow the company to reach a new level of capacity.