1、七大浪费 7 Waste,December 6th, 2007,目录 Content,精益生产的效率 Efficiency of Lean Production 浪费的定义 Define of Waste 七大浪费 7 Waste 动作研究 Motion Studies,精益生产的效率 Efficiency of Lean production,传统的效率 Traditional efficiency 简单化 Simplify 高速大量生产 High speed and mass production,精益生产的效率 Efficiency of lean production：- 消除浪费 E
2、liminating waste- 库存/等待 Storing /waiting - 搬运 Conveying- 摆放 layout,生产过剩是 最大的浪费 The most waste is overplus production,浪费 Waste,浪费是指那些导致成本增加的因素 The waste is the factors lead to much cost 虽然增加价值，但耗用资源过高 Value is adding, But it cost much resource,一种浪费通常能够导致另外一种浪费One waste will always lead to other waste
3、,发现浪费和认识浪费的能力很重要 The ability of finding the waste and know the waste is very important,隐性浪费/显性浪费 Invisible waste /visible waste,显性浪费 Visible waste 定义为可见的浪费 Define it is visible waste 这些浪费很容易签别Very easy to identify the waste 如：eg 在流程中引起不良品的错误 Mistake lead to defect part in process 等待时间浪費 waiting time
4、 waste,隐性浪费 Invisible waste 定义为看不见的浪費 Define it is invisible waste 这些浪費不易被签别not easy to identify the waste 这些工作看起来非常有价值直到使用新的策略发现其中很大的浪费. it looks like good job,but it have bigwaste after using new way如：eg.工作分配不充分 Insufficiency work distribute 高耗性增值工作 High wastage value-added work,七种浪费7 waste,1. 不良品
5、浪费Defect waste,4. 搬运浪费Convey waste,6. 动作浪费Motion waste,2. 过量生产浪费Excessive produtionwaste,3. 过分加工浪费Excessive manufacturewaste,5. 库存浪费Store waste,7. 不平衡浪费Imbalance waste,1. 不良品浪费 Defect waste,1. 人为操作失误Man-made operation mistake 2. 设备/工具不稳定Instability equipment / tool 3. 不按照标准作业Operate not according th
6、e standard 4. 来料不稳定Instability incoming material 5. 设计没考虑装配需求Wrong design 6. 环境温度/湿度/静电Environment temperature / humidity/ static 7. 存放周期长Long store period,2. 过量生产浪费 Excessive production waste,1. 超出下一操作的需求量Excessive demand quantity of next operation 2. 提前生产下一操作的需求Next operation production in ahead 3
7、. 设备速度过快 Excessive equipment speed,3. 过分加工浪费 Excessive manufacture waste,1. 超出/低于产品特定需求的精度Overtop /under the specific product precision reqirement 2. 多余的作业项目Redundant operation item,质量成本概念 Quality Cost Concept,4. 搬运浪费 Convey waste,也就是说“每个工位都从手工操作开始”. That is say every workstation is all start from m
8、anual operation- 找到、拿起、移动，用手放，然后find 、take-up 、move 、put it by hand 、then- 从手推车移到货板move from handcart to material rack- 从货仓到工厂from store to factory- 从工厂到生产线from factory to production line- 从生产线到机械化车间from production line to mechanisation shop- 从机械化车间到操作工位from mechanisation shop to workstation,讨论 Disc
9、uss ： 自动化搬运的误区 Mistake of automatic conveying,5. 库存浪費 Store Waste,存货过多 Excessive stock in trade- 过多的原材料Excessive material 交货周期过长？Excessive delivery time 错误的订货量？Wrong order goods quatity - 过多的成品 Excessive finished product 是因为生产过剩？ Because overproduction? 是因为生产排期错误？Because the wrong production plan,6.
10、 移動浪費 Motion waste,1. 动作太大 Extreme Motion 2. 单手空闲Single leisure hand 3. 转身动作过大Excessive turning movement 4. 操作动作不流畅Not fluent operation 5. 重复/不必要的动作 Repeat / needless motion 6. 不必要的弯腰动作Needless bow motion,动作经济原则 Economic Motion Principle,7. 不平衡浪费 Imbalance Waste,1. 人员工作分配不合理Insufficiency work distri
11、bution 2. 计划对人员需求不均匀Asymmetry people requirement in plan 3. 设备产能搭配不合理Inconsequence equipment capability distribution 4. 设备故障Equipment trouble 5. 物料短缺Shortage material 6. 信息流与物流不同步Not synchronization between the infomation flow and the material flow,1. 关于人体之运用: Body Motion (1)双手应同时开始并同时完成其动作。 Both ha
12、nd should start the motion at the same time then finish the motion at the same time (2)除规定时间外,双手不应同时空闲。Both hand should not leisure at the same time except the regulate time (3)双臂之动作应对称,方向并同时作业。 The motion of both arm should symmetry ,and operate at the same time (4)手之动作应用最低等级而能得到满意结果者为妥。It is bette
13、r to get satisfaction result by low level hand motion (5)物体之动作量应尽可能利用之,但如需肌力制止时,则应将其减至最小度Utilize the object motion as possible but brake something by least muscle under the safety (6)连续之曲线运动,较含有方向突变之直线运动为佳。Sequence curve motion is better than line motion with mutative direction (7)弹道式之运动,较受限制之运动轻快确定
14、。Trajectory motion is better than limit motion (8)动作应尽可能使用轻松自然之节奏,因节奏能使动作流利及自发 It is better to use the motion with easy and naturalness rhythm as possible, because rhythm make the motion fluent and spontaneity,动作经济原则共二十二项并归纳为下列三大类Economic Motion Principle as below:,(9) 工具物料应放于固定处。 Should Fix the too
15、l and material (10) 工具物料及装置应布置于工作者之前面近处。 Should layout tool and material and device nearby the front of the worker (11) 零件物料之供给,应利用其重量堕至工作者手边。The worker should utilize the object weight as possible under the safety when getting the material (12) 堕送方法应尽可能利用之。Utilize the falling way as possible under
16、the safety (13) 工具物料应依照最佳之工作顺序 排列。 Layout the tool and material according the best order (14) 应有适当之照明设备,使视觉满意舒适。Comfort the vision of the worker by the proper lighting device (15) 工作台及椅之高度,应使工作者坐立适宜。Comfort the worker by the proper height of worktable and chair (16)工作椅式样及高度,应可使工作者保持良好的姿势。 The worker
17、 should be good sitting pose by the proper height and style of worktable and chair,2. 关于操作场所布置: Layout in Assembly Area,(17) 尽量解除手之工作,而以夹具或足踏工具代替之。Use jig and tool by leg to replace the manual work as possible (18) 可能时,应将两种工具合并为之。Merge the two tools as above as possible (19) 工具物料应尽可能预放在工作位置。Place ou
18、t the tool and material in the workstation in advance as possible (20) 手指分别工作时,其各个负荷按照其本能,予以分配。Distribute the work of every finger by the proper burthen (21) 手柄之设计,应尽可能使与手之接触面积增大。Enlarge the interface between the hand and handle as possible by the proper design of handle (22) 机器上杠杆,十字杠及手轮之位置,应能使工作者极少变动其姿势,且能利用机械之最大能力。The proper position of machine lever and cross bar and handwheel should make the worker rarely change his pose as possible, and Utilize the ability of machine,3 关于工具设备: Tool and Equipment,谢谢大家 Thank you to attend the meeting,
