5S is a Japanese SEIRI (finishing), SEITON (rectification), SEISO (cleaning), SEIKETSU (clean), SHITSUKE (cultivation) of these five words, because the pronunciation in front of the five words are 'S', so collectively referred to as 5S.

Used in the manufacturing and service sectors, such as improving the quality of the environment of the scene and thinking of employees so that enterprises can effectively move towards total quality management, primarily in the production site for manufacturing of materials, equipment, personnel and other factors of production to carry out the corresponding activities. 5S for shaping the image of enterprises, reduce costs, on time delivery, safety in production, a high degree of standardization, the creation of the workplace is refreshing, on-site improvements, and has played a huge role in the quality of Japanese products to rapidly improve the success of global marketing Department.

Visual Management (VM, Visual Management), is the use of visual images suitable for a variety of colors and visual perception of information to organize the production activities at the scene, visual management based on the physiological characteristics of human beings, take full advantage of the scene in the production of lights, logo licensing, symbolic approach to the issue of color and other visual signals, clear and accurately stimulate the nerve endings, and rapid transmission of information, the image directly to the potential waste problems and are apparent. To improve labor productivity of a management tool, is also a vision for the management of the use of scientific methods. Also known as visual management, it is an essential tool for 5s.

The implementation of visual management, to prevent formalism, we must do something the reality of companies, focused, there are plans to gradually expand in the process, should be the basic requirements are: a unified, simple, clear, practical, rigorous,
◆ Uniform, that is, to implement the standardization of visual management, to eliminate the phenomenon of a variety of clutter.
◆ Simple, that is, a variety of visual display signal should be easy to understand at a glance.
◆ Clear that a variety of visual display signal should be clear, appropriate location, on-site staff can be seen, visible.
◆ Useful, that is superfluous and not before, doing more with less, pay attention to practical results.
◆ Strictly, that is, all personnel at the scene must strictly observe and implement the relevant provisions of mistakes must be corrected, reward and punishment.

Value stream analysis is to identify the value stream approach to their product family as a unit to draw the current value stream map, and then analyze the customer's point of view of the need for an event. It is to accept orders from the production plan for implementation of the flow of information delivery; from raw materials to finished products into logistics; released from concept to product design process. Value stream analysis of the implementation of lean thinking has become the most important tool.

Applies to orders, production planning, product design, product, transport links across the enterprise value chain.

 

 

In practice, companies go all out to meet the first play of the basic needs of the customer to ensure that the issues raised by customers be seriously addressed, attention to customers that do business under an obligation to try to provide customers with the convenience. In order to achieve the most basic needs of customers to satisfy. Then, companies should make every effort to meet the expectations of the customer-based demand, which is the quality of competitive factors. Providing customers with additional services or product features to make it superior to rival products and services and different, and guide customers to strengthen the good impression of this business to make customers satisfactory. Finally, to achieve customer-based demand for excitement, for the enterprises to establish the most faithful customer base.

' Heinrich Principle ' is a famous American of Safety Engineers Heinrich 300:29:1 proposed rule. By analyzing the probability of the occurrence of accidents for insurance companies operating rules proposed. This rule means that when a business has 300 hidden or illegal, is bound to occur from minor injuries and 29 failures, 29 injured in this accident or malfunction of which must include with serious injuries, death or major incident. '

Heinrich Principle to teach us that if we are serious to find the root causes of safety incidents, it is necessary to minimize the security risks to take it seriously. The same principle also applies to the scene to improve, eliminate waste and enhance the sense of quality. To improve the needs of each person at the scene of the smallest issues to be vigilant. Continuing education and maintain a high degree of sensitivity is necessary, at the same time to prevent the formation of the abnormal state of bad habits.

 

 

Taiichi Ohno holding a chalk circle drawn on the ground so that managers stand on them, training them to a work area to identify the problems in a manner already well known. 'Stand circle' of the exercises is to train staff to identify a waste of very effective ways to improve the team in charge of day-to-day provides a structured way, as well as the senior director of the limited time available to provide the opportunity to understand the scene. When you spend some time standing at the scene Taiichi Ohno circle, you will find the actual state and the gap between the target state.

In 1906，Italy  economists Wafledo.Pareto used his 80/20 rule to simplify the world for us, named Pareto principle. Pareto diagram is usually used to express.

Application of the main points:
1, Pareto diagram to be retained, the improvement of the improvement before and after the row together with plans to evaluate the consequences of the improvement.
2, Analysis of Pareto diagram front of Figure 2-3 as long as the items seized could be.
3, The classification of Pareto diagram item not too small, 5-9 is appropriate.
4, The Pareto diagram to make the project if the allocation ratio of almost, the Pareto diagram meaningless, inconsistent with the law of Pareto Chart.
5, Pareto diagram is a management tool and not an end, if the data is very clear, they no longer need to waste time making Pareto chart.
6, In front of the other items, if more than a few, it must be another layer analysis to review whether there are reasons for them.
7, Pareto diagram analysis of the main purpose is to obtain information showing that the problem is the focus of countermeasures taken, but if we rely on existing conditions of the first very difficult to solve, or even if the solution to spend a lot more harm than good, you can avoid the first, starting from the second.

Use these steps:
(1) To find the problem to be solved;
(2) The problem of fish bones in the head;
(3) Colleagues convened to discuss the possible reasons for the problem, identify the problems as much as possible;
(4)The same issues, as marked in the fish bone;
(5) Based on different views of the problem we seek to sum up the reasons for the right;
(6) Come up with any question, look at the reasons why such problems arise?
(7) To ask for the answer to the question Why? Such a depth of at least five layers (continuous asked five questions);
(8) When the depth to the fifth level, we think that the time could not continue to set out the reasons for these problems, and then list at least 20 solutions.

 

In 1917, development by Henry Gantt. The development of its internal thinking on a simple, basic is a line graph, horizontal axis represents time, vertical axis that the activities (projects), the lines on that plan throughout the period and the actual completion of activities. It is intuitive that when the mandate to carry out plans, and real progress with the plan calls for the comparison.

Gantt Chart contains the following three meanings:
1, To form the form of graphics or display activities;
2, It is a common way to display the progress of;
3, Structure should include the duration of the actual calendar days, and weekends and holidays do not count in the progress of.
Gantt chart is simple, eye-catching and user-friendly features such as the preparation, work in the enterprise management has been widely used. Gantt chart to reflect the content according to different plans can be divided into charts, load chart, the chart of idle machines, idle staff, such as charts and five forms of schedule.

Deming's concept of the first ring is the quality of management experts from the United States Deming (W.E. Deming) in the 20th century, early 50s, so it is also known as the 'PDCA' cycle.

PDCA cycle has the following three characteristics:
1, Large ring lead small ring.
2, Step-by-step raise.
3, Scientific management methods of integrated application.

 

 

Genichi Taguchi Professor used the idea of the Fisher experimental design to try to understand the impact of variation of parameters, rather than using the average. Test in the traditional design, the variation between repeat tests was considered useless, the experimenter would like to eliminate. In the brain of Taguchi, the center is to study variation.

Taguchi method is a very practical technology, the practice in the production, especially in the design of product development shows strong vitality, the charm of the main as follows:
(1) Improving product technology content, the promotion of technological innovation. Through the use of Taguchi method can only change the corporate status of the introduction of advanced equipment, and enhance the capacity of the second innovation, and improve product development capabilities.
(2) To shorten product development cycles, accelerate product upgrading. Application of Taguchi Methods in Quality Management can improve productivity and effectively.
(3) Application of Taguchi Method Famous. Taguchi method using the three design techniques designed a good product stability, the ability to resist outside interference, and fluctuations in a small, reliable, and easy to create a well-known product, market, play their own brand names.
(4) Application of Taguchi method of record-effective. Taguchi Methods of the third class cheap first-class goods parts assembly machine, truly a good value for money, so that the economic efficiency of enterprises to a higher level.

Psysiological needs, Safety needs, Love and belonging needs, Esteem needs, Self - actulization needs

According to Marlow’s explanation that exists between the level of the diverse needs of the relationship and have the following characteristics:
1. At all levels not only between the high and low demand for the points, but the difference between before and after the order;
2. A higher level of demand is then developed, as the same as biological evolution;
3. The higher the level of demand, there is the possibility of completely low, the demand for easy to disappear, at the same time accompanied by the delayed reward than all right;
4. To live in high-demand person-level means that the material things more fully, more longevity, less illness, better sleep, better appetite;
5. High-level strength of weak demand;
6. A high level to meet the needs of a more subjective, such as very happy, feeling very smooth, very rich inner life, etc.;
7. When an individual's environment (economic, environmental education, etc.) when a better, easier to meet the individual needs of high-level;
8. When individuals meet their demand for high-level, the individual more likely closer to the goal of self-realization.

A height of 4 feet (about 1.3 meters) of the Japanese lean experts named Oba, he insisted chemical visual items can not be any line of sight than his famous high. The idea is to plant in your field of vision as much as possible to prevent the generation barrier. This is also known as 'four feet rule' or ' 1.3 meters rule.'

The higher the degree of visual field, the more issues can be resolved; the process is also more stable.

 

Enterprise, there are a variety of norms, such as: A point of order, rules, regulations, standards, key, etc., to form the text of these norms are collectively referred to as the standard things (or Standard). The development of standards, and then put into action in accordance with the standard is known as standardization.

Standardization of plant operations as the basis for the realization of lean management is the management of the site to create a world-class management to the best path. Standardization of operation not only makes the standardization of operations, it is to raise the overall level of manufacturing, product quality, cost and delivery time, there has been significant improvement.

Industrial Engineering (referred to as IE) is the personnel, materials and equipment, etc., engaged in improving the overall system design and application of a science. It uses mathematics, natural science and social science expertise and skills, and the use of engineering analysis and design principles and methods for planning, forecasting, and assessment of this and related systems to obtain results.

Applied to various engineering manufacturing processes at the scene, the production of movement, handling and arrangement, the time analysis.
Way through the project (engineering approach), applied science and engineering methods and technology, to consider personnel, machinery, equipment, process, method, timing and other factors to solve the problems encountered by management.

 (SMED) Single Minute Exchange of Die, is a team work to improve the work-based approach, it can significantly reduce the length of the machine installation, set the time required for mold. Mode for a range of time is the last thing the production of qualified products and the next production of the first pieces of the time between the qualified products.

Machines used to improve plan flexibility, which can reduce the demand for all kinds of stock;
Stock can be lessÞ in less time Þ lower inventory costs;
Production can be smaller to avoid the emergence of a large number of non-performing products, to improve quality;
It can reduce the lead time, and the lead time is critical to enhance competitive advantage;
It can be achieved for die more frequently and thus more flexible;
On time delivery, improve customer satisfaction and increase profits.

TPM (Total Productive Maintenance), to establish and improve the efficiency of production systems to pursue the limits of the enterprise system as the goal, from an overall production system, the building energy consumption can prevent all (disasters, bad, fault, etc.) the mechanism, including the production of , development, design, sales and management of all departments, through the company's first line of the upper staff to the full participation and to repeat the small group activities, and ultimately to achieve the purpose of “0” loss.

Integrated in the device efficiency, pursuit of time efficiency, operation efficiency and product of the combined effect of the passing rate. In particular, most of the factory machinery and equipment, TPM is to enhance the manufacturing capacity is more powerful weapon. As part of lean manufacturing, TPM pursuit of the ultimate goal of zero failures, zero non-performing, zero accidents.

Poka-yoke (pronounced POH-kah YOH-kay - to prevent the wrong Japanese) to prevent the operators have emerged in the workplace as a result of the wrong, missing, or parts, such as anti-loading operation, which led to the methods of quality defects. Prevention, also known as error (mistake-proofing), and the Baka-yoke (fool-proofing fool can not have committed the error).

In the operation process, the operator from time to time will be forgotten because of omissions or errors in operation occur, the resulting quality defects caused by a large proportion, if the error can prevent the occurrence of to prevent such errors, the level of quality and operating efficiency will be greatly improved.
1, Anti-error means 'do a good job the first time
2, To enhance product quality, reduce waste caused by inspection
3, Caused by the elimination of rework and waste

Orders for the requirements of enterprises as the starting point is that after moving the enterprise from the production of comprehensive arrangements for the production process after the decision to join together with the content of the production process.
From downstream to upstream of a proposed production method of production control needs. Seek to boost production to eliminate excess production; it is timely to form a production system, one of the three elements.

Applicable to many varieties of small batch production. Core management issues is a goal, when we had my goal - is an order, if we are to accomplish, how to organize, delegate pull to complete the goal - the completion of orders.
In the pull system, whether or not in the same factory, through the downstream to upstream processes for the information provided. Message is usually a Kanban card states what parts or materials, the number needed, as well as time, location needs. Upstream suppliers, downstream only when the received signal after the needs of customers before the start of production. This is related to the promotion of production is exactly the opposite.

Value stream mapping is the use of a piece of paper, a pen down the material and information flow of critical data collection, that orders a product from the transport process, each and every stage of the material flow and information flow charts, and analysis tools. It helps to observe and understand the full value of products flow through the material process flow and information flow, as well as value-added and non value-added activities in order to find waste and to identify areas for improvement, identifies the problems more easily. To improve the activities and direction set out a blueprint. At the same time also help employees understand the business, and improve opportunities to participate. Value stream mapping also only be used to avoid individual lean tools, local, isolated improvements. The status quo through the mapping diagram, the ideal design of state diagram and implemented as soon as possible through this approach, can improve the overall value stream, so as to customers and suppliers to bring maximum benefits.

Analysis applied to production processes, that is, shipments from suppliers to play until the customer receiving the entire value stream analysis and improvement. Value stream is defined as the raw materials into finished products, and it gives value to all activities. These activities include: from concept to design and engineering, and technical production process, from order processing, to plan, the information delivery process, and products from raw materials to the material conversion process, and product life-cycle support and services process. Turnover rate of the product, product value-added ratios, delivery times, use of the factory site area will have a significant improvement.
• Clear objectives to improve, so that's larger and more effective impact resistance;
• The material flow and information flow have a better understanding of the relationship;
• To enable all to improve the transparency of production processes to replace only a single process improvement;
• Through the material flow and information flow from the 'door to door' to establish the form of a valid basis for the implementation of Lean;
•To the operators, engineers and managers to provide a common language and procedures, to continue to improve.

SIPOC (suppliers, process input, process, process output, the customer confirmed) map is used to process management and improvement of a technology most commonly used, often as a means of identification of the first method of the core process.

SIPOC a simple map can show the map is a group of cross-functional boundaries. An organization regardless of size, SIPOC map can be used to outline a framework for their business processes. Help to maintain the 'view' perspective, but also be able to view the additional details to add. Flow chart of a clear understanding of business processes and work flow problems. Improve the work procedures, removal of no value tasks and shorten the cycle time. Issues through the process of analysis 'to identify bottle Path' to reduce the flow and the total elimination of the 'no value activities' `cycle of supervision to enhance the productivity and competitiveness of enterprises.

One-piece flow includes the following factors:
1. Every time the production and transfer of one or a fixed small quantities (e.g. one box) parts;
2. As far as possible, the continuous flow
3. The whole process has just been a good convergence.

 

Apply to:
1. To simplify site management planning and scheduling
2. Devolution of management decision-making to improve the exception of events in response to the speed of play and creativity of employees
3. The timely discovery of quality defects, nonconforming product to prevent the emergence of mass
4. To shorten the production lead time
5. To reduce inventory and costs in the system
6. To reduce the size of the work to occupy

The meaning of the flexible modes of production mainly include two aspects: production flexibility and time flexibility. In general, the soft flexible production should be proportional to changes in sales of free range, the inverse free volume can be achieved in the range of changes in the corresponding time required.

 

 

Flexible modes of production for many species, very small quantities, delivery of the order strictly.
1. Production of flexible
Pre-production plant in the organization through market research, forecasting the market demand for products and to design production lines based on production capacity. However, as is the ever-changing market demand, design capacity and the market very difficult to completely match the actual demand, which requires the design of flexible production.
2. Flexible hours
When changes in market demand, the production line are the adjustment of production capacity will take some time. For example, a product production line of the original capacity of 500 tons per month, and now want to adjust the production of 800 tons per month, which requires a certain amount of time to complete the changes in production capacity. Therefore, the flexible modes of production are also reflected in the flexible on time.
By sector, manufacturing equipment, flexible scheduling of processes, we can make the parallel existence of two ways, complement each other.
In addition, enterprises should also make changes in personnel training and is also flexible: Flexible training can be more than able to train workers; staff changes with flexible, you can change the basis of production, flexible production lines to increase or reduce the number of operations, as far as possible with less manpower to complete more production. It should be noted that, JIT and the liberalization of the labor market is supporting each other, there is no free exchange of labor market, JIT is flexible unimaginable.

Takt is the German word is the command to adjust the rhythm of playing, T / T beat the time, according to customer demand and the factory of production for the time from the beat, that is, time is the bottleneck station to meet customer demand the production of beats.

1. The production of the role of the beat of the first production in the regulation of production control, production cycle through the beats and the comparative analysis of stability in the market circumstances, it can be a clear link needs to be improved in order to take targeted measures to adjust.
2. The production of the beat Another application is to be able to effectively prevent the waste of overproduction caused by late and production caused by the problem of sub-suppliers, and inter-process standards to determine the volume of handset.
3. The production of the beat will make use of the operating rules of the production site and production activities to achieve stability, the achievement of set management, and as the scene of the basis for improving production efficiency.

International OEE is defined as: OEE is Overall Equipment Effectiveness of the initials, which by the availability, performance and quality index composed of three key elements, namely:
OEE = Availability X Performance X Quality Index.
Of which:
1. Availability = operating time / planning time
2. Performance = ideal cycle time / (operating time / total) = (production / operation time) / production rate
3. Mass index = yield / production
Mass index to consider the loss of quality, which reflect the quality does not meet the requirements of products (including rework of products).

Practice has proved that OEE is an excellent benchmarking tool, through the various sub-OEE model analysis, it clearly and accurately tell you how efficient equipment, which links in the production of the number of losses, as well as you can for those improvements. Long-term use of OEE tools, enterprises can easily find the impact of productivity bottlenecks, and improving and tracking. To achieve the purpose of increasing productivity at the same time the company to avoid unnecessary cost.

Processes in moving parts should be balanced to receive a variety of parts and components used to realize mixed-flow production, which requires the number of products and types are balanced to prevent the possible focus for each time period to obtain or produce the same parts , while the former, the rear of the free and busy uneven process, and the resulting confusion caused by the production.

Balanced production of the benefits:
1. Parts of the use of stability
2. Load stabilization
3. Stock reduction
4. The ability to respond to changes in the market to improve

Kanban management procedures in the same process or between the before and after the logistics or the transmission of information flow. JIT is a pull-style management; it needs to work together from the last process to work together through the process of information flow on the transmission of information, which is the vector of transmission of information billboards. No Kanban, JIT can not be carried out. Therefore, JIT production is sometimes referred to as Kanban production.
Once the master production plan, the workshop will be issued to the production of various commands, and then each in turn in front of production processes of the production orders issued, and finally to the warehouse management, procurement department issued the appropriate instructions. Transmission of these production orders are done through billboards.

Kanban, Toyota Motor Corporation was first in the 20th century, from a supermarket for the 50's operating mechanism to be revelation, as a production and delivery of instruction delivery tool has been created. After nearly 50 years of development and improvement has been in many ways plays an important function.
1. The production and delivery of instruction
2. To prevent excessive over-production and delivery of
3. To conduct 'visual management' tools
4. To improve the tools

 

Enterprise organizations to participate in all of our employees and the departments concerned, the integrated use of modern science and technology and management, the impact of product quality control of the entire process and the factors of production and economic development of products to provide customer satisfaction system management activities.
In order to level the most economical, taking into account the request of the customer to fully satisfy the conditions of market research, design, manufacture and after-sales service, the enterprise sector to develop the quality, maintain quality and improve the quality of the activities as a whole constitute the an effective system

Reduce the total operating cycle
Reduce the cost of quality
Shorten the turnaround time inventory
Increase productivity
The pursuit of corporate interests and the success of
So that total satisfaction of our customers
To maximize profits