Expert Manufacturer of stainless steel bearings
1, lean: the realization of “lean” is to create value as the goal of the process of waste elimination. Expert Manufacturer of stainless steel bearings
2, lean management methods, including Jidoka and JIT (JIT) two pillars.
3, mobile production: processes and processes connected together, one by one production products. This can eliminate the waste of transportation, but also reduce WIP inventory. Expert Manufacturer of stainless steel bearings
4, pull the system (or production): after the process in the necessary time, according to the necessary amount of the previous process to obtain the required things, the former process only by the number of received production
5, Map Value Stream (VSM) is a visualization tool for describing logistics and information flow in lean production system framework. Expert Manufacturer of stainless steel bearings
6,5S:Seiri, Seiton, Seiso, Seiketsu, Sitsuke
Organize Seiri: separate what is needed and what is not, and deal with what is not needed immediately;
Rectifying Seiton: placing what needs to be regulated to facilitate use;
Cleaning Seiso: daily cleaning, keep it available; Expert Manufacturer of stainless steel bearings
Clean Seiketsu: keep, straighten, clean up, and standardize;
Literacy Sitsuke: personal mastery rules or norms, and pay in practice, develop good habits
7, visual management. Basic is to make what is normal and what is not normal clear. From the quality, is to make bad products exposed from the number, is relative to the plan to make people be able to know the progress. Not only is the machine production line, put this kind of thinking method what is suitable for the WIP, “transfer method Kanban” operation method, people no problem. The scene implementing TOYOTA production system are thoroughly implement the “visual management”. Also called visual visualization. Expert Manufacturer of stainless steel bearings
8, JIT (JIT – Just-In-Time): if you can when needed, according to the required number, get what they need, then you can eliminate the production waste is not balanced, not reasonable, improve the production efficiency. The first person of the thought is the founder of Toyoda Kiichiro – TOYOTA automobile, its successor this thought, in a production system. Not only is the in time, but just in time, which is one of the important key. “Just-In-Time” and “Jidoka” constitute the two pillars of the TOYOTA production mode. Expert Manufacturer of stainless steel bearings
9, Jidoka (Jidoka): in the TOYOTA mode of production, must be entirely with herringbone adjacent to the “Jidoka.” “Jidoka” refers to the human wisdom. “Since the industrial machine weaving machine industrial” thought from Toyota Corporation originator Toyoda Sayoshi TOYOTA since the industrial. The weaving machine structure is broken if the warp or weft is gone, the machine will immediately shut down the machine built-in device to judge. Not only on the machine, TOYOTA will also expand its thought to have operators that thoroughly implement the production line. If an exception occurs, the operator should take production line stop rules. Through the “Jidoka”, can prevent the occurrence of bad products, control over production, and can automatically check the production site of abnormal benefits. “Jidoka” contains if abnormal situation occurs, will automatically shut down or stop line. Expert Manufacturer of stainless steel bearings
10, unit type production line: a series of machines are arranged in proper order, and workers only need to stand in their own units, and materials will be delivered from outside to their production line
11, one piece flow: when a product moves from one station to the next station, only one can be moved at one time, and the production principle is not allowed between the stations
12, bottleneck: the position or process that affects the output of the whole system. Expert Manufacturer of stainless steel bearings
13, pre cycle (LT Lead Time): refers to the purchaser to order to delivery intervals, usually calculated by days or hours. To reduce the lead time of the manufacturer and the retailer can make the average inventory level is reduced, and the lead time can be reduced to the retailer model will be more stable give very good production decision makers, can guarantee in the same supply chain manufacturers and retailers to achieve a win-win situation.
14, the production cycle (MCT Manufacture Time): the production cycle time (MCT, manufacturingcycle, time), also called the manufacturing cycle, is released from the production plan to shop until the final product storage time. The preparation time is short, the manufacturer’s inventory less, when the scrap market needs change materials less adjustment to adapt to the change of the more flexibility. The manufacturing cycle time (MCT) longer, more problems workshop may occur. Expert Manufacturer of stainless steel bearings
15, WIP (WIP Work In Process): raw materials or parts have been processed into semi-finished products, but has not yet become finished products, has not yet completed warehousing procedures
Broad sense: including processed products and semi-finished products for further processing;
Narrow sense: only refers to the product being processed
16, inventory turnover rate, inventory turnover rate (English Inventoryturn over commonly referred to as ITO), a measure of material in the factory or the entire value stream, flow rate of the standard. The most common method to calculate the inventory turnover, is to use the number of products during the period (or cost) as the number of molecules. During the period divided by the average inventory (or value). Therefore, inventory turnover rate = number of goods during the period of use (or cost) / number average inventory (or value). Inventory turnover (based on the average monthly inventory turnover rate as an example): Expert Manufacturer of stainless steel bearings
- A) raw material inventory turnover rate = raw material quantity (or total cost) / raw material average inventory in a month
- B) in inventory turnover = the amount of finished goods (or total cost) / inventory in the month
- C) finished inventory turnover rate = monthly sales volume (or total cost) / finished product in the library average inventory
17, first in first out (FIFO First In First Out): refers to according to the principle of first storage, first issued
18, standard operation: a human centered approach, in accordance with no waste steps, through the combination of people and equipment work the most efficient production methods
19, operation instructions: the standard operating procedures and requirements are described in a unified format, used to guide and regulate daily work, is to guide the correct operation of staff guidance document
20, productivity: also known as productivity, refers to the output of the unit person. Expert Manufacturer of stainless steel bearings
21, SMED: Single MinuteExchange of Die, a single minute fast change mode (or: fast change mode, fast switching)
22,5W2H:Why, What, When, Who, Where, How, How, much
23, five why (5Why analysis): to find problems, please ask “why” 5 times. This is the basic attitude of scientific research methods of TOYOTA. The TOYOTA production mode, 5W is the 5 WHY. repeat 5 times “why”, you know the real reason, also know how do (HOW). To find the “true because” instead of “reason”, “reason” hiding “real reason”. No matter what, if you don’t ask “why”, “why” to seize the real cause of the reasons, countermeasures, can not implement effective action. Expert Manufacturer of stainless steel bearings
24, labor saving, humanization, fewer people: if the province of large equipment import high performance, can save manpower, namely “labor”, but more important is through its equipment less manpower, the arrangement of the required department. “Labor” for example even lost 0.9 people meaningless, because only lost one can reduce the cost with the hook, so it must implement “humanization”. TOYOTA further set a new goal, namely “humanizing”. In order to do “humanization”, the “Jidoka”, but the production time, but not by production reduce the proportion of people. This is because “Jidoka” is the quota system. At the time of slow growth, need to use the intelligent system has set up a break, to the corresponding required production quantity, whether it is a few people can carry out production line. This is the “little man The purpose of “change”
25, value added activity and non value added activities: value added activities (Valueadded) is the customer willing to pay for some activities, and these activities will change the appearance of the product, shape, assembly relations, functional performance. Non value-added activities (Non value added) is any time, but not create value for your customers. In the production activities of non value added activities are divided into non value-added but necessary activities (such as taking down the drilling machine, wrench, open quality review meeting, clean factory etc.) and non value added is not necessary, which is pure non value-added activities (such as walking, to pick up parts, waiting time, storage parts, transportation repair, bad products, excessive inventory costs), this part is also called the.26 activities of waste, waste (Muda): failed to create value. The value does not produce production activities nor the necessary activities belong to the waste from waste form, will be born Production site is divided into seven wastes: waste production of excess waste, the waste of waiting, the handling of waste, the processing waste, the waste of inventory, the action of the waste, defective products, waste.25, Muri: the staff or equipment overload.
26, Mura: not balanced
27, balanced production (Heijunka): also called leveling, in the field of production scheduling, product fluctuations greater waste will be more. Because the equipment, personnel, inventory and other required elements of production must be prepared. If the peak after the process in time and quantity to fluctuation to supply it, the farther the process, the size of its volatility will continue to expand. Including supporting cooperative enterprises, to prevent all production line fluctuations, we must strive to be the final assembly lines the fluctuation of zero. TOYOTA’s the final process is not fixed. But rows of things of the same kind in the production of a Taiwan and Taiwan the car is the premise of balanced production.
28, load rate: load rate refers to the actual output current relatively full load operation ability in a certain period of time to the equipment of production. The sales situation is not ideal, of course, reduce the load rate. On the contrary, if the increase in orders, or because of overtime shift down there may reach 120% of the load. The load rate is is the number of the equipment selection problem required with respect to.
29, mobile rate: Mobile rate refers to the state of the operation when you want to boot. This ideal is 100%., so it is necessary to implement the maintenance, but also to shorten the production time
30, utilization rate: the utilization rate refers to the equipment can provide in time in order to create value for the time. The proportion of production refers to the ratio of the number of machine equipment with the actual production quantity. Expert Manufacturer of stainless steel bearings
31, total equipment efficiency (OEE – Overall Equipment Effectiveness):
OEE consists of three indicators: the time utilization rate (availability), performance utilization rate (performance index), yield (quality index), OEE= time utilization rate performance of X utilization rate X yield rate time utilization rate = load – time downtime / load running time performance rate = theory takt time * input quantity / activation time yield = input number – the number of poor / investment amount
32, from the work of improving equipment to improve production site plan from the area is decided on the operation of the norms, redistribution, clearly marked items for display area operation improvement and the introduction of equipment, equipment Jidoka equipment improvement. Improve the equipment to spend money, but no way to correct. In lean production first of all, to work thoroughly the steps of standardization. Thus most of the problems can be improved. The first “equipment improvement”, the production site will not be “improvement”. After “improvement” should be further improved. “
33, the benefits of IE:IE industrial engineers from the United States from the production management technology, management technology. Despite its definition, in the TOYOTA production mode, is it as involving the entire production site, in quality, quantity, timing of the three up foundation of the overall coordination of the implementation of cost reduction “mode of production”. Not only is the academic discussion of the IE technique (method), the biggest feature of the TOYOTA IE “is directly associated with lower costs,” the benefits of IE.
34, TPM: the production and maintenance of full participation in the (Total-member-participation Productive Maintenance), referred to as TPM (Total Productive Maintenance), which is 70s in the United States Japanese production maintenance system based on the main point, in the “maintenance” and “full participation” on the production, through the establishment of a whole system the staff involved in the production of equipment maintenance activities, to achieve optimal performance. It also absorbed the British equipment comprehensive engineering, the masses to participate in the management China in Angang constitution. In the non Japanese countries, due to different national conditions, the understanding of TPM is: the operator of production maintenance activities, improve the comprehensive performance of.TPM target equipment can be summarized as four “zero”, that is down to zero, zero waste, zero accidents, zero speed loss.
35, preventive maintenance (preventivemaintenance): the causes of interruption for the elimination of equipment failure and production plan and planning measures, as an output of the manufacturing process design.
36, BM: after maintenance, Break-down Maintenance
37, PM: production maintenance, Productive Maintenance
38, CM: improved maintenance, Corrective Maintenance
39, MP: preventive maintenance, Maintenance Prevention