Lean Manufacturing Tools OEE TPM SMED MP Implementation

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Lean Production, referred to as “lean”, is a management philosophy derived from Toyota's production methods.
The research, application and development of Toyota's production methods on a global scale, including many well-known manufacturing companies and MIT professors, have led to the development of lean production theory and production management systems, which are still evolving. From Kaizen, which focused on the production site in the past, to inventory control, production planning management, process improvement (process reengineering), cost management, employee literacy, supply chain collaborative optimization, product lifecycle management (product concept design, product development, production line design) , workbench design, operation method design and improvement), quality management, equipment resources and human resource management, market development and sales management and other aspects of business management.
Lean production is a change through system structure, personnel organization, operation mode and market supply and demand, so that the production system can adapt to the changing needs of users quickly, and all the useless and redundant things in the production process can be streamlined and finally included. A production management method with the best results in all aspects of production, including market supply and marketing. Different from traditional large-scale production methods, its characteristics are “multi-variety” and “small batch”.
First of all, different companies have different characteristics in the industry. For process industry and discrete industry, process industry, such as chemical, pharmaceutical, metal, etc., generally prefer equipment management, such as TPM (Total Productive Maintenance), because it is in process type. The industry needs to use a range of specific equipment, the condition of which greatly affects the quality of the product; and discrete industries, such as machinery, electronics, LAYOUT, production line layout, and processes are all affecting production efficiency and quality. Important factors, so discrete industries focus on standardization, JIT (Just In Time), Kanban and zero inventory.

Lean production

At the beginning of the 20th century, since the establishment of the first automobile production line by Ford Motor Company of the United States, the large-scale production line has been a modern industry.
Lean production definition
The main features of production. The large-scale production method is to reduce production costs and improve production efficiency by standardization and mass production. This way has adapted to the national conditions of the United States at that time, the production of automobile production lines, and the car has changed from a luxury of a few rich people to a popular means of transportation. The American automobile industry has thus rapidly grown into a pillar industry of the United States. It has promoted and promoted the development of a large number of industries including steel, glass, rubber, electromechanical and transportation services. Large-scale production of water is of paramount importance in the history of production technology and production management. However, after the Second World War, society entered a new stage of diversification of market demand, correspondingly demanding the development of industrial production in the direction of multiple varieties and small batches, and the weakness of single-variety and large-scale production methods of flowing water. It is becoming more and more obvious. In order to comply with the requirements of this era, the lean production pioneered by Toyota Motor Corporation of Japan has been explored and created in practice as a way of producing high quality and low consumption under the conditions of mixed production of multiple varieties and small batches.
In 1950, Japan’s Toyota Eiji inspected the Ford Company’s car factory in Detroit, USA. At that time, the factory was able to produce 9,000 cars a month, more than the Japanese Toyota company's annual output. However, Toyota wrote in his investigation report: "The production system there is still possible to improve."
After the war, Japan’s economic depression was lacking in funds and foreign exchange. At that time, Toyota’s automobile business was in its infancy, how to establish the Japanese automobile industry? Copying the mass production methods of the United States, or according to the national conditions of Japan, another way out, Toyota chose the latter. Japan's social and cultural background is very different from that of the United States. Japan's family concept, obedience and teamwork are not available to Americans. Japan does not have as many foreign workers as the United States, nor does it have the freedom of the American way of life. And the proliferation of individualism. Japan’s economic and technological base is also far from the United States. At that time, it was impossible for Japan to fully introduce American complete sets of equipment to produce automobiles, and Japan expected the production at that time to be only a few tenths of the United States. The law of “economies of scale” is facing a test here.
Toyota Eiji and his partner Ohno Naichi conducted a series of explorations and experiments, and proposed a solution to the problem based on Japan's national conditions. After more than 30 years of hard work, a complete Toyota production method has finally been formed, which has made the Japanese automobile industry surpass the United States, with a production capacity of 13 million vehicles, accounting for more than 30% of the world's total automobile.
Manufacturing, electronics, computers, aircraft manufacturing and other industries. Toyota's production method is an important part of Japan's industrial competition strategy, which reflects Japan's management thinking in the process of repetitive production. The guiding ideology of Toyota's production method is to optimize the production process, improve the technology, streamline logistics, eliminate excessive production, eliminate inefficient labor and waste, effectively use resources, reduce costs, improve quality, and achieve maximum production with minimum investment. The purpose of the out.
The success of Japanese companies in the international market has aroused strong interest in the Western business community. Western entrepreneurs believe that the way Japan uses in production is the basis for its competition in the world market. Since the 1980s, some countries in the West have attached great importance to the study of Toyota's production methods and applied them to production management.

Lean production principle

Principle 1: Eliminate eight wastes
Principle 2: Focus on processes to improve overall efficiency
Principle 3: Establish an uninterrupted process for rapid response
Principle 4: Reduce inventory
Principle 6: Pulling production based on customer needs
Principle 7: Standardization and Work Innovation
Principle 8: Respect employees and empower employees
Principle 9: Team work
Principle 10: Meet customer needs
Principle 11: Lean supply chain
Principle 12: "Self-reflection" and "local present"
Comparison of Lean Production and Management Thoughts of Mass Production Mode
As a new management idea from the environment to the management goal, lean production is successful in practice. It is not simply applying one or two new management methods, but a set of corporate environment, culture and management methods. A converged management system, so lean production itself is an autonomous system.
(1) Different optimization ranges
(2) Different attitudes toward inventory
(3) Different views on business control
(4) Different quality views
(5) Different attitudes towards people

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