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.
Compared with mass production methods, the superiority of the lean production method adopted in Japan is mainly reflected in the following aspects:
1. The required human resources - whether in product development, production systems, or other parts of the factory, the minimum can be reduced to 1/2 compared to the factory under mass production;
2, the new product development cycle - the minimum can be reduced to l / 2 or 2 / 3;
3, the in-process inventory of the production process - the minimum can be reduced to 1/10 of the general level of mass production;
4, the factory occupied space - the minimum can be reduced to 1/2 under a large number of production methods;
5, finished goods inventory - the minimum can be reduced to 1/4 of the average inventory level in a large number of production methods;
The lean production method is to thoroughly pursue the rationality and high efficiency of production, and to flexibly produce the production technology and management technology of high-quality products that meet various needs. The basic principles and many methods have positive significance for the manufacturing industry. The core of lean production, that is, the basic ideas about production planning and control and inventory management, also plays an important role in enriching and developing modern production management theory.