A few simple steps to achieve lean manufacturing
Lean production has become the way to survive in many industries. Mold manufacturing is also affected by this trend, and moldmakers are quickly recognizing that lean manufacturing is a bright road to improving efficiency and shortening lead times. In the manufacturing process, two kinds of work activities are to be distinguished, one is the work activity that increases the value of the product, and the other is the work activity that does not increase the value of the product. The core of lean production is to reduce the activity of adding no added value. In order to achieve lean production of a process, it is necessary to carefully check each step and consider whether the cost of the product can be reduced if the step is removed. “Many mold makers believe that their processing is not the same as that of high-volume manufacturers, and lean manufacturing has generated huge benefits for high-volume manufacturers. "Rod Jones, the production consultant with more than 28 years of manufacturing experience. “The fact is that just as it is for manufacturing, lean manufacturing is also effective in mold manufacturing. ”
Lean production is based on common sense
“Lean production is a simple concept based on common sense strategies that reduce time and cost when producing products, that is, to bring greater value and quality to customers through the use of streamlined processes. ”“In the manufacturing process, it is necessary to distinguish between two types of work activities, one is the work activity that increases the value of the product, and the other is the work activity that does not increase the value of the product. The core of lean production is to reduce the amount of work activities that do not add value," Jones said. “To make a process lean,”
It is necessary to carefully examine each step and consider whether it is possible to reduce the price of the product to the customer if that step is removed. “For many manufacturers, the hardest part of achieving lean production is to challenge the technology and thinking that has been used for a long time,” Jones said. “But they have to question some old practices and not just focus on improving the flawed process, but carefully observe a certain process, pay less attention to the abstract results, and care more about the specific process steps. ”
An easy way to get started is to think carefully about the job activities in the shop that don't add value. Where are the bottlenecks of constraints? Where are the unnecessary measures? What is the reason for making this process slower than it should be? “Look back and see how molds are made in your factory,” Jones said. “If you look at this process objectively, when this process happens, question every step of it, and you will usually find countless inefficiencies. These are not the faults of workers or managers;
Rather, some processes need to be checked from time to time, and you should constantly ask yourself — can this step add value to the product? Can you remove it? & rdquo; After checking the production floor, carefully consider each step to see if every activity is adding value. When companies try to find out which processes do not add value to the product, they will find some common work activities that do not add value to the product in the mold shop. The most common are waste, obsolete technology and cost accounting systems.
For many factories, the biggest part of not adding value is waste. “In many mold factories, waste is a big problem. In waste, in inefficient systems and processes, waste is found in rework and waiting. ” Jones commented. “ A way to deal with waste
Is to maximize quality,” Jones said. “Using machines that produce higher quality parts ultimately reduces time wastage and waste. ”
A mold manufacturer should expect the machine to produce good parts directly, without rework, and with little or no time processing.
For example, use a machine with a better surface finish to save one hour of manual polishing. This produces dozens of parts, which saves a lot of time and labor. A part that passes the quality inspection once produced is a means of adding added value. If you use a machine that is of good quality and well maintained, some quality control steps can be eliminated. If the part can be cut more quickly and accurately, and does not require machining or careful inspection to ensure the quality of the cut, you can quickly move on to the next step.
Disposal of waste
Not only do you have to use efficient machines, but the process of using them is also efficient. “In a traditional manufacturing factory, due to problems with machines or workers, it is necessary to check carefully after completion. In a factory that uses lean manufacturing, when an error occurs, it can be discovered immediately, and where errors occur. ” Jones said. “This can be done in a single piece flow, which is sometimes referred to as continuous process production. & rdquo; One-piece flow is a technology in which parts are produced in a single manufacturing unit. A manufacturing unit is an area in which all the tools needed to produce a part are readily available, and from one step to another is quick and easy. In a manufacturing unit, the next step can only be entered when all the parts have been completed without any defects.
“One-piece flow reduces movement between operations, helps reduce the error rate of the machine or operator, and the finished parts do not need to be reworked. One-piece flow is an important part of a lean manufacturing plant,” says Jones.
Because of the nature of the manufacturing unit, the unnecessary movement of labor and machinery is almost completely eliminated. Because the same operations are closely linked, the loading and unloading of components becomes very rapid. Because each machine is set as part of the manufacturing unit according to its function, this reduces the time required to find tools. Because each part does not enter the next process until the previous process is completed, it greatly reduces the waiting time for queuing. Moreover, because the components have been inspected during this process, the time required for the final inspection is reduced.
In a manufacturing unit, because the “bad” parts are not allowed to proceed to the next step, rework and overproduction due to the replacement of bad parts are greatly reduced. A manufacturing unit can produce high quality parts faster and can also reduce inventory.
Makino's machines are specifically designed for manufacturing units in a single piece flow. And because the Makino machine is designed to cut parts in one shot at a time, this speeds up the single piece and minimizes waste.