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Waste Concepts and Types
Waste Concept:
The portion of various resources, such as materials, machinery and human resources, space and time, that exceeds the absolute minimum necessary to add value to a product. Contains two dimensions:
All activities that do not add value are wasteful.
Although it is an activity that adds value, it is also wasteful if it uses more resources than the "absolute minimum" threshold.
Basic business activities:
Value-added activities
Non-value-added activities
Operations that can be dispensed with, i.e., those that increase costs without adding value.
Operations that have to be done, i.e., operations that have had to be done up to now and must be carried out along with pure operations without adding value.
Types of Waste - The Eight Wastes
One: Overmanufacturing Waste: Waste from manufacturing too much or too soon resulting in inventory.
Harms of overmanufacturing:
Costs such as materials, labor, and overhead are consumed early.
It makes the "waste of waiting" invisible.
Creates a backlog of work-in-process, resulting in longer lead times and quality degradation.
Forces the workspace to become larger, increasing the distance between machines, which in turn generates other wastes such as lifting and walking.
It can build up a backlog of capital, with companies paying more interest.
It will make the information transmission is not good, resulting in managers can not determine the normal or abnormal state of the production line.
It can also make it difficult to improve the site.
bis: inventory waste: inventory is the first of all the evils.
Harms of inventory:
Waste of handling, stacking, storage, searching, etc.
Waste of additional handling to ensure first-in-first-out;
Capital consumption, loss of interest and overhead costs;
Items become stale;
The occupation of space and plant;
Misjudgment of the capacity of the equipment and the demand for personnel;
Misjudgment of the capacity of the equipment and the demand for personnel;
Misjudgment of the capacity of the equipment and the demand for personnel. Misjudgment of equipment capacity and personnel requirements;
Covering up problems and losing opportunities for improvement.
Third: Handling waste: Handling does not add value.
Reason: handling will increase the material in the space of the movement time, more labor, the use of handling equipment and tools, in the process of handling due to collision and other reasons resulting in defective products, etc.
Fourth: Processing Waste: more than necessary operations.
There are two kinds:
Waste of high quality standards.
Waste of too many operating procedures.
ECRS four-principle approach to improvement.
Fifth: Waste of action: actions that do not produce added value, irrational operations, inefficient posture and movement are waste of action.
Sixth: waiting for waste: due to some reason caused by the machine or personnel waiting.
The reasons are as follows:
Product line variety switching
Properly planned and arranged resulting in the busy and idle uneven
Shortage of materials to make the machine idle
Delays in the upstream process leading to idle downstream process
Machine and equipment failure
Seventh: defective waste: due to the emergence of defective products in the factory, in the disposal of time, manpower, and the time caused by the disposal. The waste of time, labor and material resources caused by the disposal of defective products in the factory, as well as the related losses.
Specifically, these include:
Loss of materials when the defective product cannot be repaired and produces scrap
Loss of equipment, personnel, and man-hours
Loss of additional repairs, identification, and additional inspections
Sometimes it is necessary to dispose of the product at a reduced price
Decrease in the reputation of the factory due to the delay in shipments
Eighth: Management Waste: Productivity, productivity, and material resources caused by management. Waste: Waste of productivity, cycle time, resource utilization, etc. caused by management.
The five main points of total quality management are:
1. Quality management of the entire process
2. Unified quality management for quality and efficiency
3. Quality management of the entire enterprise
4. Quality management of all staff members
5. Utilization of the scientific method for quality management
Total What are the five key points of quality management, let's find out below!
1. Quality management of the entire process
In a market economy, the quality of any product, any form of service is subject to many things. A product, from production, trip to completion, every part of the process is constrained and influenced by each other. In order to improve the quality of products and services, we must do a good job of quality management throughout the process, including prevention, control and inspection.
2. Unify quality management to improve quality and benefit
As we all know, total quality management emphasizes the unity of benefit and quality, on the basis of maximizing the satisfaction of tapping the needs of the customers and improving the amount of customer satisfaction, and obtaining the final output with the easiest inputs, in order to ensure the long-term satisfaction of the customers, so that the enterprise and the society can be benefited.
3. Quality management throughout the enterprise
From the point of view of horizontal cooperation among all departments of the enterprise, in order to ensure and improve the quality of the products, the enterprise must establish an effective, scientific and rational system from the point of view of strategic planning, implementation and evaluation of all activities in order to improve the quality management.
4. Quality management for all staff
Quality management for all staff means that all staff of an enterprise should be involved in the management of quality and should fulfill their duties. It is important to realize that the quality management of the product is a comprehensive response to the quality of the work of an enterprise, and is an indispensable part of the audit of the enterprise. Everyone affects the quality of work, and thus the quality management of all staff should be done.
5. Utilizing the scientific method for quality management
The factors affecting a product or a service are many and varied, including equipment, management, personnel composition and many other aspects. Therefore, in the process of total quality management, we have to take into account a variety of aspects, using the most appropriate response.