甚麼是精實生產(Lean Production)?
A manufacturing system and philosophy that provides quality product or service at minimal cost in a waste-free environment in the fastest time at the highest customer satisfaction. It reflect ways of thinking about production, the assumptions that underlie how people and institutions formulate solutions to the problems of organizing people, equipment, material and capital to create and deliver products and services for customers.

精實生產要點
-All work procedures, line conditions, shop policies must be clearly defined, communicated and followed.
-The ability to stop production lines in the event of such problems as equipment malfunctions, safety & quality problems or work being late.
-Delivering what the customer request, exactly when it is requested, and in the exact quantity requested.

全員生產維護(TPM)
TPM is a plant improvement methodology which enables continuous and rapid improvement of the manufacturing process through use of employee involvement, best maintenance practices and systematic equipment improvement.

使命: Eliminate all waste (see below)
-Breakdown Losses
-Set up and Adjustment Losses
-Start-up Losses
-Tooling Losses
-Minor Stops
-Idling & Minor Interruptions
-Reduced Speed Losses / Cycle Time
-Quality Defect and Rework Losses

Overall Equipment Effectiveness = Availability x Performance Rate x Quality

JIT 生產特性
Work Cell
-U-Cell Layout; moves counter clockwise
-Operations in order of process
-Material handling separated from work station
-Compact
One Piece Flow
-Pull production
-Paced to customer demand rate
Small and Inexpensive Equipment
Employee Focused
-Easy moving/standing operations
-Standard operations documented
-Manual, visual performance measures
-Cross-trained workers

精實生產系統使命
-Eliminate Waste, Reduce Non Value Added Activities, and Improve Manufacturing Competitive Performance.
-Common Lean Process Across All Operations.
-Lean Enablers Upstream in the Product Development Process.
-Operation Leaders with Lean Expertise and Experience.

精實生產基本工具
-Standard work and line balancing
-Visual management
-Problem solving techniques
-Lead time reduction
-Error and mistake proofing
-Production systems
-Training
-Waste identification & elimination
-Material flow and pull systems
-Operator density

精實生產目標
1. Development of systems that are capable of meeting operator density/utilization efficiencies.
2. Development of systems that are designed to support the elements of standard work.
3. Ensure all production launches incorporate standard Andon systems.
4. Provide manufacturing with a lean proces focusing on pre-production and new model launch activities involving shop floor processes.

真正實施精實生產的組織
1. Continuous implementing lean operating methods is the organization’s primary tool in pursuing its strategic objectives
2. Structured policy deployment techniques are used to plan the organization’s lean deployment actions
3. A non-blaming, performance oriented, process-driven organizational atmosphere exists
4. Lean progress targets are defined and have been effectively communicated
5. No employee has reason to perceive their livelihood to be jeopardized by contributing to organizational lean progress
6. Management has chosen to adhere to lean principles in the face of operating objectives inconsistent with lean progress
7. Team authority level and accountability level is clearly defined
8. Team is accountable for continuous improvement in its segment of the value chain
9. Financial system is structured to present correctly the results of lean progress

全員生產維護的實施步驟
1. Conduct TPM introductory education and publicity campaign
2. Create TPM promotion organization
3. Establish basic TPM policy and goals
4. Draft a master plan for implementing TPM
5. Kick off TPM initiatives
6. Build a corporate constitution
7. Build an early management system
8. Build a quality maintenance system
9. Build an effective administration and support system
10. Sustain a full TPM implementation

全員生產維護的基本活動
-Autonomous maintenance
-Equipment improvement
-Quality maintenance
-Maintenance Prevention

全員生產維護(TPM)和全面品質管理(TQM)
-TPM is an essential component of TQM
-TPM resembles TQM

實施精實生產的獲益
-Process defect rate down
-Customer compliant/claims down
-Products and work-in-process down
-Shutdown accidents down
-Pollution incidents down
-Improvement suggestions up
-Productivity up
-Financial losses drop
-Repair costs drop
-Maintenance labour-hours reduce
-Energy costs reduce
-Manufacturing profit ratio up
-Achieving full-self management
-Eliminating breakdowns and defects
-Growing confidence
-Making workplaces to a clean, bright and lively
-Getting more orders


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