Lean Manufacturing

LEAN MANUFACTURING (Sn xut tinh gn)

Lean Manufacturing thng c bit n gin l Lean, l cch sn xut hng ha ti u
thng qua vic loi b cc hao ph v thc hin lung, ngc li vi vic to ra l v hng
i. Lean Manufacturing l mt phng php qun l qu trnh ph bin xut pht ch yu
t Toyota Production System (TPS). TPS ni ting v vic tp trung trit tiu by hao ph,
theoToyota, nhm lm tng ton b gi tr khch hng (mc d Lean v TPS c quan im
khc nhau v cch thc hin vic ny). S tng trng vng chc ca Toyota, t mt cng
ty nh n nh sn xut t hang u th gii l nh tp trung s ch vo cch vic
thc hin iu ny.
Trong khi vic loi b cc hao ph c v r rng v n gin, cn ch rng s hao ph
thng rt kh nhn bit v tnh bo th ca ngi thc hin. iu ny lm gim r rt tim
nng ca mt mc tiu quan trng nhng n gin nh vy. Vic loi b hao ph l mc
ch ca Lean, v Toyota gi ba kiu hao ph l muda, muri v mura.
Muri l tt c cc cng vic khng hp l c cp lnh o to ra cho cng nhn v my
mc khi khng t chc km, v d nh khun vc nng, di chuyn vt dng vng vng, cng
vic nguy him, ngay c vic di chuyn qu nhanh so vi mc thng thng. iu ny t
con ngi hoc my mc vo tnh hung bt thng. iu ny c khi n gin ch l yu
cu mt quy trnh phi t hiu sut cao hn m khng c mt thay i g t ph. Nhng
yu cu khng hp l cng thng gy l nhiu dao ng.
Cn lin kt ba khi nim ny li mt cch n gin. Trc ht, muri tp trung vo s
chun b v lp k hoch cho qu trnh, hoc cng vic no c th c trnh c mt
cch tch cc v c ch ch. Tip theo, mura tp trung vo vic thc hin v s loi b s
dao ng trong vic ln k hoch hay cp hot ng, nh cht lng v sn lng.
Muda c mang vo sau qu trnh c thit lp v cc phn hi c. iu ny
c nhn bit qua s dao ng u ra. Vai tr ca qun l l kim tra muda, trong
nhng qu trnh v loi tr nhng nguyn nhn su xa hn bng vic xem xt nhng kt ni
ti muri v mura ca h thng. Nhng s bt n ca muda v mura phi c phn hi tr
li cho muri, hay vic lp k hoch, l giai on cho d n tip theo.
Mt v d in hnh ca s tng tc ca cc hao ph trn l cch thc chy theo s lng
trong cc bo co nh k. Nhu cu c nng ln, gia tng ( mura), cc s liu tr nn
thp lm cho khi sn xut c gng tng cng sut. Hu qu l cc cng vic hng ngy
hoc tiu chun b thay i.
By muda c bn:.
- Sn xut tha (s sn xut hn mc yu cu).
- Vn ti (nhng chuyn ng ca sn phm khng tht s cn thit cho qu trnh sn
xut).
- Ch i (i bc sn xut tip theo).
- Tn tr (ca tt c nguyn vt liu, bn thnh phm v thnh phm khng ang c
x l).
- S chuyn ng (chuyn ng ca ngi hay thit b hay vic i li hn mc cn
thit cho qu trnh sn xut).
- X l qu mc (do hot ng thit k cng c hay sn phm km)
- Khuyt tt (n lc tham gia vo vic kim tra v sa cha khuyt tt).
Mt s nhng nh ngha trn y c th c v kh duy tm, nhng nh ngha kh khn ny
c xem l rt quan trng. S nhn bit r rng cng vic khng thm gi tr ( non-valueadded), s phn bit r rng nhng hao ph trong cng vic, l tht cn thit nhm xc nh
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nhng s gi nh s b thch thc bc sau. Nhng t ph trong SMED v k thut
thay i qu trnh khc da vo nh ngha r rng cho c hi khi nhng s gi thit trn b
thch thc.
Cc lnh vc cn tp trung ca lnh o l:
- Cch suy ngh PDCA (ci tin lin tc: Plan Do Check Act)
- Genchi Genbutsu go and see for yourself: phng php t n v kim tra
- Xc nhn quy trnh
V Lean c xem l pht sinh t TPS cho cc ngng cng nghip v hon cnh khc, c
mt s khc bit trong vic thc hin:
1. Tp trung tm kim li nhun
2. Tp trung vo cc cng c
3. Qun l cc k thut hn l to tc nhn thay i

C IM CHNH CA CHUI TOYOTA

ng dng Lean Manufacuring-Sn xut tinh gin:
-Tit kim khng gian hay h thng cp vt t ng lc (Just in time)
-Tit kim thi gian hay l h thng phiu t vt t sn xut (Kaban)p dng h thng
Pull-phc hp:
-Build to plan (i vi sn xut bn thnh phm)
-Build to Order (i vi phn cn li ca quy trinh sn xut)
p dng h thng thng tin hiu qu lin lc ton cu,im ng ch l h thng
Dealer_Daily l yu t chin lc kt ni vi cc dealer
p dng nguyn tc Kaizen_nguyn tc i mi lin tc
S dng bng in t Andon kp thi pht hin v iu chnh cc li sai
S dng kho Cross_Docking,kho tch hng :
-Tip nhn n hng t nh cung cp,tng hp vi lng cn thit cho nh my lp rp
ng lc
-Sn phm ch n kho c tch thnh l hng ln ng lc ri giao cho khch hng.
Qun tr d tr,vt t v sn xut:
Qua nhiu thp k pht trin, tp on Toyota cht lc v ng dng nhiu phng php
sn xut hiu qu, nh th m c th loi tr nhng hao ph khng cn thit
Tp an t Toyota kt ni cc li ch ca hnh thc sn xut th cng v sn xut
hng lat. Phng thc ny gip t chc va trnh c chi ph cao ca phng thc sn
xut trc y va khc phc s cng nhc ca phng thc sn xut hin thi.
H thng Toyota c nh ngha l phng php sn xut tit kim(Lean Manufacturing)
bi v n s dng t hn tt c cc ngun lc so vi phng thc sn xut hng lat hin
thi nh ch s dng mt na s lng nhn lc, mt na khng gian sn xut, mt na
vn u t vo cc cng c, mt na thi gian k thut pht trin mt sn phm mi v
vic sn xut ch tn mt na thi gian so vi phng thc sn xut hng lat. Ni bt ln
l 2 bin php tit kim di y:
1.Tit kim khng gian hay l h thng cp vt t ng lc (Just in time):
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Cc dy chuyn lp rp ca hng Ford p dng JIT t nhng nm 1930. Cn ni thm
rng Ford l ngi i u trong vic p dng cc dy chuyn sn xut. Tuy nhin, phi n
nhng nm 1970, quy trnh sn xut theo m hnh JIT mi c hon thin v c Toyota
Motor p dng
Toyota c cm hng u tin bi h thng sn xut ti mt siu th Hoa K(Piggly
Wiggly). H quan st mt tng n gin ca nh cung cp thc ung t ng l khi
khch hng mun thc ung, anh ta s ly mt ci v mt ci khc s th ch vo . H
thy u im ca siu th l s t hng li v lu kho sn phm ch mt ln khi n c
mua bi khch hng. Toyota p dng bi hc t Piggly Wiggly bng cch gim s lng tn
kho, h ch c th gi mt mc l mi ngi cng nhn c th cn trong mt khong
thi gian ngn, v sau t hng li. iu ny th hin tiu biu cho s ng lc (Just-intime) ca h thng lu kho.
l cuc u tranh ca hng nhm hy b h thng kho cha vt t cng knh, tn km
v han thin mt h thng cung ng vt t l tng, c hiu qu c gi l h thng
cung ng vt t ng lc.JIT l nguyn vt liu hay bn thnh phm c giao ng s
lng,ng ni v va ng lc khi khu sau cn dng ti. Khu hiu chnh ca h thng
Just in time: kho cha l tin vt qua ca s, l khng gian v tch s, l chim c v l mt
bng sn xut.
2.Tit kim thi gian hay l h thng phiu t vt t sn xut ( kaban)
Phi hp vi h thng tit kim khng gian l h thng tit kim thi gian, c gi l phiu
t vt t kaban.
Kaban tr thnh ch lm vic ca tan hang Toyota, ca tng nh my, tng phn
xng, tng cng an trong dy chuyn sn xut v tng cng nhn. H thng kaban
nhm tit kim thi gian cht gia cc cng an sn xut, cho tng c nhn khi ht mt
t cung cp nguyn vt liu, bn thnh phm. mi ni sn xut u c mt kaban cho
tng ngy lm vic
Kaban l nhng t giy, ging nh cc ha n giao hng trn ghi r tng cng nhn cn
bao nhiu linh kin, vo thi im no trong ca lm vic. Do ti ch lm vic ca mi
ngi cng nhn s khng c cc b phn d tha, khng tn ch cha hoc t cc
mn d tha ny
H thng kaban iu ha tan b qu trnh cung ng vt t cho sn xut, c ngha l m
bo nhp sn xut lin tc, nhng khng cn kho cha nhiu. H thng kaban khng cho
php cung cp vt t tha cng nh thiu. nu cung cp tha c ngha l lng ph, cn nu
cung cp thiu c ngha l ngng tr sn xut.
Mt cng nhn lm vic ti hng Toyota trong 15 nm ng ta ch thy mt ln dy chuyn
sn xut b ngng tr 20 pht do thiu vt t. Chic xe ti nguyn vt liu b tai nn giao
thong trn ng cao tc. s kin ny lun b nhc li nh mt bi hc v lng ph thi gian.
Trong h thng Toyota, ngi cng nhn lm vic ti qu trnh sau s phi i n qu trnh
trc ly nhng ph kin cn thit. Sau cng vic m qu trnh trc cn lm l
ch sn xut ng s lng n v sn phm thay th nhng ci b ly i.
3.Ngoi ra cn c cc nguyn tc :
Nguyn tc gi thng bng sn xut
i vi cc b phn do cc hng, xng bn ngoi sn xut v cung cp cho cng ty
Toyota, phng php gi thng bng sn xut (prpduction leveling) cng c cp ti.
Chng hn mi thng hng cn n 1000 b phn, nh vy trong 25 ngy lm vic mi
thng, mi ngy cn 40 b phn v nu trong mt ngy lm vic ngi cng nhn lm 8
ting hay 480 pht th c 12 pht li cn mt b phn. tng ny dn n cch gi thng
bng sn xut.
H thng sn xut nh vy phi c iu hnh bng cch thit lp dng sn xut, dng
phng php lm sao duy tr c ngung cung cp khng i v nguyn liu, b phnt
bn ngoi, khin cho vic ch to hay lp rp c iu ha.
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Phng php ny cng trnh cho cng ty khng cn tn nhng nh kho qu ln v vic
kim k phc tp v phn c trch nhin ny sang cc nh cung ng ca Toyota.
V vy, i vi cc nh cung cp,cc nh qun tr ca Toyota lun phi lng nghe h, yu
cu h cng tc trong phng php lm vic mi v tho lun r rng vi h v nguyn
liu, nhn lc v tin bc.
Toyota khng tn ti d tr, vic iu hnh sn xut ca h l lm sao gim lng ph, trong
c s lng ph v cha hng(stock on hand). Do , nh my sn xut ch sn xut s
lng cn n theo mi bc i dt li v pha trc, t im cui cng l cn bao nhiu,
khi no cn, b phn trc nhn ly yu cu, tnh ton v yu cu s cung cp t b
phn trc na.
Vic d tr ng n ca Toyota trnh c s lng ph v tin bc cho chi ph qun l
d tr. :chi ph nh ca, kho hng, s dng thit b,phng tin, ph tn cho vic u t vo
hng d tr, thit hi hng d tr do b mt, h hng, khng s dng c. Cung ng vt
t cho sn xut c ngha l m bo nhp sn xut lin tc, nhng khng cn kho cha
nhiu
Nguyn tc t kim sot li( Andon)
Ti cc nh my Toyota, hu ht my mc u t ng, do vy c th ngn cn c vic
sn xut ra hng lat cc sn phm sai li v vic hng hc my mc s c t ng
kim tra.
tng t kim sat li cng c m rng ra cc dy chuyn th cng. Nu c im g
khng bnh thng xy ra trong dy chuyn sn phm, ngi cng nhn s bm vo nt
dng v tan b dy chuyn dng li. Nhm mc ch pht hin ra cc li ti cc qu
trnh, ti cc phn xng u treo mt bng in t ( c gi l Andon ) dng ch im
dng ca dy chuyn mi ngi c th nhn thy.
Bng in t Andon trong h thng Toyota ng mt vai tr quan trng gip cho vic kim
sat li t ng, ng thi cng l mt v d in hnh ca H thng kim sat trc quan
Toyota.
Nguyn tc i mi lin tc(kaizen)
Linh hn h thng Toyota l nguyn tc Kaizen. Kaizen c hiu l s i mi lin tc.
im ct yu ca n nm ch mi k s, nh qun tr, cng nhn trong dy chuyn cng
tc vi nhau khng ngng ngh t ng ha dy chuyn sn xut v xc nh cc thay
i thit yu gip cng vic din tin sun s. Toyota c gng duy tr hng tn kho cng t
cng tt, khng ch gim chi ph m cn truy cu sai st ngay lc xy ra. Dy chuyn
sn xut ca Toyota c chy vi cng sut ti a. D vy, mi cng nhn u c quyn
ngng dy chuyn v yu cu h tr cp tc nu pht hin c sai st. Toyota coi trng vic
tm cch ci thin quy trnh, tnh ti vic gii quyt cc li c th pht sinh hn l i gii
quyt cc s c xy ra.
Nguyn tc pull phc hp
Trong h thng vt t ca Toyota, mt s thnh phn ca h thng cp y v sn xut
theo n hng c s dng h tr ln nhau(h thng Pull phc hp).
Cng ty p dng h thng cp y tn kho cho mt phn ca quy trnh sn xut v p
dng h thng lm theo n hng cho phn khc ca quy trnh sn xut. (duy tr mt mc
quy nh tn kho cho mt s loi bn thnh phm v ch sn xut ra thnh phm khi c
khch hng yu cu).
Nh vy, cng ty Toyota p dng h thng cp y tn kho cho qu trnh sn xut bn
thnh phm v p dng quy trnh lm theo n hng cho phn cn li ca chuyn sn xut.
Trong H Thng Sn Xut Toyota, qu trnh sn xut c kch hot cp y mt s loi
thnh phm chng c sn khi c cn n.
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P/S :Thy mi ngi c v quan tm n m hnh sn xut ca Toyota nn vsn post bi ny
ln chia s cng mi ngi.Vsn ch cung cp mt s kin thc trong " Qun tr d tr,vt
t v sn xut " thi,cn nhng vn v " qun tr kho bi-vn ti "," h thng phn phi",
"h thng thn tin "," dch v khch hng ",v.v...vsn hok cp ti.y hok phi l ebook
nn vsn post vo mc Kin thc.Baby xem nu hok ng ch th remove dm vsn nghen.
S h tr ca cc ng dng ny trong qu trnh sn xut kinh doanh:
Just in time: Toyota s dng mt trong nhng h thng chui cung ng tinh vi nht trong
sn xut nhm m bo nhng linh kin t nh cung cp n kp thi khi n cn. Phn
mm c s dng l h thng kim sot dy chuyn tch hp ca Toyota (ALCS)
v d khi mt chic xe ra khi xng sn Georgetown, h thng s gi nh cung cp ch
ngi Johnson Controls mt tin nhn in t v cu hnh chnh xc ca chic gh c yu
cu. Cng ty ny c 4 gi vn chuyn nhng gh ti khu trong chui
Jikoda: Ti mi giai on ca dy chuyn, Toyota s dng nhng cng c cho php cng
nhn dng sn xut sa li. C th l dy thng treo trn u dy chuyn sn xut hay
l mt nt nhn. Trong trng hp khc, n c th l mt phn mm qun l tinh vi bo
ng cho nhng ngi ang hot ng sn xut.
Kaizen: y l h thng ci tin lien tc. N c th n gin l a mt linh kin n dy
chuyn, v th, mt cng nhn khng cn phi ph thi gian i b n ly linh kin hoc
cc dealer c th s dng mng Dealer Daily, mt cng Internet rt ngn thi gian ch
i sn phm ca khch hng .
Andon: Bt c khi no c th ,Toyota s dng nhng cng c kim sot c th nhn thy
hay gi l andon, chng hn l mn hnh plasma v bng ng h in t trn cao
truyn ti nhanh chng tnh trng cng vic ca h thng, v d trn sn dy chuyn sn
xut, andon trn u hin ln cho mt ngi gim st bit c tnh trng hot ng tt
(n xanh), cn c kim tra (n vng), hay dy chuyn ngng hot ng (n ).
Poka Yoke: Toyota s dng mt lot nhng cng c vi chi ph thp ngn chn li. mt
Poka Yoke c th n gin l mt tay nm cng c vi b cm ng in t hay l mt tia
sng truyn tn hiu ti my vi tnh khi c ci g lm gin on dng chy sn xut , v d
nh khi mt cng nhn khng th ly c kim cht, bulong, con tn hay nhng chi tit no
, tia sng c th pht tn hiu cnh bo.
Genchi Genbutsu: Toyota yu cu cng nhn, i ng lnh o v qun tr i v xem xt
vn trc tip v lm vic tp th tm ra gii php. V th Toyota s dng ng phn
mm:
Oracle ERP, Oracle 9i, Siebel cho my mc t ng
SAS Business Intelligence, Hyperion Intelligence, Powerplay Impromptu Intelligence,
Demand Planner i2 cho vic qun l cc robot
Dell server, SQL server, B office, Norton for Antivirus, Blackberry cho vic tip cn t xa
Cch lm vic ca Toyota vi cc nh cung ng ca mnh:
Toyota thu ban u ch l mt cng ty nh Nht, thiu vn v quy m th trng cho
php n s hu th trng cung cp linh kin cho mnh. Do vy, Toyota buc phi la chn
cc nh cung cp bn ngai, khng ch c nhng linh kin phc tp nh h thng bm
xng, h thng phanh m c nhng linh kin rt c bn nh l thp, inh c, vi bc m
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cho gh.
iu m ra kh nng chn p nhau rt ln gia cc i tc trong quan h hp ng. Nu
khng lai tr c nguy c tim n ny, Toyota khng th tr thnh mt ngi khng l
trn th trng xe hi nh hin nay.
Hin nay, Toyota la chn mt gii php rt n gin v hiu qu lai tr vn
chn p. Vi bt k linh kin no, Toyota cng t hng t nhiu nh cung cp. Ci mt c
th l tnh hiu qu v quy m: ph tn trang b li my mc sn xut ra mt linh kin
mi b tng gp i, nu c hai nh cung cp cng mt loi linh kin. Ci c l Toyota
trnh cho mnh khi b p gi thong qua u thu cnh tranh gia nhiu nh cung cp khc
nhau.
C th l nu mt nh cung cp thnh cng trong vic gim gi thnh hoc tng cht lng
sn phm, th iu to ra sc p kim tra mc n lc ca cc nh cung ng khc v
ngc li. Mi mt nh cung ng linh kin cho Toyota cng ng thi l bn hang ca cc
nh sn xut t khc nh Honda hay Nissan. Kt cc l ri ro p gi t c hai pha tham
d hp ng b lai b.
Mt li ch c bn na ca vic a dng ngun cung ng v tiu th l tri thc cng ngh
lan truyn nhanh v rng khp trong tan ngnh cng nghip.
Cc nh cung ng ca Toyota phi giao hng n mt khu vc m gn nh my, ri t
cc b phn c a thng n dy chuyn sn xut khi cn thit. Toyota, tt c
cc dch v giao hang nh vy din ra c 2 ting mt ln vi tin cy trn 99%. thc
hin c iu , Toyota phi hp cng cc nh cung ng thc hin chng trnh o to
c bt u vi vic m bo rng cc li xe s quan tm n chm sc n hng ha
trn xe, iu ha thi quen li xe u v eo dy an tan. Thnh thang cc xe ti s b theo
di m bo rng cc tiu chun c p ng. t to nn mt dch v cung ng
ng tin cy p ng c cc tiu chun do Toyota ra.
Toyota dnh khang 3 n 5 nm nh gi mt nh cung ng mi trc khi quyt nh k
hp ng u tin vi h
Toyota chp nhn mc gi sao cho nh cung ng phi c li nhun
Toyota chp nhn cc sn phm c li t nh cung ng v hy vng cc nh cung ng s
hc t cc sai lm v ng lp li sai lm ln na
Toyota a ra cc chnh sch thu mua hng nm i vi cc nh cung ng: Toyota lun gi
lin lc v t ra cc tiu chun c th r rang cho cc nh cung ng ca mnh cc kha
cnh cht lng, phn phi, gi c v tnh cung ng a dng. Nu cc nh cung ng gp
phi nhng kh khn p ng cc tiu chun ca Toyota th Toyota sn sang gi cc
chuyn gia n gip h gii quyt cc kh khn .
Cc tiu chun m Toyota yu cu t cc nh cung ng ca mnh:Toyota da vo cc nh
cung ng t bn ngai hu ht cc b phn trong mi xe m h sn xut ra. T khu pht
trin n khu sn xut u c s tham gia ca cc nh cung ng. Nhng nh cung ng
m Toota tm kim phi l nhng cng ty c kh nng v c s nhit tnh tr thnh
cng s tch cc v ch ng cho Toyota. phi l nhng cng ty chim hu nhng li
th cnh tranh tm c th gii v cht lng , gi c, phn phi v nng lc cng ngh.
Hn 3.000 u sch v bi bo trong nhiu nm vn cha th tm ra ti sao Toyota thnh
cng, vo lc cc cng ty i theo m hnh ca hng ny li tht bi.
S kin Toyota bn hn General Motors (GM) 160.000 xe trong qu I c th ch l mt tin
nh. Tuy nhin, y li l du hiu cho thy hng xe Nht Bn sp kt thc triu i GM v
nh du k nguyn mi cho mnh.
77 nm qua, d c lc thnh suy nhng GM lun bn nhiu xe hi hn bt c nh sn xut
no trn th gii. Trong khi i th Toyota ni ting l hng lm n hiu qu v duy tr kh
nng sng to ln. Theo d bo, cuc chin ca hai i gia c th kt thc vo nm nay,
vi s i ngi ngon mc.
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Gi Toyota l giu sng to l iu bt thng. Bi xe ca nh sn xut ny ch khin
khch hng thch ch cha t ti yu. Thm ch chng b ch trch l sao chp v t
c tnh. Tp ch Fortune thng xuyn tn dng tnh hiu qu Toyota nhng nhn xt sn
phm li t nht v quan liu.
[Only registered and activated users can see links]
Cng nhn Toyota ang lp rp xe Lexus ti nh my Miyata, Nht Bn: nh: AFP.
L do coi Toyota khng sng to xut pht t nh ngha ca khi nim ny. Steve Jobs cho
rng sng to l to ra nhng sn phm mi, cng ngh mi. Th nhng Toyota, sng
to li tp trung vo qu trnh sn xut hn l sn phm. H quan tm n s vn hnh
ca nh my hn l tm cch lm p showroom. V vy, rt kh nhn ra nhng g
Toyota lm c. Nhng hiu qu ca chng c th l v song.
Nguyn l thnh cng ca Toyota bt ngun t phng php sn xut Toyota, mang tn
TPS, c khai sinh vi nm sau chin tranh th gii th hai, khi Nht Bn phi lm mi th
xy dng li c s vt cht.
K s tn Taiichi Ohno a mi th tr nn c hiu qu vi mt h thng m mi thit
b, my mc v nhn cng u c s dng mt cch ti u nht.
Nguyn l ca TPS rt n gin. l loi b s lng ph bng cch cung cp thit b mt
cch chnh xc khi cng nhn cn, v khc phc li ngay khi s c pht sinh.
y l trit l khng mi v chnh Ohno nhn mnh rng Henry Ford v m hnh siu th M
l cm hng cho nhng tng trn. Tuy nhin, Toyota lm tt hn tt c cc hng t
khc v a nguyn l thnh hin thc.
Trong mt vi trng hp, TPS c thc hin vi s sng to kh c bit. Chng hn
nh kiu cnh bo andon cord, cho php bt c cng nhn no cng c dng h thng
nu anh ta pht hin li. H thng kanban th cho php cng nhn bo n tn hiu khi cn
thit b mi. Sn nh my c sp xp c th tm thit b v sn phm d dng.
Tt c s sng to c Toyota tp trung cho qu trnh sn xut vi nhng cu hi ci g?
v nh th no?. V l m hng ny lp rp nhanh nhng cn t nhn cng hn bt c
cng ty M no.
Mi vic tng chng n gin nhng hin ti, vn phi tha nhn rng c b mt trong quy
trnh TPS. D c nhn rng nhng Toyota lun dn u v hiu qu sn xut so vi cc
i th khc. Hng xe Nht m ca nh my cho khch tham quan. Thm ch lin doanh vi
GM thit k, sn xut xe hi v gip i gia M ci tin dy chuyn sn xut.
Qua nhiu nm, hn 3.000 u sch v bi bo tp trung phn tch hot ng ca Toyota
v kiu vn hnh andon ph bin nhiu nh my. S truyn b m hnh Toyota rt c
hiu qu, bi nng lc sn xut ca ngnh t tng ln ng k. Nhng lm th no Toyota
vn ng u?
Cu tr li c rt nhiu, ty thuc vo cch tip cn. Thay v ni ti qu kh, chng ta c th
thy ngay nhng im c bit hng xe ny. l s tn ti ca nguyn l c tn ting
Nht kaizen, c ngha ci tin khng ngng.
Mi b phn, nhn cng Toyota lin tc a ra cc tng theo ngy. V cp cng cao
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Lean Manufacturing
chu trch nhim cng ln.
Theo Matthew E. May, tc gi cun The Elegant Solution, ti sn ln ca Toyota l hng
triu tng mi nm, v hu ht trong s chng n t nhng cng nhn lm vic hng
ngy. Con s ny nhiu hn hng trm ln so vi mt cng ty M.
Cc tng Toyota rt nh, chng hn nh lm th no ly thit b d dng, v khng
phi tt c u c thc hin. Th nhng, nh tch ly, Toyota hc c nhiu hn v dn
dn ci tin t nh n ln. Kt qu l bao gi hm nay cng hiu qu hn ngy hm qua.
Th nhng, c th khng nh TPS vn c li, c bit vo nm 2006 khi Toyota vng
phi hng lot vn v cht lng. y c th do nhng sng to nh khng tng thch
vi nhng iu hnh v m, da trn nhng cng ngh ln.
Hin ti, cc nh nghin cu vn ang tp trung nghin cu v Toyota bng nhiu cch tip
cn khc nhau. Cho d cc kt qu thu c thng khng hiu qu ni khc.
Sut nhng nm 1990, McKinsey b cng nghin cu hng lot cng ty p dng chng
trnh ci tin nh ca Toyota. Cui cng, hai phn ba b tht bi. ng kt lun rng sng
to ca Toyota rt n gin, i thng nhng khng c tnh ph dng. Chng d hiu
nhng bt chc th v cng kh.

BN KHON
Nguyn tc ch o ca Lean l gia tng gi tr cho khch hng thng qua vic lin tc loi
b lng ph trong sut qu trnh cung cp sn phm v dch v. Lng ph y c hiu l
tt c cc hot ng ca doanh nghip khng gip to ra gi tr mong mun cho khch
hng. V th, mun p dng Lean, doanh nghip phi hiu u l nhng iu khch hng
tht s quan tm, nhng gi tr t sn phm v dch v cung cp c khch hng sn
sng tr tin Trn c s , doanh nghip s bit cch gim thiu, hoc loi b, nhng
hot ng no lm pht sinh chi ph v ko di thi gian ch i ca khch hng.
Ti hi tho ng dng Lean trong qun l doanh nghip gia tng li nhun, do Mekong
Capital t chc hi thng 9, ng Andrew Cheah, chuyn vin Cng ty T vn Lean Advisors,
cho bit nhiu doanh nghip vn hiu lm ng dng Lean l sa thi nhn vin. ng ni:
Thc ra Lean chng dnh dng g n chuyn ny m ngc li, ng dng Lean s khng
thnh cng nu doanh nghip gim bt nhn s. Cng trong hi tho, nhiu doanh nghip
Vit Nam nu ln nhng kh khn ca mnh trong qun l. Mt nh sn xut chi tr
em bng g cho bit ng ang gp kh khn vi vn lng ph nguyn vt liu. Khch
hng yu cu sn phm xut xng phi p v ng tm mua nguyn liu c cht lng
cao p ng yu cu ny. Tuy nhin, v sn phm c kch thc rt nh nn qu trnh
sn xut mc nhiu li, dn n lng ph rt nhiu vt liu. Mt nh sn xut khc li gp
vn v nng sut lao ng thp; tinh thn lm vic ca nhn vin u oi; tinh thn phi
hp nhm gii quyt cng vic cha cao. C nh sn xut li au u vi gi nguyn
liu tng m khng th tng gi bn sn phmV iu m tt c mi ngi u mun bit
l phi ng dng Lean nh th no thnh cng.
Liu doanh nghip nh c cn thit p dng Lean hay khng? Theo ng Cheah, ng nn
i cng ty ln mnh mi chuyn sang p dng Lean, v khi vic chuyn i cc hnh
thc qun tr, sn xut s rt phc tp. p dng Lean n gin ch l gii thch cho nhn
vin v nhng g cn lm tng thm gi tr cho khch hng, nhng g ngc vi mi quan
tm ca khch hng l lng ph, ng Cheah ni.
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Lean Manufacturing
Kinh nghim v thnh cng
C l Toyota Bn Thnh l cu chuyn v ng dng Lean thnh cng Vit Nam c
nhc n nhiu trong thi gian qua. y l mt trong nhng trung tm dch v bo tr hng
u ca Toyota ti Vit Nam. Nh p dng Lean, Toyota Bn Thnh rt ngn c hn
ba phn t thi gian bo tr nh k cho mt chic xe, t 240 pht xung cn khong 50
pht. u tin, Toyota Bn Thnh khc phc khong thi gian cht, chim n hn mt
phn t thi gian bo tr xe, ch yu do cc nhn vin phi i nhau trong lc giao v nhn
ph tng gia cc cng on ca quy trnh. Tuy nhin, vn cn mt na thi gian bo tr
cn phi y nhanh tin theo yu cu ca khch. ct gim lng thi gian tha ny,
Toyota Bn Thnh nghin cu li vic sp xp ch ng ca cng nhn trong thao tc
c th h tr nhau nhiu hn, t mt thi gian di chuyn hn; sp t li dng c theo tng
thao tc ph hp cng nhn s dng c thi gian ti u trong vic la chn dng c
lm vic; trang b thm cc thit b chuyn dng v hun luyn cng nhn s dng thnh
tho cc thit b ny
Cu chuyn ng dng thnh cng Lean ca Toyota Bn Thnh cho thy vic t chc quy
trnh sn xut hp l c ngha hn l i mi thit b, cng ngh nhm tng nng sut lao
ng. Trn thc t, nhiu c s sn xut cng nghip Vit Nam vn cha thy c tm
quan trng ca vic quy hoch mt bng nh xng, b tr my mc thit b ph hp, rt
ngn thi gian vn
chuyn nguyn liu t kho vo dy chuyn sn xut s gip tng hiu sut lm vic ca
cng nhn nh th no. trng hp ca Toyota Bn Thnh, vn u t cho vic mua
sm trang thit b mi ch khong 10.000 la M, cn li mi th u tng t nh cc
trung tm bo tr xe hi khc. Kt qu mang li khng ch l s hi lng ca khch hng m
cn l li ch kinh t: Toyota Bn Thnh tng s lng xe c bo tr t su ln 16
chic/ngy.
u nm nay, mt doanh nghip trong ngnh dt may cng p dng Lean kh thnh
cng. Ngi i din doanh nghip cho bit, p dng Lean thi gian u gp phi khng
t nhng nghi ng v hiu qu thit thc ca chng trnh, v n tc ng trc tip vo quan
im qun tr v cch thc iu hnh hot ng ca cng ty. Gii qun l cp cao ti doanh
nghip ny phn i vic p dng Lean v n ph nhn cng lao ng gp ca h. Theo
mt chuyn gia t vn v Lean, y l tnh trng chung m phn ng cc doanh nghip t
nhn Vit Nam gp phi v mt s ngi c xem l tr ct phi i mt vi nhng thay
i c th tc ng n v tr v tm nh hng ca h ti doanh nghip. Trong trng hp
doanh nghip dt may trn, ch doanh nghip mt mt phi ht sc mm mng thuyt
phc nhng ngi chng i, mt khc phi tin vo vic ng dng Lean.
Sau khi thng t tng trong ban gim c, ngi ch doanh nghip ny li phi i
mt vi mt kh khn khc: nhn lc qun l chuyn bit. Chng hn, trc y mi mt
sn phm may mc s c mt ngi chuyn ph trch vic ct vi, by gi p dng Lean
ch cn mt ngi ph trch vic ny cho cc nhm sn phm. y l iu cc k kh khn
v tc thi khng d tm, hay o to, mt ngi c k nng chuyn su nh th. Bn
cnh , Lean yu cu ch sn xut va , hn ch hng tn kho. Nhng iu ny li lm
l ra nhiu tn tht tim n v tng p lc cho nh qun l nh my h khng sa kp, cng
nhn bnh t xut dn n khng lm kp n hng. Tuy nhin, khi vt qua c
nhng kh khn trn th Lean thc s pht huy tc dng.
Kinh nghim u tin doanh nghip trn l thc hin chuyn mu, tc b tr cng nhn
ngi ng s my theo lung di chuyn hp l ca sn phm. Trc y, mi cng nhn
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Lean Manufacturing
t chn cho mnh mt ch ngi ty thch, dn n gin on chuyn sn xut v c khi hai
cng on lin nhau nhng hai my li t cch xa nhau. Bi hc k tip l cch tr lng.
Lu nay doanh nghip tr lng cn c theo s lng, m khng cn c vo kh ca
vic to ra sn phm tng cng on nn lun c s cch bit ln v thu nhp trong cng
mt chuyn sn xut. Nay lng c tr theo sn lng ca c mt chuyn sn xut, nn
thu nhp ca ngi lao ng c tnh ton hp l hn. Ngi c tay ngh cao hay thm
nin th doanh nghip cho nhn thm h s gi chn, ng thi khuyn khch h gip
nhng ngi yu ngh hn trong chuyn sn xut ca mnh. Nhng kt qu tip theo khi
doanh nghip ny p dng Lean bao gm gim thi gian thc hin n hng t 30 ngy
xung cn 15 ngy; gii quyt c tc nghn trong dy chuyn sn xut (v by gi ngi
gii ngh s h tr ngi yu, ngi lm cng on n gin s c phn thm vic cho
bng vi thi gian ngi lm cng on phc tp). Quan trng hn ht l gi y doanh
nghip, tnh on kt ca cc b phn tng ln, t chuyn sn xut hot ng lin tc,
cng vic gia cc thnh vin c cn bng v thi gian h hng my mc cng c rt
ngn li

CNG C V PHNG PHP

1 Chun Ho Quy Trnh (Standard Work)
Chun ho quy trnh c ngha l cc quy trnh v hng dn sn xut c qui nh v
truyn t r rng n mc ht sc chi tit nhm trnh s thiu nht qun v gi nh sai
v cch thc thc hin mt cng vic. Mc tiu ca vic chun ho l cc hot ng
sn xut lun c thc hin theo mt cch thng nht, ngoi tr trng hp quy trnh sn
xut c iu chnh mt cch c ch . Khi cc th tc quy trnh khng c chun ho
mc cao, cc cng nhn c th c nhng ngh khc nhau v cch lm ng cho mt
th tc quy trnh v d a n cc gi nh sai. Mc chun ho cao v quy trnh cng
gip cc cng ty m rng sn xut d dng hn nh trnh c nhng gin on c th
gp phi do thiu cc quy trnh c chun ho.
Cc hng dn cng vic chun trong Lean Manufacturing thng c nh ngha v vit
ra mc chi tit hn nhiu so vi yu cu ti thiu p ng iu khon 7.5.1. ca phin
bng ISO9001:2000 v Kim Sot Sn Xut v Cung Cp Dch V (Control of Production
and Service Provision), c th di hnh thc chun ho cc thao tc v trnh t cng vic
cho tng cng nhn.
Vic chun ho quy trnh trong Lean Manufacturing bao gm mt s thnh phn
chnh:
1. Trnh t cng vic chun y l trnh t mt ngi cng nhn phi tun th khi thc
hin cng vic, bao gm cc thao tc v cc bc thc hin cng vic. Vic m t r rng
gip m bo rng tt c cc cng nhn u thc hin cng vic theo cch thc tng t
nhau v hn ch cc sai bit vn c kh nng gy ra ph phm. Trong iu kin l tng,
vic chi tit ho cng vic ch r tng bc thao tc cho mi cng nhn. V d vi cng
on ct g, trnh t cng vic chun s m t t chi tit ct v cc bc thao tc nh
chun b my, chnh dao ct, cch nng gi v a vt liu qua my v thi gian x l cng
vic. i vi cng on lp rp, bng m t cn lit k chi tit tng bc thao tc thc hin
vic lp rp cho mi loi sn phm.
2. Thi gian chun Takt time (nhp ) l tn xut mt sn phm c lm ra. Takt time
c s dng m t r rng v theo di tc mt quy trnh cn c duy tr cc cng
on khc nhau. i vi cc nh sn xut lean, takt time ca mi quy trnh sn xut c
ch ng iu phi v gim st duy tr mt lung sn xut lin tc.
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