Professional Documents
Culture Documents
Khái Quát Và NG Dung Lean Tai Viet Nam
Khái Quát Và NG Dung Lean Tai Viet Nam
I HC KINH T THNH
PH H CH MINH
NGU
BO CO CHUYN
SN XUT TINH GN V VIC NG DNG VO CC
CNG TY TI VIT NAM
MC LC
Chng 1 : Tng Quan ca Bo Co
Chng 2 : C S L Thuyt
1. Lean l g
1.1 Lch s ca Sn Xut Tinh Gn (Lean)
1.2 Mc Tiu ca Lean
1.3 Cc Nguyn Tc Chnh ca Lean
1.4 Trng Tm ca Lean
1.5 Li ch t Lean
2. Cc Khi Nim trong Sn Xut Tinh Gn
2.1 Vic To Ra Gi Tr v S Lng Ph
2.2 Nhng Loi Lng Ph Chnh
2.3 Sn Xut Li Ko (Pull)
2.4 Cc M Hnh Khc Nhau ca H Thng Sn Xut Pull
2.5 V Sao Mc Tn Kho Cao Lm Tng Ph Phm v Lng Ph
2.6 Tc ng ca H Thng Pull i vi Vic Hoch nh Sn Xut
2.7 Quy Trnh Lin Tc
2.8 Phi Hp Quy Trnh Lin Tc v Khng Lin Tc
2.9 Ci Tin Lin Tc/ Kaizen
2.10 S Tham Gia ca Cng Nhn
2.11 Quy Hoch M Phng Dng T Bo
2.12 Administrative Lean (Lean cho Cng Tc Hnh Chnh)
3. Cng C & Phng Php trong Sn Xut Tinh Gn
3.1 Chun Ho Quy Trnh
3.2 Truyn t Quy Trnh Chun cho Nhn Vin
3.3 Quy Trnh Chun v S Linh Hot
3.4 Qun L bng Cng C Trc Quan
3.5 Cht Lng t Gc (hay Lm ng ngay t u)
3.6 S Chui Gi Tr
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MC LC CC HNH V TRONG BO CO
Hnh 1 : Lch s pht trin ca Lean
Hnh 2 : Mc ch ca sn xut tinh gn
Hnh 3 : So snh gia cch thc sn xut theo chc nng v lin tc
Hnh 4 : Cng c v Phng Php trong Lean
Hnh 5 : Cc bc trin khai Lean
Hnh 6 : Kt hp gia Lean v ERP
4. Kt Cu Ca Bo Co
-
Tng quan
C s L Thuyt
Phn tch tnh thc tin khi p dng vo doanh nghip Vit Nam
Kt lun
CHNG 2 : C S L THUYT
2.1 Lean l g
2.1.1 Lch S ca Lean
Lean trong ting Anh c ngha l s tinh gn, mch lc. Cc cp trong
Lean bao gm Lean (sn xut theo Phng thc Lean), Lean enterprise (Doanh
nghip thc hin Phng thc Lean), Lean thinking (T duy theo Phng php
Lean).
Nhiu khi nim v Lean bt ngun t H thng sn xut Toyota (TPS) v
c dn trin khai xuyn sut cc hot ng ca Toyota t nhng nm 1950.
T trc nhng nm 1980, Toyota ngy cng c bit n nhiu hn v tnh
hiu qu trong vic trin khai h thng sn xut Just-In-Time (JIT). Ngy nay,
Toyota thng c xem l mt trong nhng cng ty sn xut hiu qu nht trn
th gii v l cng ty a ra chun mc v in hnh p dng Lean. Cm t
Lean hay Lean Production xut hin ln u tin trong quyn C my lm
thay i Th gii (The Machine that Changed the World) xut bn nm 1990.
Nguyn tc ch o ca Lean l lm tng gi tr cho khch hng thng qua
vic lin tc loi b lng ph trong sut qu trnh cung cp sn phm, dch v.
Doanh nghip phi hiu c khch hng tht s quan tm n iu g v sn sng
tr tin cho nhng gi tr no t sn phm v dch v c cung cp. T , nhng
hot ng no ca doanh nghip khng to ra gi tr mong mun s c gim
thiu hoc loi b. Vic gia tng doanh thu l cn thit, tuy nhin chnh tit kim
chi ph t hot ng kinh doanh s trc tip ci thin
li nhun cho doanh nghip.
Lean ang c p dng ngy cng rng ri ti cc cng ty sn xut hng
u trn ton th gii, dn u l cc nh sn xut t ln v cc nh cung cp
thit b cho cc cng ty ny. Lean ang tr thnh ti ngy cng c quan tm
ti cc cng ty sn xut cc nc pht trin khi cc cng ty ny ang tm cch
cnh tranh hiu qu hn i vi khu vc chu .
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2.1.5 Li ch ca Lean
Lean c s dng rng ri nht trong cc ngnh cng nghip thin v lp
rp hoc c quy trnh nhn cng lp i lp li. Trong nhng ngnh cng nghip
ny, tnh hiu qu v kh nng ch tm vo chi tit ca cng nhn khi lm vic vi
cc cng c th cng hoc vn hnh my mc c nh hng ln n nng sut.
cc cng ty ny, h thng c ci tin c th loi b nhiu lng ph hoc bt hp
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2.2.2.4. Di chuyn
Di chuyn y ni n bt k s chuyn ng nguyn vt liu no khng
to ra gi tr tng thm cho sn phm chng hn nh vic vn chuyn nguyn vt
liu gia cc cng on sn xut. Vic di chuyn nguyn vt liu gia cc cng
on sn xut nn nhm ti m hnh l tng l sn phm u ra ca mt cng
on c s dng tc thi bi cng on k tip. Vic di chuyn gia cc cng
on x l lm ko di thi gian chu k sn xut, dn n vic s dng lao ng
v mt bng km hiu qu v c th gy nn nhng nh tr trong sn xut.
2.2.2.5. Ch i
Ch i l thi gian cng nhn hay my mc nhn ri bi s tc nghn hay
lung sn xut trong xng thiu hiu qu. Thi gian tr hon gia mi t gia
cng ch bin sn phm cng c tnh n. Vic ch i lm tng thm chi ph
ng k do chi ph nhn cng v khu hao trn tng n v sn lng b tng ln.
2.2.2.6. Thao tc
Bt k cc chuyn ng tay chn hay vic i li khng cn thit ca cc
cng nhn khng gn lin vi vic gia cng sn phm. Chng hn nh vic i li
khp xng tm dng c lm vic hay thm ch cc chuyn ng c th khng
cn thit hay bt tin do quy trnh thao tc c thit k km lm chm tc lm
vic ca cng nhn.
2.2.2.7. Sa sai
Sa sai hay gia cng li, khi mt vic phi c lm li bi v n khng
c lm ng trong ln u tin. Qu trnh ny khng ch gy nn vic s dng
lao ng v thit b km hiu qu m cn lm gin on lung sn xut thng
thong dn n nhng ch tc v nh tr trong quy trnh. Ngoi ra, cc vn lin
quan n sa cha thng tiu tn mt khi lng thi gian ng k ca cp qun
l v v vy lm tng thm chi ph qun l sn xut chung.
2.2.2.8. Gia cng tha
Gia cng tha tc tin hnh nhiu cng vic gia cng hn mc khch hng
yu cu di hnh thc cht lng hay cng nng ca sn phm v d nh nh
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bng hay lm lng tht k nhng im trn sn phm m khch hng khng yu
cu v khng quan tm.
2.2.2.9. Kin thc ri rc
y l trng hp khi thng tin v kin thc khng c sn ti ni hay vo
lc c cn n. y cng bao gm thng tin v cc th tc quy trnh, thng s
k thut v cch thc gii quyt vn , v.v.... Thiu nhng thng tin chnh xc
thng gy ra ph phm v tc nghn lung sn xut. V d, thiu thng tin v
cng thc phi trn nguyn liu, pha mu c th lm nh tr ton b quy trnh sn
xut hoc to ra cc sn phm li do cc ln th-sai tn rt nhiu thi gian.
2. 2.3 Sn Xut Li Ko(Pull)
Khi nim trng tm ca Lean l Pull Production (Sn Xut Li Ko), trong
lung sn xut trong nh my c iu tit bi yu cu t cng on cui quy
trnh li ko hot ng ca cc cng on u quy trnh, vn tri ngc vi hot
ng sn xut truyn thng theo l sn phm m trong hot ng sn xut c
thc y t u quy trnh n cui quy trnh da trn mt lch sn xut nh k.
iu ny c ngha rng ch khi no c nhu cu (tnh hiu) cng on sau th
cng on trc mi tin hnh gia cng nguyn liu.
V d trong h thng pull, mt n t hng to ra nhu cu v thnh phm,
sau ln lt to ra nhu cu cho cng on lp rp hon chnh, ri lp rp s b
v i tip ngc dng chui cung cp.
Vic trin khai c th c tin hnh nh sau:
2.2.3.1. n hng bt u t cng on cui cng
Khi mt n hng c nhn t khch hng v thng tin cho xng sn
xut, lnh sn xut trc tin c a n cng on cui quy trnh sn xut
(nh ng gi hay lp rp hon chnh) tri ngc vi cc cng on u ca quy
trnh (chng hn nh s ch nguyn liu). Cch lm ny i hi mt h thng
thng tin ht sc hiu qu m bo rng cc cng on cung cp thng
ngun lin tc nm bt c nhu cu ca khch hng cc cng on v sau ca
quy trnh sn xut.
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li. Trong khi , vic lu kho cn thm lao ng, nng lng v
mt bng.
Trch nhim trc tip khi bn thnh phm nm ch x l gia cc
cng on sn xut, tc mti mi lin h trc tip gia hai cng
on. Cng on sau c rt t kh nng phn bit c mt sn phm
c th do mt cng nhn hay nhm no sn xut. Khi cng nhn hay
t cng on trc chu trch nhim t hn s cng c nhiu kh
nng gy ra sn phm li hay sai quy cch so vi yu cu ca khch
hng. Ngc li, vic bn giao trc tip v s dng ngay vt t/bn
thnh phm bi cng on theo sau s gip m bo rng cng nhn
hay t cng on trc nhn lnh trch nhim hon ton trong vic
ch lm ra nhng sn phm tt c cng on sau chp nhn.
Tuy nhin, nh cp trong phn trc, c mt s trng hp tn kho l
iu thit yu m bo iu ho sn xut v vy mt s loi tn kho nn c duy
tr mc cho php qu trnh sn xut khng b gin on.
2.2.6 Tc ng ca H Thng Pull i vi Vic Hoch nh Sn Xut
Phn ln cc doanh nghip sn xut Vit Nam u s dng h thng
hoch nh trung tm trong Trng Phng K Hoch Sn Xut xy dng lch
sn xut v phn b lnh sn xut n cc phn xng x l theo l sn phm.
y l h thng sn xut Push (thc y), c ngha rng nguyn vt liu c y
i qua quy trnh sn xut da vo lch sn xut. M hnh Hoch nh Yu Cu
Nguyn Vt Liu ( MRP) ca phn ln cc h thng Hoch nh Ngun Lc
Doanh Nghip ( ERP) hot ng trn c s ny.
Trong mt h thng sn xut Push, nu h thng d bo sn xut khng
chnh xc (vn ph bin cc doanh nghip sn xut Vit Nam) hoc Trng
Phng K Hoch Sn Xut khng c thng tin y v tnh hnh sn xut v nhu
cu tng cng on hoc khng c cng c hu hiu phn tch nhu cu (y
cng l trng hp c th cc doanh nghip sn xut Vit Nam), ngi ph
trch c th phn b qu nhiu hoc qu t vic cho cc t v cng on khc
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Hnh 3 : So snh thi gian theo cch thc sn xut chc nng v lin tc
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Cc doanh nghip sn xut Lean nhn chung tin rng phn ln cc tng
hu dng cho vic loi tr cc hot ng khng to ra gi tr tng thm xut pht
t cng nhn trc thuc cc quy trnh sn xut.
m bo rng cc tng loi tr cc hot ng khng to ra gi tr
tng thm c thc thi, quyn quyt nh thay i cc quy trnh sn xut c
a ti mc thp nht c th c ( l cng nhn) nhng bt k mt thay i
no cng c yu cu phi p ng mt s tiu ch nht nh.
V d, Toyota cc cng nhn c khuyn khch trin khai cc ci tin
cho cc quy trnh sn xut nhng vic ci tin phi th hin tnh hp l r rng ph
hp vi phng php khoa hc, vic ci tin phi c trin khai di s gim st
ca mt ngi qun l c thm quyn v quy trnh mi phi c ghi nhn li ht
sc chi tit v ni dung, trnh t, thi gian v kt qu. Toyota trc tin trin khai
cc thay i c xut quy m nh trn c s th nghim v nu vic ci tin
c hiu qu, Toyota s tin hnh thay i xuyn sut trong hot ng sn xut ca
mnh.
C hai cch ph bin khuyn khch s tham gia ca cng nhn trong
hot ng ci tin lin tc:
2.2.10.1. Vng Kaizen (Kaizen Circles)
Cch th nht l p dng Vng Kaizen trong cc nhm 6-8 cng nhn
c lp ra tm cc tng gip gii quyt cc vn c th. in hnh, mt
Vng Kaizen s gp nhau mt gi mi tun trong sut 6-8 tun v trong thi gian
s a ra mt s xut cho ngi qun l v cch gii quyt cc vn c
th. S h tr v tham gia ca cp qun l l yu t tin quyt cho s thnh cng
ca Vng Kaizen.
2.2.10.2. Chng Trnh Xut Ci Tin
Cch th hai trong vic gia tng s tham gia ca cng nhn l xy dng
mt chng trnh xut ci tin tch cc khuyn khch vic gp ci tin v
tng thng cho cc tng c p dng thnh cng. Thng th chi ph cho
vic khen thng tng i nh so vi gi tr mang li cho cng ty t vic p dng
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ci tin. Mt s chuyn gia v lean cho rng duy tr s tham gia ca cng nhn
mc cao trong vic lin tc xut ci tin chnh l yu t then cht trong vic
p dng lean v l iu chnh yu to nn s khc bit gia Toyota so vi cc cng
ty khc v s thnh cng trong vic p dng cc nguyn tc ca lean .
2.2.11 Quy Hoch M Phng Dng T Bo
Trong b tr sn xut dng t bo, thit b v cc t lm vic c sp xp
thnh nhiu cell nh (/ngn lm vic ca cng nhn) c ni kt lin lc
cc cng on hay tt c cc cng on ca mt quy trnh sn xut c kh nng
din ra trong mt hay nhiu cell lin tc.
B tr dng t bo mang cc c tnh sau:
2.2.11.1. Quy trnh lin tc
Lung nguyn liu v ph liu di chuyn u n v hu nh khng thy c
vic vn chuyn bn thnh phm hay ch i gia cc cng on sn xut.
2.2.11.2. Lung mt sn phm
Qu trnh sn xut vi m hnh t bo p dng lung mt sn phm trong
tng sn phm mt ln lt di chuyn qua tng cng on ca quy trnh sn
xut.
2.2.11.3. Cng nhn a nng
Ch c mt hoc vi cng nhn ng ti mi cell, khng ging nh sn xut
theo l/m m trong nhiu cng nhn cng lm vic v chu trch nhim trn
mt cng on n l, trong m hnh t bo cc cng nhn ph trch tng cng
on khc nhau din ra trong mt cell. V vy mi cng nhn c hun luyn
thc hin tng cng on trong cell .
2.2.11.4. M Hnh ch U
Cc Cell thng c dng ch U, vi sn phm di chuyn t u ny n
u kia ca ch U khi c cng nhn gia cng. Mc ch ca cch b tr ny
nhm hn ch ti a khong cch i li v vic di chuyn nguyn vt liu trong
mt cell.
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- H thng (System)
+ Cn bng gia ti v dng sn xut
+ m bo vic bo tr thay th trnh vic ngng sn xut
+ To mi quan h i tc vi cc nh cung cp
+ Sn xut theo kiu ko
i vo chi tit, chng ta nn theo cc bc sau :
2.3.1 Chun Ho Quy Trnh
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 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 ISO 9001:2000 v "Kim Sot Sn Xut v Cung Cp Dch V",
c th di hnh thc chun ho cc thao tc v trnh t cng vic cho tng cng
nhn.
Mt t chc cn c cc ti liu sau:
Thng tin v cc c tnh ca sn phm;
Hng dn cng vic ph hp;
Thit b sn xut thch hp;
o lng v gim st thit b v h thng;
Cc quy trnh bao ph t cc hot ng hon tt sn phm, phn
phi v sau phn phi.
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Vic chun ho quy trnh trong Lean bao gm mt s thnh phn chnh:
2.3.1.1 Trnh t cng vic chun
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.
2.3.1.2 Thi gian chun
L tn xut mt sn phm c lm ra. 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, thi gian chun ca mi quy trnh sn xut c ch ng
iu phi v gim st duy tr mt lung sn xut lin tc. Thi gian chun khc
vi thi gian chu k sn xut l thi gian cn quy trnh hon tt mt sn phm.
V d, mt nh sn xut g c th cch 10 pht cho xut xng mt gh
sofa (takt time) nhng thc s h phi mt 3 ngy lm vic hon tt mt gh
sofa (cycle time).
2.3.1.3 Mc tn kho chun trong quy trnh
y l lng nguyn liu ti thiu, bao gm lng nguyn liu ang c
x l trn chuyn, cn c gi mt cell hay quy trnh hot ng cng
mong mun. Mc tn kho chun nn c xc nh r rng v rt cn thit phi
duy tr lng nguyn liu ti thiu ny trong chuyn khng gy ra s nh tr
cho quy trnh do thiu nguyn liu. y l yu t dng tnh ton khi lng v
tn s ca lnh sn xut (hay Kanban) cho cc ngun cung cp t cng on trc.
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tn kho cao gia hai cng on sn xut, cc cng nhn thuc cng on trc s
t cm thy c trch nhim c nhn i vi bt k khuyt tt sn phm no.
2.3.5.4. Phng php Poka Yoke
Phng php n gin kim tra cht lng trn chuyn sn xut (khng
ch kim tra bng mt), c p dng ngn chn cc sn phm li khng cho i
tip sang cng on sau. Vi Poka-Yoke, 100% sn phm c kim tra nh mt
phn cng vic ca quy trnh sn xut. Bin php ny c thc hin t ng trn
chuyn hay bi cc cng nhn (khng phi nhm kim sot cht lng).
2.3.5.5. Dng quy trnh c ch
Khi c sn phm li, hot ng sn xut s b dng cho n khi nguyn
nhn gy li c khc phc. Hnh ng ny gip duy tr vn ho khng nhn
nhng khuyt tt ng thi ngn khng sn phm li lt sang quy trnh sau v
gy nhiu hu qu ln hn. Chng hn Toyota, bt k mt cng nhn no cng
c php dng chuyn sn xut. iu ny gip m bo trch nhim gii trnh
bi cc cng nhn cng on trc.
2.3.6 S Chui Gi Tr
S chui gi tr l tp hp cc phng php gip th hin trc quan
lung sn phm v thng tin qua quy trnh sn xut. Mc ch ca phng php
ny l xc nh cc hot ng lm tng gi tr v cc hot ng khng lm tng gi
tr. S chui gi tr nn phn nh nhng g ang thc s din ra hn l nhng g
c mong mun xy ra nh cc c hi ci tin c th c xc nh.
Thng c s dng trong cc d n ci tin thi gian chu k quy trnh v
n th hin chnh xc cch thc hot ng ca mt quy trnh vi yu cu thi gian
v tng bc cng vic chi tit. Phng php ny cng c dng trong phn tch
v ci tin quy trnh bng cch xc nh v loi tr khong thi gian lin quan n
cc hot ng khng to ra gi tr tng thm.
2.3.7 Phng Php 5S
Phng php 5S bao gm mt s cc hng dn v t chc ni lm vic
nhm sp xp khu vc lm vic ca cng nhn v ti u hiu qu cng vic.
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2.3.7.1. Sng lc
Phn loi nhng g cn thit v nhng g khng cn thit nhng th
thng c cn n lun c sn gn k v tht d tm thy. Nhng mn t khi hay
khng cn dng n nn c chuyn n ni khc hay b i.
2.3.7.2 Sp xp
Sp xp nhng th cn thit theo th t d ly. Mc tiu ca yu cu ny
l gim n mc ti thiu s thao tc m cng nhn thc hin cho mt cng vic.
V d, hp cng c cho cng nhn hay nhn vin bo tr c nhu cu cn s
dng nhiu cng c khc nhau. Trong hp cng c, tng dng c c xp mt
ni c nh ngi s dng c th nhanh chng ly c cng c mnh cn m
khng mt thi gian tm kim. Cch sp xp ny cng c th gip ngi s dng
ngay lp tc bit c dng c no b tht lc.
2.3.7.3. Sch s
Gi cc my mc v khu vc lm vic sch s nhm ngn nga cc vn
pht sinh do v sinh km. Trong mt s ngnh, bi bn l mt trong nhng tc
nhn chnh gy li cho b mt hay nhim bn mu trn sn phm. tng thc
v mc bi bn, mt s cng ty cho sn ni lm vic v thit b vi mu sng
ng thi tng chiu sng ni lm vic.
2.3.7.4. Sn sng v chun ha
a 3 cng vic trn tr thnh vic p dng thng xuyn bng cch quy
nh r cc th tc thc hin cc cng vic sng lc, sp xp v gi sch s.
2.3.7.5. Su st
Khuyn khch, truyn t v hun luyn v 5S bin vic p dng tr
thnh mt phn vn ho ca cng ty. Ngoi ra vic duy tr cng bao gm phn
cng trch nhim cho mt nhm gim st vic tun th cc quy nh v 5S.
2.3.8 Bo Tr Ngn Nga
Bo tr ngn nga l mt lot cc cng vic thng nht, th tc v cc
bc c thc hin nhm xc nh v gii quyt cc vn tim tng trc khi
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chng pht sinh. Lean nhn mnh cng tc bo tr ngn nga cn thit cho vic
gim thiu thi gian dng my do hng hc v thiu ph tng thay th.
Khi tin cy ca thit b cn thp, cc nh sn xut buc phi duy tr mc
tn kho bn thnh phm cao d phng. Tuy nhin, tn kho cao c xem l
ngun chnh yu gy lng ph v sai st trong Lean .
2.3.9 Bo Tr Sn Xut Tng Th
Bo Tr Sn Xut Tng Th (TPM) l phn cng cng vic bo dng c
bn thit b bao gm kim tra, v sinh, bi trn, cn chnh cho cng nhn sn xut
l ngi vn hnh thit b. TPM phn nhim r rng trch nhim cng nhn ch
ng v c trch nhim trong vic xc nh, gim st v khc phc nguyn nhn
gy ra s c ng my khng cn thit. Bng cch phn b trch nhim cho cc
nhn vin vn hnh my, cng tc bo tr v thi gian dng my c gim thiu.
Vic ny cng i hi nhn vin vn hnh my thng xuyn cp nht cho nhm
bo tr bit v tnh trng ca thit b cc vn k thut tim tng sm c
pht hin v ngn nga.
Trong TPM, t bo tr chu trch nhim cho cc hot ng mang li gi tr
tng thm nhiu hn nh l ci thin, i tu v ci tin hiu nng thit b, sa cha
h hng v hun luyn k thut cho nhn vin iu hnh.
2.3.10 Thi Gian Chuyn i / Chun B
Lean nhm ti vic gim thiu thi gian dng chuyn bt hp l do chun
b my hay chuyn i sn phm v my dng l ngun lng ph ng k. Vic ny
i hi mt vn ho lin tc ci tin trong cng ty khng ngng tm cch gim
thi gian chuyn i v chun b my.
Thng vic chuyn i nhanh chng c th t c phn no bng cch
xy dng cc thng s k thut tht chun (v c ti liu ho y ) cho vic
sn xut tng loi sn phm ring bit khng cn s lo ngi v vic iu chnh
li cc thng s trong qu trnh chuyn i sn phm trn thit b. Cc cng ty c
danh mc, mu sc v quy cch sn phm a dng thng xem nh chi ph chuyn
i cho mi ln quy trnh sn xut phi dng li thay khun, lau ra dn dp
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vt liu thuc quy cch trc cn ng li trn my, iu chnh li thng s thit
b.v.v...
C mt s cch gim thiu thi gian chuyn i/chun b bao gm vic
thay i cch sp xp mt bng ca chuyn sn xut, chun b sn sng nguyn
liu v cng c khi cn s dng hay s dng loi thit b c ngn cha i (ph)
nhm trnh thi gian dng thit b lm v sinh.
2.3.11 Gim Thiu Quy M L Sn Xut
Lean nhm ti lung sn phm di chuyn trn chuyn c quy m l cng
nh cng tt, vi iu kin l tng l lung mt sn phm, bn thnh phm
gia cc cng on l ti thiu. Quy m l sn xut cng nh s gip cng on
trc cng c nhiu kh nng sn xut ng nhng g c khch hng yu cu v
ng lc khch hng cn n.
V vy, thay th cho cch t chc vi mt vi chuyn sn xut c quy m
cc l sn phm ln, Lean thng ng h cch t chc nhiu chuyn sn xut c
quy m l nh, vi quy hoch dng t bo l mt hnh thc c trng. Nhng li
ch chnh ca cc chuyn sn xut nh bao gm:
Quy m l nh ng ngha vi t bn thnh phm hn gia cc cng on
sn xut v cho php cng ty hot ng gn vi m hnh quy trnh lin tc;
Nhiu chuyn sn xut c quy m l nh cho php nhiu quy cch sn
phm khc nhau c trin khai ng lot, v vy s gim thiu thi gian
cht gy ra bi vic chuyn i quy cch.
Cc chuyn sn xut nh hn, cn t cng nhn hn, s nng mc trch
nhim ca cng nhn tng chuyn cao hn.
2.3.12 Quy Hoch Mt Bng Xng v Vt T ti Ni S Dng
Lean nhm ti vic gim thiu cc di chuyn v vic vn chuyn sn phm
gia hai cng on sn xut. Tng t, bn thnh phm nn c gi gn k ni
s dng k tip. iu ny gip gim thiu cc yu cu khing vc vt t, vic tht
lc vt t, gim thiu vic vt t b h hng do qu trnh vn chuyn gy ra v i
hi tn trng nguyn tc sn xut theo m hnh pull (li ko).
36
2.3.13 Kanban
"Kanban" l h thng cp y vt t theo m hnh pull s dng cc du
hiu tng hnh, nh cc th treo phn bit bng mu sc, ra hiu cho cc
chuyn pha trc khi chuyn sau cn thm vt t. V tc dng, Kanban l mt
cng c thng tin h tr sn xut theo m hnh pull. Mt Kanban c th l mt
thng rng, mt th treo, bng hin th in t hay bt k hnh thc gi nhc trc
quan no thch hp.
C hai loi Kanban c trng:
2.3.13.1. Kanban Cung Cp
Mt du hiu t khch hng ni b n ngun cung cp ni b cho bit loi
vt t cn c cung cp.
2.3.13.2. Kanban Tiu Th
Mt du hiu t ni cung cp ni b n khch hng ni b cho bit rng
vt t sng sng cho vic s dng. Trong trng hp ny, ni cung cp ni b
s khng sn xut thm cho n khi vic tiu th c thc hin bi khch hng
bn trong.
C nhiu bin th trong h thng Kanban v trong thc t c kh nhiu sch
vit ring v cch p dng Kanban hiu qu nht.
2.3.14 Cn Bng Sn Xut
Cn bng sn xut, hay iu sn xut, nhm ti vic b tr lu lng sn
xut v chng loi sn phm n nh theo thi gian nhm gim thiu s t bin
trong khi lng cng vic. Bt k s thay i no v lng nn c cn bng
chng din ra t t vi cng t s thay i t ngt cng tt. iu ny cho php
cng ty tn dng cng sut sn xut cao hn ng thi gim thiu vic chuyn i
mu m sn phm.
Yu t chnh ca cn bng sn xut l ngi chu trch nhim ra lnh
sn xut cho xng phi c mt h thng t ng iu tit cc n hng khng
c s t bin v khi lng sn xut. H thng ny gip vic phn b thit b v
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con ngi chnh xc v d dng hn. p dng phng php ny, cng ty cn
bit cng sut thc v tc thc hin tng cng on sn xut.
2.3.15 Ngi Gi Nhp
m bo chc nng iu ca lung sn xut lin tc trong lean , mi
cng on cn sn xut vi tc ph hp khng qu nhanh hay qu chm so vi
yu cu ca cng on sau. t c iu ny, cn c mt cng on c
chn lm "ngi gi nhp". Ngi gi nhp to ra nhp sn xut cho ton
chuyn v tc sn xut tng cng on c tng hay gim ph hp vi tc
ca ngi gi nhp.
Trong H Thng Pull Cp y, ngi gi nhp thng l cng on cui
chng hn nh phn rp rp hon chnh. Trong H Thng Pull Sn Xut Theo n
Hng, ngi gi nhp thng l cng on gn ni bt u quy trnh ca chui gi
tr (value stream).
2.3.16 Mc Hu Dng Thit B Ton Phn
Mc Hu Dng Thit B Ton Phn (OEE) l s o kh nng tn dng
cng sut tng ca cc thit b c th. OEE c chia ra hai phn:
Mc hu dng (Availability) - lng thi gian mt thit b c th hot ng
ti a sau khi tr i thi gian dng my bt buc;
Hiu sut thc hin (Performance efficiency) - sn lng thc t ca my
khi hot ng so vi nng sut thit k ti a hay sn lng ti a trong iu kin
hot ng lin tc.
V d, nu mc hu dng l 80% v hiu sut thc hin l 75%, vy OEE
s l:
Mc hu dng x Hiu sut thc hin = OEE
80% x 75% = 60%
(i khi hiu sut cht lng (%yield) cng c bao gm trong cng thc tnh
ny.)
38
Khi phn tch OEE, nhiu cng ty c th ngc nhin khi thy rng cn rt
nhiu kh nng tng sn lng trn tng thit b c th. Chng hn, cng ty c
th gim thiu:
-
nh sn xut km;
-
39
55.0% trin khai hu ht cc ng dng v ch c 5.9% cho bit trin khai lean
ton din.
Mt s bc n gin ban u gm c:
o lng, theo di cng sut v sn lng ca thit b;
Thit lp v ti liu ho cc quy trnh sn xut r rng hn;
Trin khai h thng 5S trong qun l nh xng;
Quy hoch li cch b tr mt bng sn xut.
2.4.3 Bt u vi Quy M Nh
Cc cng ty trin khai lean nn th nghim mt b phn nh trong hot
ng trc khi p dng cho ton b hot ng sn xut, nht l khi chuyn i t
h thng push sang pull v s thay i ny c th gy gin on sn xut.
V d nh, c th th nghim trn mt dy chuyn sn xut hoc mt chui
quy trnh nh v iu ny s gip gim thiu ri ro lm gin on cng vic. Tin
hnh hun luyn nhn vin v cc nguyn tc ca lean, ng thi thuyt phc
nhng ngi khc trong cng ty v li ch ca lean.
2.4.4 Nh Chuyn Vin
Nn s dng dch v t vn t mt chuyn vin v lean hng dn trin
khai h thng lean. c bit s chuyn i t h thng sn xut push sang pull
c th gy gin on sn xut, do qu trnh ny nn c s hng dn ca mt
chuyn vin c nhiu kinh nghim lin quan.
2.4.5 Lp k hoch
Cng ty nn thit lp mt k hoch trin khai chi tit v r rng trc khi
tin hnh chuyn i sang lean.
Chng ta c th s dng hnh v sau thuyt minh :
40
44
Lean ERP
Lp k hoch sn xut da vo s
kt hp cc n t hng thc t v
d bo bn hng
Thi gian lp k hoch v sn xut
c th ngn trong vi tun nhng
cng c th di trong mt nm hoc
hn.
Trung
bnh
thng
vo
khong 12 tun
Sn xut ch da vo n t
hng thc t nhn c
Lp k hoch v iu sn
xut da trn nng lc sn xut
hng ngy v cc n t hng
thc t nhn c
45
v lu v di
chic
Cc sn phm c di chuyn
xuyn sut nh my theo lot vi
nhng nguyn cng ring r c
hon thnh trc khi di chuyn n
nguyn cng tip theo
Do mi nguyn cng c
hon thnh trn mt b phn
n l, mi b phn c di
chuyn n nguyn cng tip
theo trong dng cng vic lin
tc
Yu cu chuyn sn xut phi
xut c ng b ha
Mua sm vt t da vo iu Kanban c s dng xc
sn xut d bo thng qua h nh nhu cu mua vt t v ph
thng ERP truyn thng
tng
47
49
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.
3.1.2 Cng ty Bao B ng Nam Vit
Cng ty TNHH Bao b ng Nam Vit l cng ty con ca cng ty Liksin,
c thnh lp vo nm 2003 vi nh my t ti tnh Bnh Dng.
Lnh vc hot ng l sn xut thng carton 3 v 5 lp cht lng cao, in
nhiu mu, phc v cho nhu cu trong nc v xut khu, c bit l cc thng
carton in offset vi cht lng cao. Cng ty c cp giy chng nhn ISO
9001:2000 thng 2 nm 2006, Cng ty tin hnh cc hot ng nhm nng cao
hiu qu trong cng tc qun l nhm gim gi thnh, a n bn hng nhng sn
phm cht lng tha mn yu cu. tin hnh hot ng 5S, thc hin p dng sn
xut tinh gn (LEAN),v tin ti thc hin ISO 22.000 tch hp gia phin bn
ISO 9001:2008 v ISO 14.000.
Cng ty lm cc thnh vin trong Hip hi Bao b Vit Nam (Vinpas)
bt ng khi trin khai thnh cng 5S, ng thi tr thnh n v u tin ca
Vinpas p dng th im thnh cng h thng sn xut tinh gn (Lean ) vo thng
4/2009. Mc tiu ca vic p dng ny l tng nng sut lao ng 8-10%, gim tn
kho 30%, xy dng h thng qun l theo 5S v qun l trc quan.
C s l lun ca Lean ti cng ty ng Nam Vit
Ban u, nh my, kho xng u c sp xp thong ng, mi trng
lm vic sch s, ngn np, tm l ca cn b cng nhn lm vic thoi mi hn
trc, nng sut tng ln.
K tip, lnh o cng ty c mt s thnh vin ban gim c tham gia
ban d n sn xut tinh gin, ng thi tham gia kha hun luyn hai ngy mi
tun vi nhn vin, trng cc b phn. b sung cho phn l thuyt hc c,
ban d n cn quay phim, chp nh quy trnh lm vic trc v sau khi vn dng
sn xut tinh gin. Hng tun, ban u c bui hp v Lean rt kinh nghim
50
51
53
55
3.3.5 S dng cm
Qu trnh ng dng Lean l qu trnh chuyn i cch lm truyn thng
sang cch lm chuyn nghip, khoa hc v quan trng nht l hnh thnh mt vn
ha t chc mi. l qu trnh ny sinh nhng th thch v kh khn i hi s
dng cm rt ln ca Ban lnh o t chc.
Dng cm loi b nhng c nhn, tp th d l nhng con ngi ti nng
v c v tr quan trng trong t chc khi h nht nh khng theo ch trng Ban
lnh o t ra.
Dng cm i mt vi nhng thch thc xy ra trong qu trnh chuyn i
(thng gp trong giai on u ca qu trnh ng dng) c th nh hng n li
nhun ca t chc. Chng hn nh s chuyn i quy trnh, cch thc lm vic,
sp xp b tr li my mc thit b, nh xng. thm ch l i ng i kim tra
cht lng.
3.3.6 S cng quyt
Trong thc hin Lean, tm nh hng ca Ban lnh o i vi ton th
cn b cng nhn vin l rt quan trng, l nhng ngi ng vai tr u tu trong
sut con ng i. Ban lnh o phi lun thng nht v cng quyt trong mi
hnh ng thc hin Lean, iu cho mi ngi thy c quyt tm ca Ban
lnh o. Khng ch mt th h m qua nhiu th h, iu phi lun c duy
tr thc hin.
3.3.7 S kin tr
xy dng mt h thng sn xut Lean hiu qu trong ton t chc, i
hi s kin tr thc hin rt ln. Ban lnh o phi kin tr thc y cc hot ng
ng dng Lean lun c thc hin mt cch lin tc, ngay c khi c kh khn.
Kinh nghim cho thy, s ng dng Lean mt cch mit mi, khng b gin
on s to nh hng rt ln n tp th ngi lao ng. H thy c s chuyn
i v quyt tm ca nhng ngi lnh o. S khng lin tc trong qu trnh ng
dng s lm chm tin trnh v ngi lao ng nhanh chng qun i nhng g
va mi chuyn vo trong tm tr h.
56
57
CHNG 4 : KT LUN
c th a cc nh sn xut Vit Nam ngang tm vi cc nh sn xut
khc trn th gii, chng ta cn phi p dng nhng dy chuyn sn xut hin i.
Bn cnh , vn qun l cht lng cng mt h thng sn xut tinh gn l
vn rt ng c quan tm. H thng sn xut Lean v ang c p dng
rng ri trn ton th gii nhng thp nin va qua. Cc doanh nghip Vit Nam
c th tin hnh hc hi v p dng vo doanh nghip mnh nhm to ra c mt
li th cnh tranh cng nh chin lc kinh doanh ng n cho doanh nghip
mnh.
iu quan trng nht by gi l cn phi c mt i ng t vn trnh
v kinh nghim thc t, am hiu vn ha v ngn ng Vit Nam, nhm gip
nh hng cho cc doanh nghip trong nc tip cn theo mt l trnh bi bn v
chnh thng khi trin khai p dng Lean. ng thi cn truyn b v thng t
tng cho cc doanh nghip gip cc lnh o doanh nghip bit c tm quan
trng ca vic trin khai p dng Lean v hiu qu li ch tht s t vic ny.
58
http://www.diendanquantri.com/quantri,1,698,print.htm
Qun Tr iu Hnh i Hc Kinh T TPHCM TS. H Tin Dng
http://www.sangtaotre.com/tintucDetail.asp?catID=16&newsID=97
http://www.nangsuatchatluong.vn/nang-suat-chat-luong/16-trien-khailean.html
5. http://www.dongnamvietpackaging.vn
6. www.samco.com.vn
7. www.leansigmavn.com
8. http://thuvien-ebook.com/forums/showthread.php?t=1479
9. www.cis.tennessee.edu/library/pdf/2009_Lean.pdf
10. www.leanconstruction.org/lcj/V2_N2/LCJ_05_011.pdf
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