Qun tr sn xut tinh gn

Lean Manufacturing
Lean Manufacturing (tm dch l Sn Xut Tinh Gn) l mt nhm phng
php, hin ang c p dng ngy cng rng ri trn khp th gii, nhm loi b
lng ph v nhng bt hp l trong quy trnh sn xut, c chi ph thp hn v
tnh cnh tranh cao hn cho nh sn xut.

Bo co ny, do Mekong Capital son, l ti liu gii thiu khi qut v

Lean Manufacturing (cn c gi ngn gn l lean). Trong mt thm d gn
y c ng trn IndustryWeek, c khong 36% cc doanh nghip sn xut
M trin khai hay ang trong qu trnh trin khai lean. Mt s thay i do Lean
Manufacturing t ra c th gy gin on hot ng sn xut nu khng p dng
ng, ng thi mt vi phng din ca Lean Manufacturing khng th p dng
cho mi cng ty.

1.1 Mc Tiu ca Lean Manufacturing:Lean Manufacturing, cn gi l

Lean Production, l mt h thng cc cng c v phng php nhm lin tc loi
b tt c nhng lng ph trong qu trnh sn xut. Li ch chnh ca h thng ny

l gim chi ph sn xut, tng sn lng, v rt ngn thi gian sn xut. C th

hn, cc mc tiu bao gm:
1. Ph phm v s lng ph Gim ph phm v cc lng ph hu hnh
khng cn thit, bao gm s dng vt nh mc nguyn vt liu u vo, ph
phm c th ngn nga, chi ph lin quan n ti ch ph phm, v cc tnh nng
trn sn phm vn khng c khch hng yu cu;
2. Chu k sn xut - Gim thi gian quy trnh v chu k sn xut bng cch
gim thiu thi gian ch i gia cc cng on, cng nh thi gian chun b cho
quy trnh v thi gian chuyn i mu m hay quy cch sn phm;
3. Mc tn kho Gim thiu mc hng tn kho tt c cng on sn xut,
nht l sn phm d dang gia cc cng on. Mc tn kho thp hn ng ngha
vi yu cu vn lu ng t hn;

4. Nng sut lao ng Ci thin nng sut lao ng, bng cch va gim
thi gian nhn ri ca cng nhn, ng thi phi m bo cng nhn t nng sut
cao nht trong thi gian lm vic (khng thc hin nhng cng vic hay thao tc
khng cn thit);
5. Tn dng thit b v mt bng S dng thit b v mt bng sn xut
hiu qu hn bng cch loi b cc trng hp n tc v gia tng ti a hiu sut
sn xut trn cc thit b hin c, ng thi gim thiu thi gian dng my;

6. Tnh linh ng C kh nng sn xut nhiu loi sn phm khc nhau

mt cch linh ng hn vi chi ph v thi gian chuyn i thp nht.
7. Sn lng Nu c th gim chu k sn xut, tng nng sut lao ng,
gim thiu n tc v thi gian dng my, cng ty c th gia tng sn lng mt
cch ng k t c s vt cht hin c.

Hu ht cc li ch trn u dn n vic gim gi thnh sn xut v d

nh, vic s dng thit b v mt bng hiu qu hn dn n chi ph khu hao trn
n v sn phm s thp hn, s dng lao ng hiu qu hn s dn n chi ph
nhn cng cho mi n v sn phm thp hn v mc ph phm thp hn s lm
gim gi vn hng bn.

Trong mt bi iu tra ca tp ch Industry Week, cc cng ty M ang

trin khai lean manufacturing cho bit trung bnh c th gim 7% gi vn hng
bn nh p dng Lean. Chng ti tin rng mc tit kim chi ph cn c th cao
hn cho cc cng ty Vit Nam v mc lng ph y thng cao hn cc nh
sn xut M.

Mt cch hiu khc v Lean Manufacturing l vic nhm n mc tiu:

vi cng mt mc sn lng u ra nhng c lng u vo thp hn t thi
gian hn, t mt bng hn, t nhn cng hn, t my mc hn, t vt liu hn v t
chi ph hn.

Khi cng ty Lantech, mt cng ty sn xut thit b ca M hon tt vic

trin khai Lean nm 1995, cng ty cho bit t c cc ci tin sau so vi h
thng sn xut theo l sn phm trong nm 1991 (theo James Womack, Daniel
Jones & Daniel Roos: The Machine that Changed the World):
Mt bng sn xut trn mi my gim 45%;

Ph phm gim 90%;

Chu k sn xut gim t 16 tun xung cn 5 ngy 14 gi; v

Thi gian giao hng gim t 4-20 tun xung cn 1-4 tun.

Cc khi nim ca Lean Manufacturing

Cc Khi Nim

Trnh by mt s khi nim trong Lean Manufacturing nh vic to

gi tr v s lng ph, h thng sn xut pull, mc tn kho, quy trnh lin tc
v khng lin tc, ci tin lin tc, quy hoch dng t bo (cellular layout),
Lean p dng trong qun l hnh chnh.

2.1 Vic To Ra Gi Tr v S Lng Ph:Trong Lean Manufacturing, gi

tr ca mt sn phm c xc nh hon ton da trn nhng g khch hng tht
s yu cu v sn lng tr tin c c. Cc hot ng sn xut c th c
chia thnh ba nhm sau y:
- Cc hot ng to ra gi tr tng thm (Value-added activities) l cc
hot ng chuyn ho vt t tr thnh ng sn phm m khch hng yu cu.
- Cc hot ng khng to ra gi tr tng thm (Non value-added activities)
l cc hot ng khng cn thit cho vic chuyn ho vt t thnh sn phm m
khch hng yu cu. Bt k nhng g khng to ra gi tr tng thm c th c
nh ngha l lng ph. Nhng g lm tng thm thi gian, cng sc hay chi ph
khng cn thit u c xem l khng to ra gi tr tng thm. Mt cch nhn
khc v s lng ph l bt k vt t hay hot ng m khch hng khng sn
lng tr tin mua. Th nghim v kim tra nguyn vt liu cng c xem l lng
ph v chng c th c loi tr trong trng hp quy trnh sn xut c ci
thin loi b cc khuyt tt. Vui lng tham kho thm phn 2.2 lin quan n
cc loi lng ph.
- Cc hot ng cn thit nhng khng to ra gi tr tng thm (Necessary
non value-added activities) l cc hot ng khng to ra gi tr tng thm t quan
im ca khch hng nhng li cn thit trong vic sn xut ra sn phm nu
khng c s thay i ng k no t quy trnh cung cp hay sn xut trong hin

ti. Dng lng ph ny c th c loi tr v lu di ch khng th thay i trong

ngn hn. Chng hn nh mc tn kho cao c yu cu dng lm kho m d
phng c th dn dn c gim thiu khi hot ng sn xut tr nn n nh hn.

Theo nghin cu ca Trung Tm Nghin Cu Doanh Nghip Lean (Lean

Enterprise Research Centre) ti Anh Quc (Going Lean Peter Hines & David
Taylor 1.2000) cho thy trong mt cng ty sn xut c trng th t l gia cc
hot ng c th c chia ra nh sau:

- Hot ng to ra gi tr tng thm 5%

- Hot ng khng to ra gi tr tng thm 60%

- Hot ng cn thit nhng khng to ra gi tr tng thm 35%

- Tng cc hot ng 100%

Nghin cu ny ch ra rng c n 60% cc hot ng ti mt cng ty sn
xut c trng c kh nng c loi b.