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activitate care nu creează valoare adăugată. În gemba sunt exercitate două tipuri de
activităţi: cele care creează valoare adăugată şi cele care nu creează. Munca se
analizează într-o serie de procese sau etape care încep cu materiile prime şi se termină
cu produsul final sau serviciul final. În fiecare proces, o valoare este adăugată la piesa
la care se lucrează apoi se trece la procesul următor. În fiecare proces, resursele -
personal, maşini, materii - creează sau nu o valoare adăugată. MUDA se raportează
activităţilor care nu creează deloc valoare adăugată. Taichi Ohno clasifică MUDA în
şapte categorii: 1. Muda în supraproducţie; 2. Muda stocajului; 3. Muda în
reparaţii/revizii; 4. Muda în deplasări; 5. Muda în prelucrare; 6. Muda în aşteptări; 7.
Muda în transport. Muda, mura, muri Cuvintele muda, mura şi muri sunt adesea
utilizabile împreună. Sunt desemnate în Japonia prin abrevierea cei "3M". Aşa cum
mura ţine loc de avertisment comod pentru a demara Kaizen, cuvântele muri şi mura
sunt utilizate ca mod de gândire practic pentru a demara Kaizen în Gemba. Muri
înseamnă munca ce solicită un efort prea mare şi mura înseamnă iregularităţi. Tot ceea
ce este iregularitate cere un efort prea mare, indică existenţa unei probleme. În altă
ordine de idei muri şi mura contribuie la muda şi trebuie eliminate. LEAN
MANAGEMENT Lean Thinking/Management nu este o invenţie de origine japoneză.
Lean Thinking s-a dezvoltat în Japonia plecând de la schimbarea logică a tuturor
metodelor de producţie şi de marketing avansate de industria occidentală de
avangardă. Conceptul a demarat într-o perioadă de depresie economică. Severele
restricţii de credit au limitat capitalurile disponibile. La baza Lean Thinking se află
parteneriatul. A învăţa şi a schimba în permanenţă încep prin voinţa unui parteneriat
între conducători şi colaboratori, clienţi, furnizori şi parteneri, aceasta este ceea ce
prescrie lean management. Lean Management este în măsură să dubleze
productivitatea, să amelioreze în mod considerabil calitatea şi în acelaşi timp să
crească sensibil flexibilitatea fabricaţiei. Exemple cunoscute în Europa, Statele Unite şi
Japonia arată acest lucru foarte clar. Lean Thinking este un sistem global complex şi
compact, eficace doar în totalitatea sa. Experienţa arată că aplicarea izolată a
diverselor strategii şi metode cum ar fi just-in-time (JIT), calitatea totală, muncă în
grupuri, etc. nu conduce la ameliorarea productivităţii şi la „rafina
MUDA : orice activitate din procesul dvs. care nu adaugă valoare. MUDA nu creează valoare pentru
client. Pe scurt: WASTE
Type I muda: Sarcini fără valoare adăugată, care se dovedesc a fi esențiale. Condițiile de afaceri trebuie
schimbate pentru a elimina acest tip de deșeuri.
Tip II muda: sarcini fără valoare adăugată care pot fi eliminate imediat.
Ce este "Mura"?
MURA : Orice variație care duce la situații dezechilibrate. Pe scurt: UNEVENNESS , inconsecvent,
neregulat.
Mura există atunci când fluxul de lucru este în afara echilibrului și volumul de muncă este inconsistent și
nu este incompatibil cu standardul.
De obicei, cei trei nu pot fi văzuți separați. Atunci când un proces nu este echilibrat (mura), aceasta duce
la o supraîncărcare a echipamentelor, a instalațiilor și a oamenilor (muri), care va cauza tot felul de
activități care nu au valoare adăugată (așteptarea este de asemenea o activitate!), Ducând astfel la
muda.
Pentru a elimina componentele MURA și MURI, trebuie analizate mai multe părți ale sistemului, nu doar
un pas sau o operațiune de proces sau proces, ci un întreg Value Stream. Makigami, VSM sau "Process
Kaizen" elimină MUDA.
Peter Schilling sugerează:
Mura și Muri sunt, de cele mai multe ori, principalele cauze ale lui Muda
Muda, de asemenea, rădăcini în sine.
Muri și Mura de asemenea.
Muda tip II este ușor de eliminat și oferă rezultate rapide .... dar pentru cât timp?
Asa de:
Luați o privire atentă la Mura și la Muri, pe măsură ce începeți să vă luptați cu Muda.
Întrebați de ce ar trebui să existe mai multe variante în activitățile dvs., apoi solicitate de
comportamentul clienților.
Apoi, întrebați modul în care variația reală a cererii clienților rămase poate fi netezită intern pentru a vă
stabiliza operațiunile.
În cele din urmă, întrebați cum suprasolicită echipamentul dvs., iar oamenii - din orice cauză - pot fi
eliminați în mod constant.
Aceasta va fi o muncă grea și va necesita curaj, deoarece uneori va cere să re-gândiți la practicile de
vânzări, gestionare și contabilitate de lungă durată care creează Mura și Muri.
Cu toate acestea, dacă puteți elimina Mura și Muri la contur pentru a crea un mediu stabil pentru
echipele de vânzări, operațiuni și de gestionare a aprovizionării, veți descoperi că Muda poate fi
îndepărtat mult mai repede.
Odată eliminată, va rămâne eliminată.
Muda eliminat doar având în vedere că MUDA înseamnă că MUDA se poate întoarce ca un lunetist.
Acesta este un motiv pentru a implementa OEE și chiar TPM înainte de a încerca să creeze flux prin
inițiative slabe.
De ce? Ei bine, cum puteți crea flux (= elimina muda) când performanța mașinii este instabilă?
Deci:
TPM este instrumentul dvs. de bază pentru reducerea Muda.
Six Sigma este setul tău de instrumente Mura (variabilitate).
http://www.makigami.info/forum/index.php?topic=2.0
3m method
Manufacturing Supermarket
A replenishment process which ensures that all manufacturing components ordered from outside
suppliers are available to be loaded and delivered in one consignment. Derived from the system used by
retail supermarkets, it levels the occasional spikes in demand experienced in individual factories by
requiring suppliers to smoothly and systematically gather unusually large orders to a separate holding
area, or ‘virtual truck’, ahead of the regular loading schedule. This process avoids any disruption to the
tempo of deliveries and last-minute rushing around to complete an order.
Muda (English: Waste): In management terms, refers to a wide range of non-value-adding activities. For
example, anything an operator has to do within a process which does not add value but does add cost.
Eliminating waste is one of the main principles of the Just-In-Time system. Waste incurs unnecessary
finance costs and storage costs.
The first of three types of waste mentioned within the Toyota Production System (the others being
Mura and Muri), the identification and reduction of which will reduce the unnecessary consumption of
resources and increase profitability. Toyota divides Muda into seven resources that are frequently
wasted: 1) Transportation — a cost that adds no value to the product but increases the risk of a product
being damaged, lost or delayed; 2) Inventory — a capital outlay that if not processed immediately
produces no income; 3) Motion — any damage inflicted through the production process, such as normal
wear and tear in equipment, repetitive stress injuries, or by unforeseen accidents; 4) Waiting —
products that are not in transport or being processed; 5) Over-processing — when more work is done
than necessary, or when tools are more complex, precise or expensive than necessary; 6) Over-
production — larger batches or more products being made than is required; and 7) Defects — the loss
involved in rectifying faulty parts or products.
The second of three types of waste mentioned within the Toyota Production System, notably identified
and leveled through the application of Heijunka principles and Kanban devices. Workflow is also
smoothed by requiring members to operate multiple machines — also known as ‘multi-process
handling’ — within any particular process, and by predicting and preparing for times of high demand.
Muri (English: Overburden): Eliminating overburden of equipment and people is one of the main
principles of the Just-In-Time system, the main pillar of the Toyota Production System. To avoid
overburden, production is evenly distributed in assembly processes.
The third of three types of waste highlighted within the Toyota Production System, requiring the
balancing of manufacturing pace to allow members sufficient time to achieve the correct standard of
work. A reduced time frame will be too burdensome to achieve the objective, while the allowing of too
much time is a waste of resource. (Related: Takt Time [derived from German word Taktzeit, or ‘cycle
time’] — matching the pace of production with customer demand and the available work time).
http://blog.toyota.co.uk/toyota-production-system-glossary
Why do many enterprises attempting to employ a lean transformation fall at the first hurdle?
Frustratingly, they often put in the hard yards but still fail.
They ensure that the basic building blocks are in place. They take great care to listen to the customers,
so that they have an in-depth understanding of what exactly it is that they value. They define the many
different processes within their organisational structures. And of course they’ve tackled waste too –
both internally and externally. But have they? And do they truly understand waste?
An enterprise may have focused on Muda, for example, but has it also taken the time to grapple with
the other two key areas of the Toyota Production System – Muri and Mura?
According to Peter Hines, the Director of the Lean Enterprise and Research Centre (LERC), an enterprise
needs to pay close attention to Muda, Muri and Mura if it wants its Lean implementation to be
successful. [i]
Muda
When the late Shigeo Shingo, one of the leading exponents of the Toyota Production System, defined
waste, he began by defining Muda. Therefore, Muda, which the Toyota Production System defines as ‘a
wide range of non-value adding activities’ – is the first place most enterprises start their lean
transformation. [ii]
Mura
Mura translates as unevenness or irregularity. On a busy automotive factory floor for instance this might
mean workers on the assembly line working flat out in the morning to produce certain car parts, only to
become inactive in the afternoon. This uneven cycle of work is caused by uneven processes in the
facility. Unevenness often can be eliminated by level scheduling and careful attention to the pace of
work.
Muri
Muri refers to the overburdening of factory operators by requiring them to operate at higher pace than
equipment designs and workforce management allow.
Reducing waste by Muda
Conveniently for those companies, Shingo identified and wrote a list of seven types of Muda, which
provided them with an almost ready-made blueprint for action. Shingo categorised the seven wastes as
follows: [iii]
Sources
[i] Staying Lean: Thriving, not just surviving
By Peter Hines, Pauline Found, Gary Griffiths and Richard Harrison
It is hard to see how this factory would ever be productive with this much waste.
The definition of Lean is to reduce waste. Here we will look at the THREE types of waste the may occur
in a process. We will explore the “7 wastes”, often referred to as Muda, and update our understanding
of the other two, lesser know wastes Mura – the waste of unevenness, and Muri – the waste of
overburden. These two wastes are often overlooked at we journey along the Lean path.
As you look into Lean, you come across the 7 wastes (or the 8 wastes, depending on which “Lean
school” you went to!). Developing a “Waste elimination culture” is a key aspect of Lean. However the
Toyota Production System, which is the foundation for all modern lean methodology, also talks about
the additional wastes of unevenness and overburden; while there are not mentioned very often, they go
a long way to explaining what is going on in today’s busy company.
THE 7 WASTES (MUDA)
When we talk about waste in a Lean sense, we are referring to the activities we do each day that our
customer doesn’t pay us for, not just the waste that ends up in the bin. In summary the seven categories
for the waste are:
Transport is the excessive movement of components and materials from one location to another,
without adding value
Inventory is the cost of having finished components, work in progress and raw materials and
consumables within your factory walls. While a level of inventory is necessary to keep your factory
running smoothly, it is still money spent and needs to be viewed as such.
Motion outlines the mini movement of people and components within a manufacturing cell or factory;
not to be confused with transport, which is defined as the larger scale movement.
Waiting is often the unseen waste, as it is disguised in many ways; waiting includes for information and
instruction, as well as not having the parts, tooling or machine available when needed
Over production is another waste hidden as using our time well in the factory; we often see companies
making stock to keep our people “busy”. It needs to be managed carefully as it masks the uses of
resources as something productive when it may be just wasteful.
Over processing is another activity hard to identify in a high quality organisation but it does show itself
through value stream mapping and involving our teams to question everything they do
Defects and rework are obvious wastes in manufacturing but often seen as acceptable waste due to
poor quality and processes; holding your company the right level of quality can go a long way to
improving overall quality and eliminating this obvious waste.
THE WASTE OF UNEVENNESS (MURA)
The waste of unevenness can often been seen through the fluctuation in schedule and demand on our
people, particularly for seasonally influenced industries, like food manufacturing, and seasonal
variations, like Christmas and the End of the financial year, or even at the end of the sales month.
While we understand the concept as we experience it on a regular basis, there are few key strategies as
to how we tackle this in an agile manufacturing environment. Here are three concepts to help reduce
the waste of unevenness:
1. BUFFER FLOW WITH INTERNAL SUPERMARKETS
Determine where in your process it makes sense to hold work in progress and design your systems
around these points. You must consider the risks when making only to stock. Reducing lead times makes
making to order a preferred option, depends on your industry and customer expectations.
2. REVIEW DATA TO PREDICT DEMAND
Can we see patterns from previous years to determine how we can smooth out the low times by making
ahead to soften the busy times? Use this time for improvements and trials. Understand the real costs of
your boom and bust cycles.
3. ISOLATE YOUR FACTORY FROM CUSTOMER DEMANDS
Consider how you can balance the efficiency of your factory while still providing your customer a quality
product, at a good price and a great lead-time. Particularly in make to order businesses, with little order
cancellation, having the factory removed from customer installation demands can help improve the
efficiency of the factory, as you know the product will still be needed and paid for, but just not when
you initially expected it to.
THE WASTE OF OVERBURDEN (MURI)
While overburden is the least discussed of the three wastes, at TXM we believe it is the greatest
challenge in current times. Everywhere we go we are feeling busier, trying to do more with less. While
people can sustain this for a short time when there is a true crisis, we find companies are permanently
working at the old “crisis” level and it’s just not sustainable.
Before your factory or office process can begin to remove overburden, it is important to create a stable
work platform. The stable platform needs Work Standards which form the base of your defined
processes. Once these standard are set in place, they can be trained to, audited to and maintained over
time. Improving stability across staffing levels, equipment utiitstation (OEE) and reliability, material
quality and supply is essential for identifying and removing the waste from any workplace
Your team must also be realistic with scheduling and planning resources. Allow for rework, training and
absenteeism across your plan. There is no point having a work plan and “hoping” all of your team is
always there and on their best game. Create a system that is designed to succeed, and robust enough to
do so,most of the time.
IN CONCLUSION
Fujio Cho, Vice Chairman of Toyota Motor Corporation, describes the use of lean tools and lean
management as “We get brilliant results from average people managing brilliant processes. We observe
that our competition often gets average (or worse) results from brilliant people managing broken
processes.”
So start to fix your broken processes and let your people do their best. By taking the time to investigate
the wastes, evenness and overburden in your business you will be able to create stability and reduce
waste,
http://txm.com.au/blog/understanding-wastes-muda-mura-muri
Waste reduction by Muda, Mura and Muri
http://leanmanufacturingtools.org/71/muda-mura-and-muri-lean-manufacturing-wastes/