Mekong Capital

Gii Thiu v Lean Manufacturing cho cc Doanh Nghip Vit Nam

04.06.2004 Lu : Bo co ny, do Mekong Capital son, l ti liu gii thiu khi qut v Lean Manufacturing (cn c gi ngn gn l lean). 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. Trong mt thm d gn y, c khong 36% cc doanh nghip sn xut M trin khai hay ang trong qu trnh trin khai lean1. 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. 1.1 1.2 1.3 1.4 1.5 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 3. 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 4. 4.1 4.2 4.3 4.4 4.5 5. 5.1 5.2 5.3 5.4
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Lean Manufacturing l g? .................................................................................................... 2 Mc Tiu ca Lean Manufacturing ............................................................................................ 2 Cc Nguyn Tc Chnh ca Lean Manufacturing ......................................................................... 3 Lch S ca Lean Manufacturing .............................................................................................. 3 Trng Tm ca Lean Manufacturing ......................................................................................... 3 Nhng Doanh Nghip no s c Li t Lean Manufacturing? .................................................... 4 Cc Khi Nim trong Lean Manufacturing ............................................................................ 5 Vic To Ra Gi Tr v S Lng Ph .......................................................................................... 5 Nhng Loi Lng Ph Chnh ..................................................................................................... 5 Sn Xut Pull (Li Ko) .......................................................................................................... 6 Cc M Hnh Khc Nhau ca H Thng Sn Xut Pull .................................................................. 7 V Sao Mc Tn Kho Cao Lm Tng Ph Phm v Lng Ph .......................................................... 8 Tc ng ca H Thng Pull i vi Vic Hoch nh Sn Xut .................................................... 8 Quy Trnh Lin Tc ................................................................................................................ 8 Phi Hp Quy Trnh Lin Tc v Khng Lin Tc......................................................................... 9 Ci Tin Lin Tc/ Kaizen ....................................................................................................... 9 S Tham Gia ca Cng Nhn .................................................................................................10 Quy Hoch M Phng Dng T Bo (Cellular Layout) .................................................................10 Administrative Lean (Lean cho Cng Tc Hnh Chnh) ..............................................................11 Cng C & Phng Php trong Lean Manufacturing ........................................................... 12 Chun Ho Quy Trnh (Standard Work) ...................................................................................12 Truyn t Quy Trnh Chun cho Nhn Vin.............................................................................12 Quy Trnh Chun v S Linh Hot...........................................................................................13 Qun L bng Cng C Trc Quan (Visual Management)............................................................13 Cht Lng t Gc (hay Lm ng ngay t u) ...................................................................13 S Chui Gi Tr (Value Stream Mapping) ...........................................................................14 Phng Php 5S ..................................................................................................................14 Bo Tr Ngn Nga (Preventative Maintenance) ........................................................................15 Bo Tr Sn Xut Tng Th (Total Productive Maintenance) ........................................................15 Thi Gian Chuyn i/Chun B (Changeover/setup time) ..........................................................15 Gim Thiu Quy M L Sn Xut ............................................................................................15 Quy Hoch Mt Bng Xng v Vt T ti Ni S Dng .............................................................16 Kanban ..............................................................................................................................16 Cn Bng Sn Xut ..............................................................................................................16 Ngi Gi Nhp (Pacemaker)..................................................................................................16 Mc Hu Dng Thit B Ton Phn (Overall Equipment Effectiveness) ..........................................17 Trin Khai Lean .................................................................................................................. 18 S Tham Gia ca Lnh o Cp Cao .......................................................................................18 Bt u bng Vic Trin Khai Lean Tng Phn..........................................................................18 Bt u vi Quy M Nh .......................................................................................................18 Nh Chuyn Vin .................................................................................................................18 Lp k hoch.......................................................................................................................18 Kt Hp Lean vi Cc H Thng Khc ................................................................................. 19 H Thng Sn Xut Toyota ....................................................................................................19 Lean Six Sigma....................................................................................................................19 Lean v ERP ........................................................................................................................19 Lean v ISO9001:2000 .........................................................................................................20

http://www.industryweek.com/CurrentArticles/asp/articles.asp?ArticleID=1589 Trang 1 trn 20

Mekong Capital Gii Thiu v Lean Manufacturing

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1.1

Lean Manufacturing l g?
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; 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; 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; 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); 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; 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. 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.

Mc Tiu ca Lean Manufacturing

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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 Lean2. 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 19913: 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.

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http://www.industryweek.com/CurrentArticles/asp/articles.asp?ArticleID=1589 James P. Womack & Daniel T. Jones: Lean Thinking (T Duy Lean). Simon & Schuster, 1996. trang 121. Trang 2 trn 20

Mekong Capital Gii Thiu v Lean Manufacturing

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1.2
Cc nguyn tc chnh trong Lean Manufacturing c th c tm tt nh sau: 1. Nhn thc v s lng ph Bc u tin l nhn thc v nhng g c v nhng g khng lm tng thm gi tr t gc khch hng4. Bt k vt liu, quy trnh hay tnh nng no khng to thm gi tr theo quan im ca khch hng c xem l tha v nn loi b. V d nh vic vn chuyn vt liu gia cc phn xng l lng ph v c kh nng c loi b. Chun ho quy trnh Lean i hi vic trin khai cc hng dn chi tit cho sn xut, gi l Quy Trnh Chun, trong ghi r ni dung, trnh t, thi gian v kt qu cho tt cc thao tc do cng nhn thc hin. iu ny gip loi b s khc bit trong cch cc cng nhn thc hin cng vic. Quy trnh lin tc Lean thng nhm ti vic trin khai mt quy trnh sn xut lin tc, khng b n tc, gin on, i vng li, tr v hay phi ch i. Khi c trin khai thnh cng, thi gian chu k sn xut s c gim n 90%. Sn xut Pull Cn c gi l Just-in-Time (JIT), sn xut Pull ch trng ch sn xut nhng g cn v vo lc cn n. Sn xut c din ra di tc ng ca cc cng on sau, nn mi phn xng ch sn xut theo yu cu ca cng on k tip. Cht lng t gc Lean nhm ti vic loi tr ph phm t gc v vic kim sot cht lng c thc hin bi cc cng nhn nh mt phn cng vic trong quy trnh sn xut. Lin tc ci tin Lean i hi s c gng t n s hon thin bng cch khng ngng loi b nhng lng ph khi pht hin ra chng. iu ny cng i hi s tham gia tch cc ca cng nhn trong qu trnh ci tin lin tc.

Cc Nguyn Tc Chnh ca Lean Manufacturing

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Nhiu khi nim v Lean Manufacturing 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-InTime (JIT)5. 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 Manufacturing. Cm t Lean Manufacturing hay Lean Production xut hin ln u tin trong quyn C my lm thay i Th gii (The Machine that Changed the World)6 xut bn nm 1990. Lean Manufacturing 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 Manufacturing 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 .

Lch S ca Lean Manufacturing

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Trng Tm ca Lean Manufacturing

nh hng Hoch nh Quy m mi l Kim sot cht lng Hng tn kho Sn xut hng lot Theo nh cung cp Cc n hng c a ti nh my da trn hoch nh/d bo sn xut Ln Nhn vin kim sot cht lng kim tra ly mu ngu nhin Tp hp sn phm d dang gia cc cng on sn xut Lean Manufacturing Theo khch hng Cc n hng n vi nh my da trn yu cu khch hng hay nhu cu ca cng on k tip Nh Cng nhn kim tra trn chuyn Khng c hoc rt t sn phm d dang gia cc cng on sn xut

Lu : Trong bo co ny, thut ng khch hng ch c khch hng bn ngoi cng ty mua thnh phm cng nh khch hng ni b chng hn nh cng on sn xut k tip nhn bn thnh phm. Tng t, thut ng nh cung cp ch c cc cng ty bn ngoi cung cp nguyn vt liu hay dch v cng nh nh cung cp ni b l cng on trc trong quy trnh sn xut. 5 http://www.factorylogic.com/glossary_11.asp
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James Womack, Daniel Jones and Daniel Roos: The Machine that Changed the World. Simon & Schuster, 1992. Trang 3 trn 20

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Bn giao sn phm d dang Thi gian chu k Vt liu sau mi khu c tp trung vo kho bn thnh phm trc khi c a vo khu k tip Chu k sn xut s mt nhiu thi gian hn thi gian tht s dnh cho vic x l vt liu. Vt liu c bn giao trc tip t mi khu cho khu k tip Chu k sn xut c rt ngn gn bng thi gian dnh cho vic x l vt liu.

1.5

Lean Manufacturing 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 l. Vi c th ny, c mt s ngnh c th bao gm x l g, may mc, lp rp xe, lp rp in t v sn xut thit b. V Lean Manufacturing loi b nhiu vn lin quan n lch sn xut v cn bng chuyn km nn Lean Manufacturing c bit thch hp cho cc cng ty cha c h thng Hoch nh Ngun lc Doanh nghip (ERP) hoc cha c h thng hoch nh yu cu vt t (MRP), lch sn xut hay iu phi sn xut. iu ny c bit quan trng Vit Nam v chng ti nhn thy nhiu cng ty t nhn Vit Nam ang hot ng di mc cng sut kh ng k, hoc thng giao hng khng ng hn do cc vn trong h thng qun l v ln lch sn xut. Lean Manufacturing cng thch hp cho cc ngnh c chin lc u tin vic rt ngn thi gian chu k sn xut ti mc ti thiu to c th mnh trong cnh tranh cho cng ty. Gn y mt vi doanh nghip trong nc ch ng tin hnh o to v p dng cc phng php lean nhm loi tr nhng bt hp l trong hot ng kinh doanh dn n vic ci thin thi gian quy trnh sn xut v dch v. Chng hn nh Toyota Bn Thnh, mt trung tm dch v bo tr xe ca Toyota Vit Nam, qua qu trnh p dng lean gim thiu ng k quy trnh dch v bo tr xe t 240 pht xung ch cn 45-50 pht cho mi xe ng thi tng lng xe c bo tr trong ngy t 4-6 xe ln ti 16 xe ti mi im bo tr. Toyota Bn Thnh t c nhng gim thiu ng k v thi gian quy trnh bng cch loi b thi gian ch i khng cn thit cng vi cc thao tc v di chuyn khng hp l ca cng nhn7.

Nhng Doanh Nghip no s c Li t Lean Manufacturing?

tham kho thm chi tit v vic thc hin ci tin ca Toyota Bn Thnh, hy xem bi vit ca Hong Ly: C th tng nng sut m khng cn u t. Thi Bo Kinh T Si Gn, 27-5-2004. Mekong Capital Gii Thiu v Lean Manufacturing Trang 4 trn 20

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2.1

Cc Khi Nim trong Lean Manufacturing

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 cho thy trong mt cng ty sn xut c trng th t l gia cc hot ng c th c chia ra nh sau8: Hot ng to ra gi tr tng thm Hot ng khng to ra gi tr tng thm Hot ng cn thit nhng khng to ra gi tr tng thm Tng cc hot ng 5% 60% 35% 100%

Vic To Ra Gi Tr v S Lng Ph

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.

2.2

Nguyn thy c 7 loi lng ph chnh c xc nh bi H Thng Sn Xut Toyota (Toyota Production System). Tuy nhin, danh sch ny c iu chnh v m rng bi nhng ngi thc hnh lean manufacturing, nhn chung bao gm cc mc sau: 1. Sn xut d tha (Over-production) Sn xut d tha tc sn xut nhiu hn hay qu sm hn nhng g c yu cu mt cch khng cn thit. Vic ny lm gia tng ri ro s li thi ca sn phm, tng ri ro v sn xut sai chng loi sn phm v c nhiu kh nng phi bn i cc sn phm ny vi gi chit khu hay b i di dng ph liu. Tuy nhin, trong mt s trng hp th lng bn thnh phm hay thnh phm ph tri c duy tr nhiu hn mt cch ch ch , k c trong nhng quy trnh sn xut c p dng lean. Khuyt tt (Defects) Bn cnh cc khuyt tt v mt vt l trc tip lm tng chi ph hng bn, khuyt tt cng bao gm cc sai st v giy t, cung cp thng tin sai lch v sn phm, giao hng tr, sn xut sai quy cch, s dng qu nhiu nguyn vt liu hay to ra ph liu khng cn thit. Tn kho (Inventory) Lng ph v tn kho ngha l d tr qu mc cn thit v nguyn vt liu, bn thnh phm v thnh phm. Lng tn kho ph tri dn n chi ph ti chnh cao hn v tn kho, chi ph bo qun cao hn v t l khuyt tt cao hn. Lin quan v khi nim ny, xin tham kho phn 2.5 bn di.

Nhng Loi Lng Ph Chnh

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Peter Hines & David Taylor: Going Lean (Tin ti Lean). Lean Enterprise Research Centre, thng Ging 2000. Trang 5 trn 20

Mekong Capital Gii Thiu v Lean Manufacturing

Mekong Capital
4. Di chuyn (Transportation) 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. Ch i (Waiting) 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. Thao tc (Motion) 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. Sa sai (Correction) 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. Gia cng tha (Over-processing) 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 bng hay lm lng tht k nhng im trn sn phm m khch hng khng yu cu v khng quan tm. Kin thc ri rc (Knowledge Disconnection) 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.

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2.3

Khi nim trng tm ca Lean Manufacturing 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: 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. Hy tham kho thm phn 3.13 v Kanban tm hiu thm v ng dng ny. Sn phm c li ko trong qu trnh sn xut da trn nhu cu ca cng on sau Mi cng on sn xut c xem l mt khch hng ca cng on gn k trc n. Khng c sn phm no c gia cng bi cng on trc nu cng on ng sau (khch hng) khng yu cu. Tc sn xut c iu phi bi tc tiu th ca cc cng on sau Mc sn xut tng cng on hay t bng vi mc nhu cu/tiu th ca cng on theo sau (khch hng).

Sn Xut Pull (Li Ko)

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Phng php pull tng t nh khi nim sn xut Just-in-Time (va ng lc) c ngha l nguyn vt liu hay bn thnh phm c giao ng s lng v va ng lc khi khu sau cn dng n.
Mekong Capital Gii Thiu v Lean Manufacturing Trang 6 trn 20

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Trng hp l tng ca h thng sn xut pull l nguyn vt liu s c ni cung cp (cng on trc) chun b sn ng lc cng on sau cn n. iu ny c ngha rng ton b lng nguyn liu tn kho u ang trong tnh trng c x l, ch khng phi ang ch c x l, v khch hng thng phi hoch nh trc bng cch d on s cn g da trn thi gian p ng ca nh cung cp. V d, nu nh cung cp cn 2 gi cung cp nguyn liu k t lc c khch hng yu, khch hng s phi t lnh yu cu 2 gi trc khi nguyn liu cn c s dng n.

2.4

Nhiu nh sn xut p dng lean duy tr mt lng tn kho c tnh ton cho nguyn liu, bn thnh phm v thnh phm nhm: phng khi nhu cu khch hng thay i; phng khi nh cung cp giao nguyn vt liu chm hn d tnh hay hot ng sn xut b chm tr; iu ho lung sn xut bng cch sn xut lin tc mt s sn phm d khch hng cha yu cu; thch ng vi thc t rng nguyn liu phi c giao theo l v thnh phm phi c xut theo l; thch ng vi thc t rng vic gia cng mt vi cng on sn xut phi c thc hin theo l do bn cht ca thit b hay quy trnh. Nhn chung, cng t kh nng d on cc n t hng, qu trnh sn xut cng bt n nh (nh l nhng chm tr v tc nghn ngoi d tnh), hay mc tin cy ca cc nh cung cp nguyn liu cng thp th mc tn kho c yu cu cng cao phng khi c nhng bin ng t ngt trong nhu cu ca khch hng, s bt n nh ca sn xut hay thiu ht nguyn vt liu. Trong nhng trng hp trn, cc chuyn sn xut lean c duy tr lng tn kho nguyn liu, bn thnh phm hay thnh phm lm vng m d phng trc nhng thay i khng lng trc c. thch ng vi nhng tnh hung va nu, mt s h thng khc nhau c th c p dng cho m hnh sn xut pull nh sau: 1. H Thng Pull Cp y (Replenishment Pull System) Trong h thng ny, cng ty c duy tr mt lng tn kho thnh phm cho tng chng loi hay nhm sn phm v ch khi tn kho ca mt loi sn phm thp hn mc xc nh th mt lnh lm y kho c ban hnh yu cu sn xut thm sn phm. H thng cp y tn kho c p dng ph bin hn cng ty c nhiu khch hng nh thng t mua cc sn phm c quy cch chun. Trong h thng ny, lch sn xut c bit trc kh lu nn mc tn kho nguyn liu cng c quy nh c th. H Thng Pull Sn Xut theo n Hng (Sequential Pull System) Trong h thng ny, cc lnh sn xut ch c gi n xng sn xut khi khch hng bn ngoi yu cu. Tt c sn phm c lm theo n t hng. H thng ny c p dng ph bin cng ty c t khch hng nhng l khch hng ln, mua cc sn phm c yu cu c bit. Mc d cc cng ty p dng h thng ny nn c lng kho thnh phm thp hn, h vn cn c kho nguyn liu hay bn thnh phm ln hn do lch sn xut khng c bit trc (v kh on trc chnh xc khch hng s cn g v vo khi no). H Thng Pull Phc Hp (Mixed Pull System) Trong h thng phc hp, mt s thnh phn ca h thng cp y v sn xut theo n hng c s dng h tr ln nhau. V d mt cng ty c th sn xut mt s sn phm trn c s cp y tn kho trong khi sn xut mt s sn phm khc vi h thng lm theo n t hng. Mt chn la khc, mt cng ty c th p dng h thng cp y tn kho cho mt phn ca quy trnh sn xut vap dng h thng lm theo n hng cho phn khc ca quy trnh sn xut. V d nh mt cng ty 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. Trong trng hp ny, cng ty 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 n9.

Cc M Hnh Khc Nhau ca H Thng Sn Xut Pull

2.

3.

http://www.aug.edu/~sbajmg/quan6610/Lean%20Concepts/leanWP1.pdf Trang 7 trn 20

Mekong Capital Gii Thiu v Lean Manufacturing

Mekong Capital
2.5
Pull production (sn xut li ko) gip loi b tn kho khng cn thit gia cc cng on. Mc tn kho cao gia cc cng on sn xut dn n t l khuyt tt sn phm cao hn v nhng l do sau: 1. Kim sot li km trong sn xut theo l khi sn xut theo l, s c nhiu sn phm li c to ra trc khi b pht hin cng on sn xut tip theo. V d, nu kch thc mi l cng on in bao l ba ngn bao trc khi chuyn cho cng on k tip, ng thi nhn vin kim phm khng pht hin c li (do ch kim xc sut), s c rt nhiu kh nng l v s bao in li c to ra trc khi sai xt c pht hin cng on sn xut k tip. H hng v lng ph do lu kho v di chuyn - mt s li pht sinh trong qu trnh di chuyn v trong thi gian lu kho. V d trong ngnh sn xut g, vic bn thnh phm b tng m do tip xc vi mi trng m trong qu trnh gia cng cng c xem l 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 mt i 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.

V Sao Mc Tn Kho Cao Lm Tng Ph Phm v Lng Ph

2.

3.

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.

2.6

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 (Materials Requirements Planning hay MRP) ca phn ln cc h thng Hoch nh Ngun Lc Doanh Nghip (Enterprise Resource Planning hay 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 nhau, v vy s d dn n tc nghn lung sn xut, d tha v tn kho, rt t kh nng trin khai sn xut trn c s quy trnh lin tc v ni chung l km hiu qu trong vic s dng ti nguyn. Ngc li, ngoi tr vic cn bng sn xut, yu t chnh ca h thng sn xut pull l vic phn b lung cng vic cho xng sn xut c xc nh da trn nhu cu ca chuyn sn xut ch khng phi lch sn xut hay h thng phn b sn xut c hoch nh bi h iu hnh trung tm. Mc d cc doanh nghip sn xut p dng lean vn c mt k hoch sn xut, k hoch ny ch yu c s dng cho cc mc tiu sau: hoch nh yu cu nng sut thit b, bao gm nhng thay i i vi thng s ca cc chuyn hay cc cell (/ngn gia cng sn phm); hoch nh yu cu nhn lc; iu ho cc lnh sn xut cho xng (xem phn 3.14 v Cn bng sn xut); v (trong mt s trng hp) hoch nh nhu cu nguyn vt liu.

Tc ng ca H Thng Pull i vi Vic Hoch nh Sn Xut

2.7

Quy trnh lin tc l vic phi hp cc thao tc v hot ng ca thit b tr thnh mt lung hi ho hon ho, trong bn thnh phm lin tc trong trng thi chuyn i v khng bao gi phi nm ng trong tnh trng ch i c x l. Quy trnh lin tc loi tr thi gian ch i ca bn thnh phm, thit b hay cng nhn.
Trang 8 trn 20

Quy Trnh Lin Tc

Mekong Capital Gii Thiu v Lean Manufacturing

Mekong Capital
Trong quy trnh lin tc, iu kin l tng l chui mt sn phm (one-piece flow) hay cc l gia cng c s lng nh c th c x l m khng tn thi gian ch i gia cc cng on sn xut. Quy trnh lin tc c th yu cu vic ti thit k mt bng sn xut t vic sp t cc nhm hay cng on tng t nm gn k nhau tr thnh cc chuyn sn xut phi hp, trong bn thnh phm c th di chuyn nhanh chng v d dng t cng on ny sang cng on khc. Quy trnh lin tc c th gip gim thiu ng k tng thi gian chu trnh sn xut. V d: Cng ty Simms Fishing Products, chuyn sn xut trang phc dnh cho ng dn c c s M, khi p dng Lean Manufacturing, tng thi gian quy trnh sn xut ca h gim xung t 17 ngy xung ch cn 2-3 ngy10. Cng ty Woodland Furniture, chuyn sn xut g cao cp c c s M, sau khi p dng Lean rt ngn thi gian giao hng t 12 tun xung ch cn 1 tun11.

2.8

i khi quy trnh lin tc khng kh thi i vi mt s cng on trong quy trnh sn xut. Trong trng hp ny th quy trnh lin tc ch c th c trin khai mt s khu trong quy trnh sn xut. Mt s in hnh trong quy trnh lin tc khng ph hp i vi mt vi cng on sn xut nh sau: Thi gian chu k khng ng b gia mt s cng on trong mt s quy trnh vn hnh vi chu k rt nhanh v phi chuyn i p ng nhiu chng loi sn phm khc nhau. Khong cch gia cc cng on l iu khng trnh khi trong mt vi trng hp v c ngha rng vic di chuyn nguyn vt liu phi c thc hin theo tng l tng i ln. Mt s quy trnh c tin cy qu thp nn khng th d bo v hiu sut v c th gy gin on cho hot ng ca quy trnh lin tc. Mt s cng on phi c thc hin theo l ln. V d l sy g hot ng theo chu k vi cc l ln nn g ra l sau s c lu tr trong kho mt thi gian v lng g khng th c dng ht ngay mt ln. i lc ph phm hay vt liu thi ra sau khi gia cng c gi li di dng tn kho s dng v sau nhm gia tng hiu sut s dng vt t. V d mt s mu g cn d sau khi ct c th c s dng li v sau khi c nhu cu s dng g vi quy cch tng ng cc mu nh cn li. iu ny c ngha l mt s tn kho bn thnh phm c th c to ra mt cch c ch cc cng on m ph phm c th dng li c. Trong trng hp ny, mt lung sn xut lin tc hon ton s dn n mc lng ph cao hn so vi cch ti a hiu sut m trong ph phm hay cc mu tha c c gi li s dng trong tng lai12. Trong mt s trng hp khc, cng ty c th c duy tr lng tn kho bn thnh phm mt s cng on ca quy trnh sn xut.

Phi Hp Quy Trnh Lin Tc v Khng Lin Tc

2.9

V kh c mt cng ty no c th t n mc hiu qu tuyt i, Lean Manufacturing i hi mt cam kt ci tin lin tc, v tt nht l c mt quy trnh h thng nhm m bo vic ci tin lin tc, nh cng ty khng ngng tm kim cc hot ng khng to ra gi tr tng thm v cch thc loi b chng. Trng tm ca vic ci tin lin tc nn nhm vo vic xc nh cc nguyn nhn tim tng ca cc hot ng khng to ra gi tr tng thm v loi b chng bng cch ci tin quy trnh sn xut. Kaizen, mt thut ng trong ting Nht, c ngha l ci tin lin tc, vi trng tm hng n cc ci tin nh din ra t t. Ch chnh ca Kaizen l to ra mt vn ho ci tin lin tc, phn nhiu bng vic phn cng trch nhim cho cng nhn v khuyn khch h xc nh cc c hi ci tin, nh c nu trong phn 2.10 di y.

Ci Tin Lin Tc/ Kaizen

10 11 12

http://www.apparelmag.com/bobbin/search/search_display.jsp?vnu_content_id=2010873 http://www.techhelp.org/about_success_details.asp?ID=37 http://woodpro.cas.psu.edu/WoodPro%20Word%20HTML%20files/WoodPro%20TechNotes%202003-1.htm Trang 9 trn 20

Mekong Capital Gii Thiu v Lean Manufacturing

Mekong Capital
2.10 S Tham Gia ca Cng Nhn
Trong Lean Manufacturing, cng nhn c ch nh trch nhim r rng nhm xc nh cc ngun hot ng khng to ra gi tr tng thm v xut gii php khc phc. 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. Nhn nh ny c minh chng qua mt ti liu nghin cu kh quan trng13.

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 qu14. 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: 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. Chng Trnh Xut Ci Tin (Suggestion Programs) 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 ci tin.

2.

Mt s chuyn gia v lean manufacturing 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 manufacturing15.

2.11 Quy Hoch M Phng Dng T Bo (Cellular Layout)

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: 1. 2. 3. 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. 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. 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 . 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.

4.

13 14

http://www.sme.org/cgi-bin/get-newsletter.pl?LEAN&20040309&1&

Steven Spear v H. Kent Bowen: Decoding the DNA of the Toyota Production System (Gii M Gien H Thng Sn Xut Toyota). n bn Harvard Business Review, Thng 9-10 1999. 15 Steven Spear: Learning to Lead at Toyota (Nghin Cu Cch Dn Dt Toyota). n bn Harvard Business Review, thng 5 2004. Mekong Capital Gii Thiu v Lean Manufacturing Trang 10 trn 20

Mekong Capital
B tr dng t bo gip t c nhiu mc tiu ca Lean Manufacturing nh kh nng loi tr nhiu hot ng khng to ra gi tr tng thm t quy trnh sn xut nh thi gian ch i, tc nghn, di chuyn vt liu v bn thnh phm. Mt li ch khc ca m hnh t bo l trch nhim v cht lng c n nh r rng cho cng nhn trong mt cell c th v v vy ngi cng nhn khng th li cho cc cng nhn cng on trc. Nhiu cng ty trin khai m hnh t bo cho mt s cng on ch khng p dng cho ton b qu trnh sn xut. V d, cc cng on sn xut c quy trnh sy hay nung trong thi gian di thng khng ph hp cho vic p dng m hnh t bo v kh lin kt cng on ny vo quy trnh lin tc ca dng t bo. Cc nh my sn xut g ch yu trin khai m hnh t bo cho mt s cng on nh ct x, lp rp v hon thin ch khng p dng cho cng on sy g hay lm kh sn. Mt in cu v vic p dng sn xut theo m hnh t bo cho mt lot cc cng on sn xut trung gian ti Franklin Corp., mt nh sn xut gh bc da M, c th c tm c a ch sau: http://www.ifmm.msstate.edu/doubled.pdf. Bi nghin cu cho bit mc ci thin 36% v nng sut lao ng l kt qu t c sau khi cng ty trin khai p dng h thng lean manufacturing. B tr theo m hnh t bo khng hn ph hp cho tt c cc cng ty v c nhiu cng ty thnh cng trong vic p dng Lean Manufacturing m khng cn a vo m hnh t bo. Chng hn nh mt s ngnh i hi vic x l cc l sn phm ln do tnh cht ca thit b hay s gin on ng k gia cc cng on sn xut v v vy khng thch hp p dng m hnh t bo. Hy xem phn 3.11 v Gim thiu quy m l sn xut.

2.12 Administrative Lean (Lean cho Cng Tc Hnh Chnh)

Administrative lean l vic p dng cc khi nim v cng c ca lean manufacturing ci thin cc quy trnh th tc giy t ngoi hot ng sn sut ca xng. c bit i vi cc quy trnh hnh chnh c tnh lp li v bao gm khi lng ln cc giao dch nh nhn n hng, thu mua, k ton hay cc cng vic hu cn. Tuy nhin, vic p dng lean cho cc quy trnh hnh chnh khng ph bin bng vic p dng cho cc quy trnh sn xut.

Mekong Capital Gii Thiu v Lean Manufacturing

Trang 11 trn 20

Mekong Capital
3.
3.1

Cng C & Phng Php trong Lean Manufacturing

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)16, 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. Thi gian chun Takt time (nhp ) l tn xut mt sn phm c lm ra17. 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. 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.

Chun Ho Quy Trnh (Standard Work)

2.

3.

3.2

Cc hng dn cng vic chun khng nn ch dng vn bn m bao gm c hnh nh, cc bng hin th trc quan v thm ch c cc v d. Thng cc nhn vin rt t chu c cc ti liu hng dn sn xut bng vn bn nhm chn v vy cc bng hin th trc quan v v d thc t c hnh nh nn c s dng cng nhiu cng tt. Cc hng dn nn r rng v chi tit, nhng ng thi c trnh by theo cch gip nhn vin tht d hiu v lin quan mt thit n u h cn bit. iu ny c bit ng vi trng hp Vit Nam khi c nhiu cng nhn vi mc hc vn thp s thy cc bng hin th bng hnh nh d hiu hn so vi cc ti liu vn bn. Mt s cng ty thm ch p dng vic hun luyn bng phim video cho cc loi cng vic phc tp hay cc vn lin quan v an ton lao ng.

Truyn t Quy Trnh Chun cho Nhn Vin

Yu cu 7.5.1. ni rng mt t chc cn c cc ti liu sau: a) thng tin v cc c tnh ca sn phm; b) hng dn cng vic ph hp; c) thit b sn xut thch hp; d) o lng v gim st thit b v h thng; e) cc quy trnh bao ph t cc hot ng hon tt sn phm, phn phi v sau phn phi. 17 Khc vi thi gian chu k sn xut (cycle time) 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). Mekong Capital Gii Thiu v Lean Manufacturing Trang 12 trn 20

16

Mekong Capital
3.3
Mt s doanh nghip Vit Nam th hin s lo ngi rng vic thit lp cc quy trnh chun v sn xut s dn n s cng nhc, thiu linh hot. Mc d quy trnh chun i hi c mc chi tit cao, Lean Manufacturing, cc hng dn cng vic chun nn c cp nht thng xuyn cng tt nhm gn kt vi cc ci tin quy trnh ang din ra. Trong thc t, cc cng ty c khuyn khch ti a ho tc ci tin quy trnh ng ngha vi vic cp nht lin tc cc hng dn cng vic chun. Ngoi ra mt quy trnh chun thng bao gm cc hng dn r rng cng nhn x l cc tnh hung bt thng, do thc y h ng x theo cch linh hot i vi cc tnh hung bt thng. thc hin thnh cng vic ny, trch nhim nn c phn cng r rng trong vic chun b v phn pht cc ti liu cn thit, cc bng hin th, cng nh m bo rng bt k mt thay i no cng u c cp trn truyn t r rng cho nhn vin bn di. Mt khi trch nhim c phn cng r rng, cc quy trnh cng vic chun c th c b sung mt cch thng xuyn. Trn thc t, cc cng ty p dng lean manufacturing nh Toyota c bit n bi d linh hot c di hnh thc sn phm a dng v kh nng ci tin cc quy trnh sn xut mt cch nhanh chng, v vy gip cng ty phn ng nhanh hn i vi cc thay i v nhu cu ca khch hng.

Quy Trnh Chun v S Linh Hot

3.4

Cc h thng qun l bng cng c trc quan cho php cc cng nhn ca xng c thng tin y v cc quy trnh sn xut, tin v cc thng tin quan trng khc gip h lm vic c hiu qu nht. Cc bng hin th ln ni chung thng l cng c thng tin hiu qu hn cho cng nhn trong chuyn sn xut so vi cc bo co v ch th v vy nn c s dng cng nhiu cng tt. Trong trng hp cn ci thin s tun th i vi mt quy trnh th vic trnh by trc quan gip nhm hiu r hn mt quy trnh phc tp bao gm cc bc thao tc ng, cch thc hin ng cho tng ng tc, cc mi quan h bn trong v bn ngoi gia cc hot ng v vi cc tc nhn khc. Cc cng c trc quan thng di cc hnh thc sau: 1. Cc bng hin th trc quan Cc biu , bng o lng hiu qu, cc th tc v ti liu quy trnh lm ngun thng tin tham kho cho cng nhn. V d, biu xu hng v hiu sut thc hin, % dao ng ca t l li, tin xut hng trong thng, v.v... Cc bng kim sot bng trc quan Cc ch s dng kim sot hay bo hiu iu chnh cho thnh vin nhm. Cc bng biu c th bao gm c thng tin v tin sn xut, thng tin theo di cht lng, v.v... V d cc bng mu ch th gii hn kim sot nhit hay tc gip ngi vn hnh thit b nhanh chng pht hin khi quy trnh vn hnh vt mc cho php. Cc th Kanban l mt v d khc v kim sot bng trc quan. Cc ch dn bng hnh nh Cng c ny gip truyn t cc quy trnh sn xut hay lung vt t c quy nh. Chng hn, vic s dng cc v trn nn nh xng phn bit khu vc cha vt liu s dng c vi ph phm hay cc ch dn lung di chuyn nguyn vt liu v bn thnh phm trn mt bng xng.

Qun L bng Cng C Trc Quan (Visual Management)

2.

3.

3.5

Cht Lng t Gc hay Lm ng ngay t u c ngha l cht lng nn c a vo quy trnh sn xut khuyt tt khng c iu kin pht sinh hay mt khi xut hin s ngay lp tc b pht hin. Cc h thng Lean Manufacturing thng nhc n t Jidoka trong ting Nht c ngha l cc vn nn c xc nh v loi tr ngay ti ngun pht sinh. Mt s yu cu chnh c lin quan: 1. Kim tra trong chuyn Trch nhim chnh ca cng tc kim tra cht lng c thc hin trn chuyn sn xut bi cng nhn, khng phi bi cc nhn vin kim tra cht lng c lp ly mu xc sut. Mc d mt s nhn vin kim sot cht lng vn thng c s dng trong cc chuyn lean, vai tr ca h kh hn ch (l tng vn l khng c nhn vin kim sot cht lng v s hin din ca h c xem l mt dng lng ph i vi Lean Manufacturing). Kim sot ti ngun Vi yu cu ny, bn thn cc nhn vin kim tra cht lng khng i tm khuyt tt sn phm m tm ngun gy ra khuyt tt. Chng hn, h c th kim tra xem cc quy trnh chun c c cng nhn tun th khng, hay trong trng hp pht sinh khuyt tt trn sn phm, h c th chu trch nhim xc nh ngun gc ca cc khuyt tt ny. T cch lm ny,

Cht Lng t Gc (hay Lm ng ngay t u)

2.

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Mekong Capital
cng vic ch yu ca nhm kim sot cht lng l gii quyt cc ngun gc gy ra li sn phm, trin khai cc bin php ngn nga v o to cho cng nhn khuyt tt khng ti xut hin. 3. Trch nhim r rng gia cc cng nhn Vi Lean Manufacturing, nu khng c tn kho bn thnh phm, cc cng on s bn giao sn phm trc tip, c ngha rng cc cng nhn thuc cng on trc chu trch nhim hon ton v cht lng sn phm h bn giao cho cng on k v nhn trch nhim khi c pht sinh khuyt tt trn sn phm. Mt khc, nu lng 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. 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). 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.

4.

5.

3.6

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 nh18. S chui gi 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.

S Chui Gi Tr (Value Stream Mapping)

3.7

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. 1. Sng lc (Sort) 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. Sp xp (Straighten/Set in order) 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. Sch s (Scrub/Shine) 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. Sng sng (Stabilize/Standardize) 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. Su st (Sustain) 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.

Phng Php 5S

2.

3.

4. 5.

c thm ni dung chi tit v phn ny hy tham kho Peter Hines & David Taylor: Going Lean (Tin Ti Lean). Lean Enterprise Research Centre, thng Ging 2000. http://www.cf.ac.uk/carbs/lom/lerc/centre/goinglean.pdf Mekong Capital Gii Thiu v Lean Manufacturing Trang 14 trn 20

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Mekong Capital
3.8
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 chng pht sinh. Lean Manufacturing 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 Manufacturing.

Bo Tr Ngn Nga (Preventative Maintenance)

3.9

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.

Bo Tr Sn Xut Tng Th (Total Productive Maintenance)

3.10 Thi Gian Chuyn i/Chun B (Changeover/setup time)

Lean Manufacturing 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 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.

3.11 Gim Thiu Quy M L Sn Xut

Lean Manufacturing 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 Manufacturing 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.

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Mekong Capital
3.12 Quy Hoch Mt Bng Xng v Vt T ti Ni S Dng
Lean Manufacturing 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).

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: 1. 2. 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. 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.

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 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.

3.15 Ngi Gi Nhp (Pacemaker)

m bo chc nng iu ca lung sn xut lin tc trong lean manufacturing, 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).

Mekong Capital Gii Thiu v Lean Manufacturing

Trang 16 trn 20

Mekong Capital
3.16 Mc Hu Dng Thit B Ton Phn (Overall Equipment Effectiveness)
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 = 80% x 75% = OEE19 60%

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: hng hc thit b bt ng; thi gian dng do chun b v iu chnh thit b; lng cng v ngng chuyn do thiu nguyn liu, n tc hay hoch nh sn xut km; Hot ng thp hn tc thit k do tay ngh cng nhn km, thiu bo tr hay cc tc nhn khc; khuyt tt trn sn phm cn gia cng li; o lng OEE rt c ch trong vic xc nh cc ngun gy ch tc, ra cc quyt nh u t thit b v gim st tnh hiu qu ca cc chng trnh tng nng sut thit b. Tuy nhin, Lean Manufacturing thng u tin ti a ho vic dng ngi hn l vic tn dng thit b. Mt trong cc l do l cc nh my sn xut a dng v sn phm s khng c kh nng s dng tt c cc thit b trong mi lc v cc yu cu s dng my khc nhau ty tng loi sn phm.

19

i khi hiu sut cht lng (%yield) cng c bao gm trong cng thc tnh ny. Trang 17 trn 20

Mekong Capital Gii Thiu v Lean Manufacturing

Mekong Capital
4.
4.1

Trin Khai Lean

Cng nh bt k d n quan trng no khc v ci tin quy trnh, s cam kt v h tr ca cp lnh o cao nht l iu thit yu. Chc chn s ny sinh nhiu vn khi trin khai h thng lean v cc vn ny ch c th c gii quyt khi ban Gim c ton tm vi vic trin khai thnh cng lean.

S Tham Gia ca Lnh o Cp Cao

4.2

Mt s cng ty bc u ch trin mt phn ca lean manufacturing v dn dn tin ti trin khai ton din hn. Trong mt cuc kho st ti cc cng ty sn xut M bi tp ch Industry Week trong nm 2004, trong s cc cng ty bt u cc chng trnh lean manufacturing c 39.1% cho bit ch trin khai mt s ng dng ca lean, 55.0% trin khai hu ht cc ng dng v ch c 5.9% cho bit trin khai lean ton din20. 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.

Bt u bng Vic Trin Khai Lean Tng Phn

4.3

Chng ti xut rng 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.

Bt u vi Quy M Nh

4.4

Chng ti xut cc cng ty t nhn Vit Nam nn s dng dch v t vn t mt chuyn vin v lean manufacturing 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.

Nh Chuyn Vin

4.5

Cng ty nn thit lp mt k hoch trin khai chi tit v r rng trc khi tin hnh chuyn i sang lean. C th ti bi bo Building the lean machine (Xy dng c my lean) trong tp ch Advanced Manufacturing, k bo thng 9 nm 200021 c th tham kho danh sch cc vn cn c bao gm trong k hoch trin khai.

Lp k hoch

20 21

http://www.industryweek.com/CurrentArticles/asp/articles.asp?ArticleID=1589 http://www.advancedmanufacturing.com/pdfs/buildingthelean.pdf Trang 18 trn 20

Mekong Capital Gii Thiu v Lean Manufacturing

Mekong Capital
5.
5.1

Kt Hp Lean vi Cc H Thng Khc

Mc d bt ngun t H thng Sn xut Toyota (TPS), Lean Manufacturing c nhiu cng ty n nhn v v th c m rng phm vi hn so vi TPS. TPS c th c xem l cch trin khai lean thun ty cho mt cng ty c th. Trong h thng TPS, cc ch chnh c nhn mnh bao gm22: 1. Chun ho quy trnh Tt c cc quy trnh sn xut u rt c th v ni dung cng vic, chui s kin, thi gian v kt qu. Mc tiu l loi tr nhng khc bit trong cch cng nhn thc hin cng vic. Bn giao trc tip Mi im kt ni gia khch hng vi nh cung cp phi hon ton trc tip, v phi lun lun c th hin mt cch r rng, c-hay-khng, truyn t yu cu sn xut gia nh cung cp v khch hng. iu ny m bo nh cung cp phi chu trch nhim ti mc ti a v lung thng tin c ti u. Lung sn xut - ng i ca mi sn phm v dch v phi tht n gin v r rng, vi lung sn xut nh trc. iu ny c ngha l sn phm khng c a ti nhn vin hay my cn trng k tip, m c a ti mt nhn vin hay my c th nh v nhn vin hay my ny nn c t v tr cng gn ngun cung cp cng tt. Giao quyn cho cng nhn trong ci tin quy trnh - Tt c cc ci tin phi c thc hin da theo phng php khoa hc, di s gim st ca mt chuyn vin, nhng nn bt ngun t cp thp nht trong t chc. Toyota khuyn khch cng nhn xut cc ci tin cho quy trnh sn xut bng cch trin khai th nghim, nhng bt c thay i no trong quy trnh sn xut u phi c nh ngha chi tit theo chun mc ca Toyota v Chun Ho Cng Vic, nh m t trn.

H Thng Sn Xut Toyota

2.

3.

4.

5.2

Six Sigma l mt phng php lun c h thng nhm ci tin t ph quy trnh sn xut bng cch xc nh nhng nguyn nhn gy ra bin ng trong qu trnh sn xut v dn n ph phm, ri sau loi tr cc bin ng ny v gim thiu ph phm. V loi tr ph phm cng l mt mc tiu then cht ca Lean Manufacturing nn cc cng c v thng k v gii quyt vn ca Six Sigma c th c s dng khi trin khai Lean Manufacturing. Thng thng khi hai phng php ny c trin khai ng thi, ngi ta gi l Lean Six Sigma. bit thm thng tin v Six Sigma, xin tham kho bi vit Gii thiu v Six Sigma cho Doanh Nghip Vit Nam ca Mekong Capital.

Lean Six Sigma

5.3

Hoch nh Ngun lc Doanh nghip (ERP) bt ngun t h thng Hoch nh Yu Cu Vt t (MRP), trong lch sn xut c thit lp da trn k hoch sn xut theo m hnh push. Lch sn xut c cp nht da trn thng tin v tnh hnh sn xut a t xng ti h thng MRP. Mt vn thng ny sinh vi h thng MRP l d liu v tnh hnh sn xut v hng tn kho t xng khng c ghi nhn kp thi hoc sai st, dn n vic s dng cc gi thit khng chnh xc trong k hoch sn xut ca h thng MRP, khin gy ra tc nghn hoc h thng MRP a ra yu cu mc tn kho d phng cao hn mc cn thit. Hu ht cc phn mm ERP u c thit k cho h thng sn xut theo m hnh push v c hoch nh tp trung. Gn y mt s h thng ERP cng c ti u ha h tr lean manufacturing. Cc cng ty nn cn nhc iu ny khi la chn h thng ERP. bit thm thng tin v vic nh gi tnh ph hp ca h thng ERP cho Lean Manufacturing, xin tham kho bi vit ca Brian Nakashima, Can Lean and ERP Work Together? (Liu c th kt hp Lean v ERP?), trong tp ch Advanced Manufacturing23. Cng xin lu rng cc h thng ERP thng bao gm mt s tnh nng khng lin quan n hoch nh sn xut v d nh k ton, phn tch ti chnh, qun l nhn s, qun l bn hng, v.v.... Cc tnh nng ny c th em li nhiu li ch cho cng ty v khng gy nh hng trc tip n kh nng trin khai lean manufacturing.
22

Lean v ERP

Steven Spear and H. Kent Bowen: Decoding the DNA of the Toyota Production System (Gii M Gien H Thng Sn Xut Toyota). n bn Harvard Business Review, thng 9-10 1999. 23 http://www.advancedmanufacturing.com/September00/informationtech.htm Mekong Capital Gii Thiu v Lean Manufacturing Trang 19 trn 20

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5.4 Lean v ISO9001:2000

ISO9001:2000 l mt h thng qun l cht lng gip m bo rng cng ty c mt h thng c bn p ng yu cu cht lng ca khch hng mt cch nht qun. So vi ISO9001:2000, Lean Manufacturing c th c xem nh mt h thng qun l tnh hiu qu nhm lm gim tt c s lng ph v bt hp l trong qu trnh sn xut. Mc d cc mc tiu ny cng trng lp trn nhiu phng din, c bit c hai u nhm gim thiu mc ph phm n tay khch hng, ni chung hai h thng vn c nhiu im khc bit quan trng. V d, mt cng ty c th tun th 100% theo ISO9001:2000, nhng mc lng ph v km hiu qu vn cn cao. Mt cch phn bit quan trng l ISO9001:2000 i hi cc quy trnh trong cng ty phi t ti mt tiu ch ti thiu, trong khi Lean nhm ti ci tin quy trnh lin tc v cung cp mt lot phng php t c cc ci tin ny. Nhn chung, ISO9001 c xem nh mt nn tng tt cho Lean v c hai phng php u b sung cho nhau.

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Mekong Capital Gii Thiu v Lean Manufacturing Trang 20 trn 20