1

B GIO DC V O TO TRNG HKT TPHCM KHOA O TO SAU I HC

TIU LUN :

NG DNG H THNG SN XUT TINH GN (LEAN MANUFACTURING) TI CNG TY TOYOTA

GVGD :TS.H TIN DNG HVTH : NGUYN CH BO LP : QT M 3 KHA : 17

TP.HCM NM 2009

MC LC
Trang LI M U ................................................................................................................ 6 CHNG I : TNG QUAN V H THNG SN XUT TINH GN (LEAN MANUFACTURING) ...................................................................................... 7 I.1 KHI LC V H THNG SN XUT TINH GN (LEAN MANUFACTURING) ................................................................................................... 7 I.1.1 Lch s ca vn .................................................................................... ........ 7

I.1.2 Ti sao by gi ngi ta li quan tm n LEAN? ......................................... ...... 10 I.1.3 Cc quan im chnh ca LEAN ............................................................................ 11 I.1.4 Tin hnh LEAN trong doanh nghip nh th no? ............................................... 12 I.2 LEAN MANUFACTURING L G? .................................................................... 15 I.2.1 nh ngha v Lean Manufacturing ....................................................................... 15 I.2.2 Mc tiu ca Lean Manufacturing ........................................................................ 16 I.2.3 Cc nguyn tc chnh ca Lean Manufacturing ..................................................... 18 I.2.4 Trng tm ca Lean Manufacturing ...................................................................... 19 I.2.5 Cc ng dng ca LEAN .................................................................................... 119 I.2.6 Kt qu trn thc t ca vic ng dng LEAN ...................................................... 20 I.2.7 Nhng doanh nghip no s c li t Lean Manufacturing? ............................. 21 I.2.8 Doanh nghip quan tm iu g khi lm LEAN? ................................................... 22 I.3 CC KHI NIM TRONG LEAN MANUFACTURING ................................. 26 I.3.1 Vic to ra gi tr v s lng ph ........................................................................... 26 I.3.2 Lin quan n cc loi lng ph ............................................................................. 26

I.3.3 Nhng lai lng ph chnh ..................................................................................... 27 I.3.4 Sn xut Pull (Li Ko) ........................................................................................ 30 I.3.5 Cc m hnh khc nhau ca h thng sn xut Pull (Li Ko) ............................... 31 I.3.6 V sao mc tn kho cao lm tng mc ph phm v lng ph? .............................. 32 I.3.7 Tc ng ca H Thng Pull i vi vic hoch nh sn xut ............................. 33 I.3.8 Quy trnh lin tc .................................................................................................. 34 I.3.9 Phi hp quy trnh lin tc v khng lin tc ........................................................ 35 I.3.10 Ci Tin Lin Tc/ Kaizen .................................................................................. 35 I.3.11 S tham gia ca cng nhn ................................................................................. 36 I.3.12 Quy hoch m phng dng t bo (Cellular Layout) ........................................... 36 I.3.13 Administrative Lean (Lean cho Cng Tc Hnh Chnh) ..................................... 38 I.4 CC CNG C V PHNG PHP TRONG LEAN MANUFACTURING ................................................................................................... 38 I.4.1 Chun ho Quy Trnh (Standard Work) ................................................................ 38 I.4.2 Truyn t Quy Trnh Chun cho nhn vin ......................................................... 39 I.4.3 Quy Trnh Chun v S Linh Hot ....................................................................... 39 I.4.4 Qun l bng Cng C Trc Quan (Visual Management) ..................................... 40 I.4.5 Cht lng t Gc (hay Lm ng ngay t u) ................................................ 40 I.4.6 S Chui Gi Tr (Value Stream Mapping) ...................................................... 41 I.4.7 Phng Php 5S ................................................................................................... 42 I.4.8 Bo Tr Ngn Nga (Preventative Maintenance) ................................................... 42 I.4.9 Bo tr sn xut tng th (Total Productive Maintenance) ..................................... 43 I.4.10 Thi gian chuyn i/chun b (Change over/setup time) ..................................... 43

I.4.11 Gim thiu quy m l sn xut ............................................................................ 44 I.4.12 Quy hoch mt bng xng v vt t ti ni s dng .......................................... 44 I.4.13 Kanban ............................................................................................................... 44 I.4.14 Cn bng sn xut ............................................................................................... 45 I.4.15 Ngi Gi Nhp (Pacemaker) ............................................................................. 45 I.4.16 Mc Hu Dng Thit B Ton Phn (Overall Equipment Effectiveness) ............. 45 I.5 TRIN KHAI LEAN MANUFACTURING ........................................................ 46 I.5.1 S Tham Gia ca Lnh o Cp Cao ................................................................... 46 I.5.2 Bt u bng Vic Trin Khai Lean Tng Phn .................................................... 46 I.5.3 Bt u vi Quy M Nh ...................................................................................... 47 I.5.4 Nh Chuyn Vin .................................................................................................. 47 I.5.5 Lp k hoch ......................................................................................................... 47 I.6 KT HP LEAN VI CC H THNG KHC ............................................... 47 I.6.1 H Thng Sn Xut Toyota ................................................................................... 47 I.6.2 Lean Six Sigma ..................................................................................................... 48 I.6.3 Lean v ERP .......................................................................................................... 48 I.6.4 Lean v ISO9001:2000 .......................................................................................... 49 CHNG II : NG DNG H THNG SN XUT TINH GN TI CNG TY TOYOTA .................................................................................................. 50 II.1 VT KH VI CON NG TINH GN CA TOYOTA II.2 CC M HNH CA TOYOTA ......................................................................... 50 II.2.1 M hnh 8 lng ph theo "Phng thc Toyota - The Toyota Way" ...................... 50 II.2.2 M hnh 4P ca Con ng Toyota ............................................................... 52 II.2.3 M hnh Ngi nh cht lng ca Toyota ......................................................... 53

II.3 CON NG LEAN ........................................................................................... 54 II.4 THNH QU T C V CC THI IM NG GHI NH CA TOYOTA ..................................................................................................................... 55 II.5 CON NG THNH CNG CA TOYOTA THE TOYOTA WAY ........ 56 II.5.1 Sc mnh tm c th gii ca Con ng Toyota ............................................. 56 II.5.2 Cc nguyn tc kinh doanh trong Con ng thnh cng ca Toyota ............... 57 II.6 KINH NGHIM V THNH CNG TI CNG TY TOYOTA BN THNH ...................................................................................................................................... 62 II.7 BI HC KINH NGHIM CHO CC DOANH NGHIP VIT NAM .......... 63 KT LUN .................................................................................................................. 66

LI M U
Nu bn l nh qun l mt n v sn xut kinh doanh, bn lun lun phi i mt vi nhng sc p t i th cnh tranh, t khch hng v cht lng, gi c, giao hng ng hn, v t li nhun. C th bn bit tt c nhng bin ng v chi ph, nng sut, cht lng l do cc bin ng u vo ca h thng sn xut nh bin ng v nhn s, bin ng trong qu trnh to sn p hm, bin ng v nguyn vt liu, bin ng v my mc thit b, mi trng. Nhng quan trng l bn c nhng cng c no gim thiu nhng bin ng ny hay cha? i khi bn c gng giao hng ng hn nhng khi nhn li, bn li git mnh v lng tn kho qu nhiu. Bn thy cng ty ca bn rt bn rn, mi ngi u rt mt mi phi gii quyt cc vn pht sinh hng ngy trong sn xut kinh doanh, nhng kt qu em li li khng nh mong i. Bn ang bi ri!? Bn s git mnh mt ln na khi bit rng mt kho st ca Trung tm nghin cu doanh nghip Lean (Lean Enterprise Research Center) ca Anh quc ch ra rng: trong mt cng ty sn xut c trng th: +Hot ng to ra gi tr tng thm l 5% +Hot ng khng to ra gi tr tng thm l 60% +Hot ng khng to ra gi tr tng thm nhng cn thit l 35% Tng cc hot ng l 100% Khch hng ch tr cho bn cc hot ng tng thm gi tr (5%) thi. y l ti sao bn rt bn nhng khng hiu qu. H thng sn xut tinh gn Lean vi cc cng c hu hiu s gip bn xc nh v gim thiu cc hot ng khng to ra gi tr tng thm. N s to ra trong doanh nghip ca bn mt h t tng loi b lng ph, mt h thng sn xut kinh doanh tinh gn, n nh, to c s cho ci tin lin tc, gim thiu, loi b lng ph, bin ng trong sn xut. Nhiu khi nim v LEAN Manufacturing bt ngun t h thng sn xut Toyota (TPS) v dn c trin khai xuyn sut cc hat 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 c xem l mt trong nhng cng ty sn xut hiu qu nht th gii, v l cng ty a ra chun mc v in hnh p dng LEAN Manufacturing. LEAN Manufacturing ang c p dng ngy cng rng ri ti cc cng ty sn xut hng u trn ton th gii v ang tr thnh ti 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 .

CHNG I
TNG QUAN V H THNG SN XUT TINH GN

(LEAN MANUFACTURING)
I.1 KHI LC V H THNG SN XUT TINH GN (LEAN MANUFACTURING) I.1.1 Lch s ca vn ***Vo nhng nm 1900 l thi k ca K nng v s kho lo/ Skilled Craftsmanship

Vo thi k nay Frederich Taylor s dng cc phng php v cng c nh Ti u chun ha cng vic, nghin cu thi gian v thao tc chun p dng cho sn xut n chic. c tnh ca sn xut n chic: da vo k nng v s kho lo ca ngi thao tc khi m k thut v cng ngh cha pht trin Chng ta hnh dung khi sn xut xe t: Chic xe ng yn, ngi thao tc di chuyn t xe ny qua xe khc hon thnh cng vic ca h Yu cu nng lc c nhn mc rt cao c th hon thnh cng vic, ngi lnh ngh c coi trng Khng c chnh xc hai cng vic hon ton nh nhau. Cht lng rt tuyt vi

Tn rt nhiu chi ph cho sn xut

***Thi k sn xut hng lot/Mass Production/1930 Henry Ford cp ti dy chuyn lp rp v sn xut theo dy chuyn nhm to dng nguyn liu lin tc trong sut qu trnh sn xut, chun ha cc quy trnh v lai b lng ph c tnh ca sn xut hng lot : K nng ca ngi thao tc thp, thc hin mt cng vic nh trong dy

chuyn S lng rt quan trng S tha mn trong cng vic thp Chi ph sn xut r

*** S ra i ca h thng sn xut Toyota - tin thn ca Lean Manufacturing/1960 Cch tip cn Lean Manufacturing nh hng t Edwards Deming, Juran c tc ng ln ti h thng sn xut ca th gii. Sau th chin th II s ln mnh ca Nht Bn v cht lng ca sn phm. T thp nin 1960 cc cng ty ton cu n lc ci tin da trn cc tng ca h. H thng sn xut Toyota (TPS) ra i da trn s k tha v pht trin H thng sn xut lm i thay th gii. Nm 1950, Eiji Toyoda v cc gim c thc hin chuyn nghin cu cc nh my Hoa K 2 tun. H ngc nhin khi thy k thut sn xut hng lot khng thay i nhiu t nhng nm 1930. Bng quan st thc t, Taiichi Ohno thy s lng ph ln t vic sn xut hng lot, to ra mt lng ln thnh phm v bn thnh phm

tn kho, ph phm v bn thnh phm li n trong nhng l ln sn phm. Tan b ni lm vic v t chc v mt kh nng kim sat. Vi cc xe nng di chuyn hng ni vt liu khp ni, nh my trong ging nh nh kho nhiu hn. Khng my n tng trc nhng hnh nh nh vy, Mr. Ohno v cc cng s trong Toyota d nhn thy c hi bt kp nc M. ng bt u bng vic nghin cu li cun sch Hm nay v ngy mai ca Henry Ford. Trong cun sch ca mnh, Ford nu ln tm quan trng ca vic to dng nguyn liu lin tc trong sut qu trnh sn xut, chun ha cc quy trnh v lai b lng ph. Nhng thc t Cng ty ca ng khng lun thc hin iu ny. K tha bi hc ca Henry Ford cng vi vic nhn thy h thng ko c cc siu th M s dng. bt k siu th hot ng hiu qu no th lng hng ha trn k c b sung chnh xc bng s khch hng va ly i. Ngha l vic sn xut han tan ph hp s lng va tiu th. Toyota cng trn trng p dng bi ging v cht lng ca W.Edwards Deming (s t ca qun l cht lng hin i) v vic p ng v p ng vt yu cu ca khch hng l nhim v ca t chc. Deming cng a ra nguyn tc bc tip theo l khch hng v m rng khi nim khch hng bao gm khch hng bn trong v khch hng bn ngai. Toyota cn thc hin ci tin lin tc theo PDCA Hach nh Thc hin o lng Ci tin (cn gi l chu trnh Deming). Tt c to nn H thng sn xut Toyota (Toyota Production System TPS), tp trung vo vic sn xut dng sn xut 1 sn phm lin tc (one -pieceflow), rt ngn thi gian sn xut bng vic lai b lng ph c trong tng cng an ca qui trnh sn xut t cht lng tt nht m chi ph l thp nht, cng vi mc an tan v tinh thn lm vic cao. Phn ln cc quan nim ca LEAN khng phi l mi. Rt nhiu quan nim LEAN c thc hin ti Ford trong sut nhng nm 1920 v quen thuc i vi nhiu k s cng ngh. Trong vng khong 15 nm nay, mt thut ng mi LEAN c mt trong kho t vng v sn xut. Nhng ngi ra quyt nh nhng nh lnh o cp cao, c

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bit trong qun l trin khai, cht lng, cc ngun lc, cc hot ng tc nghip v cng ngh, gn y nghe ni nhiu v LEAN hn nhng phng php khc. Vin tiu chun v cng ngh m rng i tc sn xut (NIST/MEP), mt c quan ca b thng mi Hoa K, cho rng LEAN l cch tip cn h thng nhm xc nh v loi b lng ph (cc hot ng khng c gi tr gia tng thng qua ci tin lin tc, sn xut ra sn phm ch khi khch hng cn n (c gi l Pull Ht), hng ti s hon thin. Thut ng Lean Manufacturing ln u xut hin nm 1990, trong cun "The Machine that Changed the World" (C my lm thay i th gii) ca cc tc gi Daniel Jones, James Womack v Danile Roos. Ln u tin LEANc s dng lm tn gi cho h phng php sn xut tinh gn, lin tc ci tin cc quy trnh kinh doanh. LEAN ch trng vo vic gia tng cc gi tr ngun lc t quan im ca khch hng. Ni cch khc, n phi mang li cho khch hng: +Nhng g h mun +Khi h mun n +Ni no h mun n. +Vi gi c cnh tranh. +Vi s lng v chng loi h cn +Vi cht lng nh mong mun. I.1.2 Ti sao by gi ngi ta li quan tm n LEAN S d hin nay LEAN c coi l chin lc ginh thng li c bit quan trng l v: Nhu cu cnh tranh hiu qu trong nn kinh t ton cu hin nay. p lc i hi gim gi t khch hng. Nhng thay i ca cng ngh mt cch nhanh chng.

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nh hng ca th trng tip tc t vo cht lng, chi ph v vic giao hng ng thi hn. Cc nh sn xut thit b nguyn gc (tm dch) OEMs (orginal equipment manufactures) m nhim cc chuyn mn chnh ca h v phn b li cc nh sn xut cn li. Cc yu cu OEMs i hi cc nh cung ng phi ph hp vi cc tiu chun cht lng nh: ISO 9000: 2004 hoc QS-9000 (ang c thay th bng tiu chun quc t ISO/TS 16949) trong ngnh t. S mong i ca khch hng gia tng khng ngng. S cn thit phi chun ha cc qu trnh lun t c kt qu nh mong mun. I.1.3 Cc quan im chnh ca LEAN Sng to trc khi b vn: LEAN quan tm n tp hp sng kin v gii php ca c nhm thay v u t vi chi ph vn ln. Nhng ngi lm vic trong cng qu trnh phi cng nhau tho lun khai thc nhng kinh nghim, k nng v tr c ca tp th nhm to ra k hoch gim lng ph v c cc ci tin qu trnh. p dng ngay mt gii php tuy cha hon ho nhng ng lc th tt hn l p dng mt gii php hon thin nhng li mun. Cn tin hnh kp thi. Lu kho khng phi l c ti sn d tr m l lng ph hoc phi mt chi ph. S dng phng php Hoch nh Tin hnh Kim tra Khc phc trin khai cc ci tin c khi pht trin v sa i. Khi c bt u th s phi tin hnh lin tc LEAN v n l qu trnh khng c im kt thc. Thng thng, ti 95% thi gian sn xut chnh (lead time) khng tng gi tr. Rt ngn khong cch gia thi gian sn xut chnh vi thi gian qu trnh thc s bng cch loi b thi gian v cc kt qu khng gia tng gi tr v c chi ph v thi gian chu trnh.

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Henrry ford ngi sng lp ra hng t ford nhn thy iu ny t nm 1926, khi ng ni: mt trong nhng thnh tu ng gi nht khi gi c gi cc sn phm ca ford thp l thu ngn dn chu trnh sn xut. Mt chi tit cng di v cng chuyn ng trong qu trnh sn xut th chi ph ti u ca n cng ln. I.1.4 Tin hnh LEAN trong doanh nghip nh th no? Tin hnh LEAN trong doanh nghip c nhng thch thc khc so vi trin khai LEAN trong sn xut. Ti phn xng, mt sn phm hu hnh ang c sn xut. Tn dng cc cng c v k thut gim chi ph v thi gian sn xut i t nguyn liu th thnh cc sn phm hon thin c th s dng c l iu d nhn thy. Ti cc phng ban chc nng ca mt cng ty sn xut hoc mt t chc dch v, c nhiu cng c v k thut tng t c th ng dng c nhng dng c mt t thay i. Thay v phn cng, bn hy xem xt qu trnh gia tng gi tr v s dng thng tin hoc phn mm Khi nim vch dng (streamlining) v loi b cc bc khng tng gi tr t khi mt n t hng (hoc mt yu cu) c gi ti cho n khi nhn c khon thanh ton ang c quan tm. Cc khu gy nh tr sn xut c gii quyt bng cch s dng m hnh PDCA v cc khi xy dng LEAN ph hp. a.Loi b cc ro cn: Cc nh lnh o bit rng khng th ng yn trc cuc cnh tranh ton cu bi v cc i th khng gim chn ti ch m ang ci tin qu trnh v h thng ca h bt kp bn. Nu bn cng khng ci tin, khng sm th mun h s qua mt bn. Bn mt th phn, gim bin v doanh thu bn hng cng nh li nhun tn hi. V th, nu bn bit mnh cn ci tin, th vn ti sao ngi ci tin khng phi l bn. Qun l vic hoch nh v trin khai hp l l nhng b quyt t c thnh cng lu di khi trin khai LEAN. LEAN khng phi l s thay i nhanh chng. Bn s t a gin chnh mnh nu bn ngh rng p dng LEAN l iu d dng. Thnh cng i hi khng ch cc kinh nghim qun l s thay i m cn c s

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tch hp LEAN v chin lc kinh doanh tng th. Cn trnh hi chng cho rng ch cn vi tun l tin hnh c LEAN. Vic tin hnh LEAN c th khng dnh cho tt c mi ngi v th mt k hoch tng th cn thn, r rng da trn phn tch chi ph li nhun l bc tin quyt c ch. Cc li ch to ln t vic p dng LEAN trc tin xut pht t vic tp trung vo qu trnh bn c, cc sn phm m bn lm, mi trng ni bn ang vn hnh, tnh hung cnh tranh bn ang phi i mt v s cn thit s dng ng k thut ng lc. b.Vai tr ca lnh o cp cao p dng thnh cng, cc lnh o cp cao phi ng vai tr tch cc trong nhiu lnh vc: Xy dng 1 phng php tip cn c hoch nh tin hnh LEAN (khng phi l cc gii php ring l). Cung cp cc ngun lc cn thit. Phn quyn v khuyn khch cc CBCNV tham gia, nhn mnh lm vic theo nhm v s hp tc. C cc knh thng tin tt c t trn xung di v t di ln trn. Thu hiu c tm t ca CBCNV nh s mt vic khi LEAN. m bo rng tt c mi ngi hiu c s cn thit thay i cng nh cc vai tr mi khi tin hnh thay i. To ra mi trng th nghim, mt mi trng chp nhn ri ro v mt mng li an ton th nghim v kim li. a ra cc gii thng v cc chng trnh khen thng, cc h thng ghi nhn, thng chc. Khin mi ngi u hiu c cc l do cnh tranh v li ch ca LEAN cho t chc cng nh i vi chnh c nhn h.

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To ra mt tm nhn v tng lai sau thay i Gii thiu mt h thng o lng s thc hin cng vic da trn vic p ng cc mc tiu ca cng ty. Phn tch v chia s cc thng tin v li nhun so vi chi ph Nhn mnh trch nhim x hi ca mi ngi. c.Ba thnh phn ct yu tin hnh LEAN thnh cng l: 1.Cam kt, thc hnh lu di t lnh o cp cao. 2.o to tt c cc nhn vin v cc khi xy dng LEAN. 3.Qun l thay i vn ha tt trong sut qu trnh chuyn i tr lc y truyn thng sang tm l lc ko ca LEAN. Lean Production khng phi l mt phng php, hay mt nhm cc phng php. Hiu mt cch su sc nht, LEAN phi l mt trit l sn xut. d.iu kin trin khai LEAN ti doanh nghip Phi c mt nn vn ha mnh, c bn sc Hiu LEAN theo cch t duy v mt trit l sn xut di hn Lnh o phi lun lun cam kt, lun lun ng h (iu ny v cng quan trng, v s DN tht bi trong ci cch v lnh o khng lm c vic ny) Truyn t c v mt nhn thc cho ton b h thng con ngi. Nu khng nhn c s ng h ca ton b con ngi trong doanh nghip, vic tin hnh ci cch/ci t/thay i chc chn tht bi. Hy ngh v quy lut Pareto: 80/20. Cui cng, chng ta mi tnh n Cng ngh, quy trnh, sn phm .v.v... e. H thng y - H thng ko -V bn cht, sn xut l to ra mt sn phm tha mn mt (hoc nhiu) nhu cu no ca con ngi. Nhng nhu cu ca con ngi trong x hi vn d khng phi l bt bin bt nh. V vy, h thng ko - Pull System - l u vit hn..

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- Bn c th thy nhng sn phm xut ra th trng mt cch t, nh du gi u, kem nh rng, sa tm .v.v... Nhng tht ra, h vn l h thng ko, khng phi h thng y nh chng ta c th lm tng. B phn Marketing ca h vn tng ngy tng gi lng nghe khch hng thit k chin lc sn phm sao cho ph hp vi nhu cu.

f. Khng hong thiu c th xy ra nu nh cung cp thay i? - Cu hi ny ca bn, rt nhiu lnh o Doanh nghip t ra. Nu nh cung cp ca chng ti t ngt ph sn, t ngt thay i, vn vn v vn vn ..... th sao??? Khi , lm th no chng ti c th p ng c thi hn ca cc n hng? - LEAN c 2 tri tim: JIT (Just in Time) v jidoka. JIT bo rng phi gim thiu tn kho, c tn kho sn phm ln nguyn vt liu ca cc on trong quy trnh. Nhng nh vy khng c ngha l khng tn kho. H vn xc nh cc mc tn kho Max v Min, bn s c th thy u ngi ta gch 1 vch xanh v 1 vch ch cha nguyn vt liu cho cng on sau, vch di xc nh mc Min. Mc tn kho s c cn i trong 2 vch y. Ngi ta lm c iu ny bng cch thit k v phn tch chi tit tng cng on ca Quy trnh lung 1 sn phm, sau tin hnh "bnh chun ho" cc nguyn liu u vo cho mi khu ca qu trnh. V ch sn xut thm khi c yu cu t cng on sau, cc khu/cng on bo hiu cho nhau bng cng c gi l th Kanban.

- Ngoi ra, cc nh sn xut lun c phng n d phng cho nhng trng hp khn cp. I.2 LEAN MANUFACTURING L G? I.2.1 nh ngha v Lean Manufacturing

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LEAN trong ting Anh c ngha l s tinh gn, mch lc hay lin mch. Cc cp khc nhau bao gm: lean manufacturing (sn xut tinh gin), lean enterprise (doanh nghip tinh gn) v lean thinking (t duy tinh gn). 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. H thng sn xut tinh gn 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 cng sn lng v rt ngn thi gian sn xut dn n xy dng h thng sn xut khng c d tha. C th m t nh sau : C 1 dng nc ang chy t A ti B, trn ng i ca dng chy c nhng chng ngi, , ... lm dng chy phi chy vng qua. Khi LEAN PRODUCTION s nhm mc ch loi b cc chng ngi , gip ct gim cc lng ph v ngun lc. Ni ngn gn LEAN PRODUCTION --> Cut waste LEAN PRODUCTION l mt khi nim tng quan ha --> Toyota Production l cch trin khai LEAN ti Toyota. Do qu trnh trin khai t ti mc mu mc --> Thnh mt chun mc ca th gii I.2.2 Mc Tiu ca Lean Manufacturing 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;

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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 th i 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.

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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 1993: 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. I.2.3 Cc nguyn tc chnh ca Lean Manufacturing Tuy c p dng Toyota vo nhng nm ca thp nin 1950 nhng mi n u thp nin 1990 phng php ny mi c c kt v ph bin M. 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 chi ph tit kim t hot ng kinh doanh s trc tip ci thin li nhun cho doanh nghip 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 hng. 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. 2. 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.

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3. 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%. 4. 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. 5. 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. 6. 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. I.2.4 Trng tm ca Lean Manufacturing

I.2.5 Cc ng dng ca LEAN

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Da trn m hnh sn xut tinh gn, nhiu doanh nghip ang s dng nhng ngun lc quan trng :

Gim thi gian chun b sn xut. Ci thin ti a chu k sn xut - Gim thi gian quy trnh v chu k sn xut bng cch gim ti a 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; Ci thin cch b tr nh my da trn vic sp xp lu chuyn nguyn liu hiu qu; Gim nhng ngun lc cn cho vic kim tra cht lng; Quan h gn gi hn vi s lng nh cung cp t hn, cht lng tt hn v ng tin hn, nhng nh cung cp c th cung cp nhng l nh vt liu v ph tng trc tip cho cc qu trnh sn xut, va , va ng cho sn xut; gim ti a tn kho. S dng vic trao i thng tin in t vi nhng nh cung cp v khch hng; Hp l ha tng th sn phm loi b nhng mu sn phm v bin th t mang li gi tr tng thm cho khch hng; Thit k nhng sn phm vi t thnh phn hn v ph bin hn; Thit k nhng sn phm v dch v m yu cu ty bin ca khch hng c th thc hin c da trn nhng b phn v v mun c chun ha, v cng mi cng tt.

Hu ht cc ng dng trn u lm doanh nghip t c mc tiu 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. 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. I.2.6 Kt qu trn thc t ca vic ng dng LEAN Mt s cng ty ng dng Lean cho thy kt qu nh sau:

Mt bng sn xut trn mi my trung bnh gim 45%; Ph phm c th gim n 90% Chu k sn xut gim t 16 tun xung cn khong 5 - 6 ngy. Thi gian giao hng gim t 4-20 tun xung cn 1-4 tun.

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.

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Li ch chnh ca h thng ny l gim chi ph sn xut, tng sn lng v rt ngn thi gian sn xut. I.2.7 Nhng doanh nghip no s c li t Lean Manufacturing? 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 ho c 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

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ch i khng cn thit cng vi cc thao tc v di chuyn khng hp l ca cng nhn. I.2.8 Doanh nghip quan tm iu g khi lm LEAN? Qua nhng dp tip xc vi cc doanh nghip t nhn ti cc bui gii thiu chuyn cng nh qu trnh h tr mt s doanh nghip trong nc trin khai ng dng LEAN, phn ln cc ch doanh nghip vn t ra ngn ngi trong vic bt tay vo thc hin LEAN mc d hiu r tm quan trng v li ch thc tin do LEAN mang li. Tht ra, nhng vn c cc doanh nghip mang ra chia s vn cng l nhng trn tr ca hu ht cc doanh nghip va v nh khp ni trn th gii. Vic nhn dng nhng vn tim n c ngha quan trng trong vic gip doanh nghip c bc chun b thch hp trong qu trnh vn dng LEAN loi b lng ph nhm gia tng li nhun v nng lc cnh tranh di hn. Vn doanh nghip t ra l vi nhng kh khn trc mt nh vy, lm sao c th p dng Lean. Tuy nhin, cu hi l ra phi l liu Lean c gip gii quyt c nhng vn m doanh nghip ang gp phi hay khng. Liu Lean c ph hp cho doanh nghip nh Vit Nam ? C l y l cu hi ph bin nht t cc doanh nghip. Lm sao p dng c LEAN trong khi vn cn cht vt vi ISO, h thng v phng thc qun l cn ty tin thiu chuyn nghip, nng lc nhn s qun l cn yu km. Nhiu trng hp cho rng doanh nghip mnh rt c th, khng ging ai, quy trnh hot ng phc tp khng ai bng Ngoi ra, nhng kinh nghim au thng trong vic trin khai khng thnh cng mt s h thng hay chng trnh qun l trc y (ISO, ERP) to ra tm l ch i tm kim mt gii php hon ho hoc e ngi thay i. S v cha hiu ng v LEAN

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LEAN l quan im qun l v phng thc kinh doanh. p dng LEAN khng c ngha l bin doanh nghip bn tr nn ging Toyota. Mc tiu y khng phi l xy dng h thng LEAN m l ch trng vo n lc lin tc ci tin cc hot ng ca doanh nghip hng ti vic rt ngn thi gian t lc khch hng t hng n lc giao hng, nhn tin. *Chi ph t vn cn cao Lo ngi ny ch ng nu nhn n kha cnh b tin mi t vn v o to nhn vin. Tuy nhin, doanh nghip nn xem y l mt khon u t cho tng lai. Vn cn li l chn chuyn gia t vn c nng lc c c s hng dn ph hp v gip nhanh chng thy c kt qu. *Lm th no cp qun l v nhn vin ng h Lean Tm s ca mt Tng gim c ti mt doanh nghip c nhng chuyn bin ng k sau thi gian ngn trin khai LEAN: u tin phi t tho thun vi mnh (t thuyt phc mnh trc), sau mi c th tho thun/thuyt phc c vi nhn vin cp di. *Khng d t my m p dng Trn phng din l thuyt, LEAN a ra nhng bc trin khai v cng c h tr gii quyt vn kh hon chnh. Trong thc t, tng doanh nghip phi vn dng tinh thn v phng php LEAN ty hon cnh c th v c th ngnh ngh ca mnh. V vy, c c chuyn vin gip hng dn trin khai s c li cho doanh nghip v nhiu mt. *Khng d t chc my mc thit b theo lung lin tc Hu ht cc doanh nghip u phi i din vi thc t ny do trc y vic t chc ch yu theo m hnh sn xut l hng ln c cng quy cch, t phi thay i mu m. iu ny dn ti vic u t my mc thit b c cng sut ln nhm ti

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u chi ph khu hao trn n v sn phm. Tuy nhin nu nng lc thit b v h thng khng cn bng, lung sn phm thng b tc nghn khng ra c thnh phm. Thch thc ngy mt r khi nhu cu khch tr nn a dng, quy m l hng nh hn nhiu, bt buc phi chuyn i quy cch mu m sn phm nhiu ln trong ngy. D sao, iu ny khng c ngha rng doanh nghip s khng th p dng LEAN. *Ci m khng thy tin Sai lm thng gp khi doanh nghip thc hin ci tin l d b mt phng hng dn n vic ci tin mang tnh cc b khng gip ci thin hiu qu ca ton h thng. Chng hn, doanh nghip thng ch trng vo vic gia tng nng sut ca tng phn xng hoc thit b ring l nhng nng sut ca ton nh my v chi ph sn xut khng h c ci thin. *L thuc nh cung cp Vn lin quan n nh cung cp nh giao hng khng ng hn, cht lng khng n nh vn c xem l kinh nin. Vy Toyota lm vic vi cc nh cung cp th no? Cc nh my sn xut giy th thao ca Nike v Adidas cng cn phi nhp nguyn liu t nh cung cp ngoi, hoc mt s cng on phi a i gia cng ngoi. Mt trong nhng phng thc khi p dng LEAN l t chc h thng th no cc s c c nhanh chng pht hin v c kp thi khc phc. Tuy nhin, mc tn kho nhiu ch gp phn che y nhng yu km trong qun l. *Mt bao lu tr nn Lean? LEAN khng phi l mt danh hiu hay chng nhn. Qu trnh p dng LEAN cn c tc dng to ng lc gii quyt nhng kh khn, tn ng nh c nu ra phn trn. Toyota khng sn xut v t cung ng mi linh kin trong chic xe

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hi; h cng phi lm vic vi cc nh cung cp bn ngoi v phi gii quyt cc vn v chui cung ng. Toyota p dng LEAN t nhng nm 50, t lc cn l mt doanh nghip cha c tn tui mi bt tay vo hc cch lm xe hi. Mi cho n ngy hm nay, hn 50 nm sau, Toyota vn chung thu vi trit l LEAN v khng ngng tm kim c hi ci tin ngy mt lean hn. *Vy doanh nghip cn chun b th no tip nhn LEAN? Trc tin, doanh nghip s cn nh gi mc bc bch trong vic ci thin sc kho (cnh tranh, gi thnh, giao hng ng hn, lun chuyn tin mt, li nhun), nhng nu phi i n lc gp khng hong mi ngh n chuyn thay i th e rng khng kp. i khi, khch hng kh tnh chnh l ng lc gip doanh nghip vt qua ro cn tm l ban u. V d, Adidas tuyn b ch tip tc k hp ng gia cng vi cc nh my p dng v duy tr LEAN. L do l ch c cc nh my ny mi p ng c yu cu v thi gian thc hin n hng ngn. Vic tm hiu r v phng php v cch thc ng dng LEAN ng nhin l iu khng th thiu. D liu v hnh nh v hot ng hin ti ca doanh nghip cn c tp hp li lm c s v nh hng cho qu trnh trin khai LEAN. V sau, mt s iu chnh nh trong b tr c cu t chc c l s cn thit gip duy tr vic ci tin lin tc. Tuy nhin, phng thc tr lng cho cng nhn cn c xem xt iu chnh tng ng vi vic ti b tr lung sn xut. T chc o to l mt phn khng th thiu khi lm LEAN. o to gip ci thin cng tc bo tr bo dng my mc thit b sn xut, cng tc chuyn i nhanh, cn bng chuyn, o to cng nhn a k nng, v quan trng hn ht l o to phng php v k nng gii quyt vn cho tng nhn vin. Phng chm qun l ca Toyota l To ra con ngi trc khi to ra sn phm. Chng hn, Toyota gi khon 600 nhn vin c tuyn vo lm vic ti mt nh my ca Toyota

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M, bao gm c nhng ngi tng b General Motors sa thi, sang hun luyn ti nh my Toyota Nht, v ch sau 1 nm th nng sut v cht lng ti nh my M cng cao tng ng vi nh my Nht. Suy cho cng, vic ng dng LEAN c th c xem nh mt quyt nh cho nh hng tng lai ca doanh nghip. C hi cho mi doanh nghip trong vic tn dng LEAN l ra l nh nhau, tic thay, trong thc t ch c mt s doanh nghip c th nm bt c hi ny v h lun trong t th n nhn nhng iu mi m lin tc vn ln. I.3 CC KHI NIM TRONG LEAN MANUFACTURING I.3.1 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. I.3.2 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.

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I.3.3 Nhng lai lng ph chnh 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. 2. 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. 3. 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. 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. 5. 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. 6. 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

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th khng cn thit hay bt tin do quy trnh thao tc c thit k km lm chm tc lm vic ca cng nhn. 7. 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, c c 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. 8. 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. 9. 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. Tm ra 9 lng ph ny l mc tiu c bn khi tin hnh LEAN. Vic loi b hoc gim lin tc cc lng ph ny l mc tiu c bn khi tin hnh LEAN. Vic loi b hoc gim lin tc cc lng ph ny s gim c chi ph sn xut v chu trnh sn xut ng k. Phn tch nguyn nhn gc r ca tng lng ph ny s gip bn c c cng c LEAN ph hp gii quyt cc nguyn nhn xc nh c. V d: Nu cc khong thi gian lm ra sn phm lu v l thi hn giao hng l nhng khu yu chnh th khi xc nh cc l do tim n c th ch ti nh: cc giai on chun b cho n hng, thi gian ngng my, ngh khng php ca nhn vin, cng nhn, nh cung ng giao hng tr, cc vn cht lng hoc sn xut tha dn ti hng ho b tn kho Nhiu lng ph c th xut pht t cc bin thin trong cc qu trnh. Cc cng c thng k, bao gm c phng php DMAIC (xc nh, o lng, phn tch, ci tin, kim sot) ca 6 sigma c th ph hp gii quyt cc lng ph trn. V th LEAN v 6 sigma khng loi tr ln nhau m cn b sung cho nhau. Mt s t chc s dng kt hp hi ho gia LEAN, 6 sigma, l thuyt cn tr (theory of constrains) v TQM trong n lc phn u nhm ci tin thng xuyn v to ra li th cnh tranh

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n y th cu hi t ra l doanh nghip s phi ct gim chi ph v chng lng ph nh th no? S chui gi tr Khi doanh nghip quyt nh bt tay vo thc hin LEAN, bc u tin phi thc hin l ghi nhn li cc hot ng c th xy ra trong sut tin trnh cung cp sn phm, dch v. Qu trnh lp s chui gi tr s gip ch doanh nghip nhn thy hin trng hot ng, bao gm cc bc thc hin cng vic; qu trnh di chuyn ca thng tin v giy t; thi gian x l tng cng on; tng thi gian thc hin mt giao dch i vi khch hng. Sau khi c thng tin nhn ra s lng ph cng nh nhn thy cc c hi ci tin, doanh nghip s thit lp m hnh hot ng trong tng lai ci thin theo tng giai on mi su thng hay mt nm. Mi doanh nghip c th cng lc c nhiu s chui gi tr ty vo tnh cht c th ca cc nhm sn phm, dch v hay nhm i tng khch hng. Trng hp doanh nghip nhn thy c qu nhiu vn phi ci tin trong khi thi gian v ngun lc li c hn, hy tp trung vo cc vn n gin trc nhm to ng lc ban u. Trong qu trnh trin khai LEAN, cp qun l nn gp nhau mi tun nh gi tin trin khai, o lng hiu qu cng nh c nhng iu chnh kp thi. Mt s cng c thc hin Khi bt u thc hin ci tin chng lng ph, nguyn liu v sn phm tn kho l phn t c doanh nghip lu v a s cho rng y l bin php d phng cho nhng tnh hung bt kh khng gy thiu ht hng ha. Tuy nhin, tn kho nhiu li th hin nhng yu km trong qun l doanh nghip nh t l h hng sn phm cao, my mc thit b khng n nh, nghip v nhn vin km, cc phng ban lm vic thiu phi hp. Do , khi doanh nghip t chc li khu ny, vic gim lng tn kho cn c tin hnh thn trng v bi bn. Doanh nghip phi quyt tm gii quyt tn gc tng vn mt, nu khng s d quay v cch lm trc y - tn kho nhiu cho chc n. Thit k lung cng vic lin tc l bc m mang tnh t ph gip gim thiu ng nguyn vt liu cng nh thi gian sn xut. Vic b tr sn xut theo phng ban hay cm thit b c cng chc nng c th s gy ra s ch i gia cc khu, n y trch nhim gia cc b phn, l cha k thng tin gia cc phng ban c th khng c trao i kp thi. C mt doanh nghip dt may TPHCM sau khi chuyn sang p dng phng php trn t l hng b li gim hn 60% so vi trc nh pht hin v ngn chn kp thi nhng sai st ca cng on trc. Thi gian hon tt n hng ch bng mt na so vi trc kia nh loi b s ch i gia cc cng on. Cc thit b c xp lin tc gn nhau gip gim thi gian di chuyn bn thnh phm, ng thi gii phng c n 40% mt bng nh xng cho nhu cu s dng trong tng lai.

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Khi p dng cch trn, doanh nghip cn lu t chc lung cng vic lin tc l iu khng n gin. Trc ht phi c tin hnh th nghim thn trng trn quy m nh, sau khi hon chnh mi p dng i tr cho ton cng ty. Ngoi ra, doanh nghip cn lin tc t chc o to tay ngh a k nng gip cho vic phn b nhn vin c linh hot, uyn chuyn. Nh hot ng ca quy trnh s khng b nh tr khi c nhn vin ngh php, b m hoc c vic t xut phi vng mt. C rt nhiu cng c s dng khi thc hin LEAN. Chng hn nh cn bng chuyn l phng php gip ngi qun l cn i li tc x l cng vic cho nhp nhng hn, hoc chuyn i nhanh li l phng php gip gia tng thi gian hu dng ca cc thit b, c s vt cht ca doanh nghip. Cho d s dng cng c no, vic ng dng LEAN s kh em li kt qu nhanh chng nu doanh nghip khng bit tn dng cht xm ca tng nhn vin. Cc cng c khng t n gii quyt c vn ca doanh nghip, chnh nhn vin s l ngi a ra nhng gii php thc t v kh thi nht ci thin cng vic m h ang lm. Nhu cu khch hng ang thay i theo chiu hng ngy mt a dng v quan tm nhiu hn n yu t thi gian. Cc doanh nghip Vit Nam ri cng n lc phi tin ra bin ln vi mi trng cnh tranh khc nghit hn khi cnh ca WTO m toang. Vn cha qu mun nu lc ny doanh nghip nhanh chng nm bt tinh thn ca LEAN v quyt tm a vo ng dng. C hi doanh nghip pht huy ni lc v tr nn ln mnh vn cn pha trc. I.3.4 Sn xut Pull (Li Ko) 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 (tn 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.

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2. 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. 3. 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). Phng php pull tng t nh khi nim sn xut Just -inTime (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. 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. I.3.5 Cc m hnh khc nhau ca h thng sn xut Pull (Li Ko) 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 dy 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.

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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. 2. 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). 3. 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 v ap 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 n. I.3.6 V sao mc tn kho cao lm tng mc ph phm v lng ph? 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

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xc sut), s c rt nhiu kh nng l v s bao in li c to ra trc khi sai st c pht hin cng on sn xut k tip. 2. 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. 3. 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. 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. I.3.7 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 (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.

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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; v (trong mt s trng hp) hoch nh nhu cu nguyn vt liu. I.3.8 Quy trnh lin tc 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. 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 ngy. 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 tun.

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I.3.9 Phi hp quy trnh lin tc v khng lin tc 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 lai. 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. I.3.10 Ci Tin Lin Tc/ Kaizen 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.

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I.3.11 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 trng. 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: 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. 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. 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 Manufacturing. I.3.12 Quy hoch m phng dng t bo (Cellular Layout)

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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. 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. 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. 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 . 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. 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. 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

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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. I.3.13 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 xut 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. I.4 CC CNG MANUFACTURING C V PHNG PHP TRONG LEAN

I.4.1 Chun ho quy trnh (Standard Work) Chun ho quy trnh c ngha l cc quy trnh v hng dn sn xut c qu y nh v truyn t r rng n mc ht sc chi tit nhm trnh s thiu nht qun v gi nh sai v cch thc thc hin mt cng vic. Mc tiu ca vic chun ho l cc hot ng sn xut lun c thc hin theo mt cch thng nht, ngoi tr trng hp quy trnh sn xut c iu chnh mt cch c ch . Khi cc th tc quy trnh khng c chun ho mc cao, cc cng nhn c th c nhng ngh khc nhau v cch lm ng cho mt th tc quy trnh v d a n cc gi nh sai. Mc chun ho cao v quy trnh cng gip cc cng ty m rng sn xut d dng hn nh trnh c nhng gin on c th gp phi do thiu cc quy trnh c chun ho. Cc hng dn cng vic chun trong Lean Manufacturing thng c nh ngha v vit ra mc chi tit hn nhiu so vi yu cu ti thiu p ng iu khon 7.5.1. ca phin bng ISO9001:2000 v Kim Sot Sn Xut v Cung Cp Dch V (Control of Production and Service Provision), c th di hnh thc chun ho cc thao tc v trnh t cng vic cho tng cng nhn. Vic chun ho quy trnh trong Lean Manufacturing bao gm mt s thnh phn chnh: 1. Trnh t cng vic chun y l trnh t mt ngi cng nhn phi tun th khi thc hin cng vic, bao gm cc thao tc v cc bc thc hin cng vic. Vic m t r rng gip m bo rng tt c cc cng nhn u thc hin cng vic theo cch thc tng t nhau v hn ch cc sai bit vn c kh nng gy ra ph phm. Trong iu kin l tng, vic chi tit ho cng vic ch r tng bc thao tc cho mi cng nhn. V d vi cng on ct g, trnh t cng vic chun s m t t chi

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tit ct v cc bc thao tc nh chun b my, chnh dao ct, cch nng gi v a vt liu qua my v thi gian x l cng vic. i vi cng on lp rp, bng m t cn lit k chi tit tng bc thao tc thc hin vic lp rp cho mi loi sn phm. 2. Thi gian chun Takt time (nhp ) l tn xut mt sn phm c lm ra. Takt time c s dng m t r rng v theo di tc mt quy trnh cn c duy tr cc cng on khc nhau. i vi cc nh sn xut LEAN, takt time ca mi quy trnh sn xut c ch ng iu phi v gim st duy tr mt lung sn xut lin tc. 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. I.4.2 Truyn t Quy Trnh Chun cho nhn vin 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 lo i cng vic phc tp hay cc vn lin quan v an ton lao ng. I.4.3 Quy Trnh Chun v S Linh Hot 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.

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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 s 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. I.4.4 Qun l bng Cng C Trc Quan (Visual Management) 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... 2. 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. 3. 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. I.4.5 Cht lng t Gc (hay Lm ng ngay t u) 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

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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). 2. 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, 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. 4. 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). 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. I.4.6 S Chui Gi Tr (Value Stream Mapping)

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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. 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 th m. I.4.7 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. 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. 2. 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. 3. 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. 4. 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. 5. 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. I.4.8 Bo Tr Ngn Nga (Preventative Maintenance)

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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. I.4.9 Bo tr sn xut tng th (Total Productive Maintenance) 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. I.4.10 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.

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I.4.11 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. I.4.12 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). I.4.13 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. 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. 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

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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. I.4.14 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. I.4.15 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). I.4.16 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

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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% 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. I.5 TRIN KHAI LEAN MANUFACTURING I.5.1 S Tham Gia ca Lnh o Cp Cao 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. I.5.2 Bt u bng Vic Trin Khai Lean Tng Phn 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

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ca lean, 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. I.5.3 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. I.5.4 Nh Chuyn Vin 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. I.5.5 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. C th ti bi bo Building the lean machine (Xy dng c my lean) trong tp ch Advanced Manufacturing, k bo thng 9 nm 2000 c th tham kho danh sch cc vn cn c bao gm trong k hoch trin khai. I.6 KT HP LEAN VI CC H THNG KHC I.6.1 H Thng Sn Xut Toyota 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 gm:

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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. 2. 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 -haykhng, 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. 3. 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 vi n hay my c th nh v nhn vin hay my ny nn c t v tr cng gn ngun cung cp cng tt. 4. 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 m t 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. I.6.2 Lean Six Sigma 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. I.6.3 Lean v ERP 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

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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 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. I.6.4 Lean v ISO9001:2000 ISO9001:2000 l mt h thng qun l cht lng gip m bo rng c ng 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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CHNG II NG DNG H THNG SN XUT TINH GN TI CNG TY TOYOTA

II.1 VT KH VI CON NG TINH GN CA TOYOTA Kh khn l c hi vt ln chnh mnh khng nh bn thn. Khong 50 nm trc, cc doanh nhn Nht Bn cng han cnh v iu kin ht sc khc nghit: t nc b tn ph nng n, kinh t kit qu v chin tranh. Trong tnh hung kh khn Eiji Toyoda v cc gim c khc ca Toyota, trong ni bt l Taiichi Ohno khng chu li bc trc kh khn, kin tr nghin cu hc hi, sng to v thc hnh, to ra mt h thng sn xut lm thay i th gii. l h thng sn xut Toyota (Toyota Production System), gi tt l TPS. chu , nm 2005, li nhun ca Toyota nhiu hn c General Motors, Ford v Chrysler gp li. Trong khi General Motors chun b sa thi gn 30.000 cng nhn, ng ca hn chc c s sn xut th Toyota li m rng thm nh xng M v mt s ni trn th gii. V tr s mt ca General Motors (GM) trong sut 75 nm qua ang b lung lay khi nm ngoi Toyota qua mt Ford Motor chim lnh v tr s hai, ng thi t ra mc tiu vt qua GM v s xe xut xng trong ba nm na.. B quyt no gip Toyota lm nn nhng k tch nh th? B quyt thnh cng ca Toyota chnh l Lean! Lean chnh l mt trong nhng b quyt quan trng gip mang li thnh cng cho hng xe hi ny. II.2 CC M HNH CA TOYOTA II.2.1 M hnh 8 lng ph theo "Phng thc Toyota - The Toyota Way"

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Trit loi b lng ph Cc doanh nghip ang loay hoay vi bi ton chi ph, khng bit nn gim ci no, gi ci no, khng kho th "h tin l h ra l hng". Quan st thc t sn xut thu o v h thng, Ohno tp trung vo vic pht hin cc hnh vi em li gi tr gia tng cho sn phm v loi b nhng hnh vi khng c gi tr gia tng. Trit lai b lng ph chnh l tri tim h thng sn xut tinh gn ca Toyota (Lean Production). Theo Jeffrey K. Liker, tc gi ca cun sch "Phng thc Toyota" (The Toyota Way) th c tt c 8 hnh thc chnh gy lng ph, khng mang li gi tr gia tng trong qu trnh kinh doanh hoc sn xut. 1. Sn xut tha: Sn xut khi khng c n hng gy lng ph v vic tuyn thm ngi, tng chi ph kho bi v vn chuyn do tn kho sn phm d tha. 2. Thi gian ch: Thi gian ch i gia cc cng on, cng nhn khng c vic lm do ht hng, c nhiu s chm tr, thi gian thit b khng lm vic v cc yu t lm nh tr sn xut. 3. Vn chuyn khng cn thit: ng vn chuyn qu di trong nh my, t chc khng hp l vic vn chuyn, di chuyn vt t, thnh phm ra vo kho hay vo gia cng on sn xut. 4. Gia cng, ch to (bn thnh phm, thnh phm) qu mc cn thit hoc khng chnh xc: Thc hin cng on khng cn thit trong gia cng, ch to, hay cung cp sn phm c cht lng cao hn mc yu cu ca khch hng. 5. Tn kho qu mc: C qu mc cn thit nguyn vt liu th, sn phm d dang, hoc thnh phm d tha dn n thi gian sn xut b ko di, pht sinh vn chuyn, lu kho. 6. ng tc tha: L bt k thao tc tha no m ngi cng nhn thc hin trong khi lm vic nh tm kim, vn ti hay xp t cc b phn, dng c, di chuyn i li .v.v... 7. Sn phm li: Sn xut sn phm b li dn ti vic chnh sa, gia cng li, to ra sn phm ph, sn xut thay th v kim tra li dn ti lng ph vo nhng vic khng ng c. 8. Khng khai thc sc sng to ca ngi lao ng: Vic khng thc y hay lng nghe cc sng kin ci tin ca cng nhn c ngha l bn ang nh mt thi gian, tng, k nng, s i mi v c hi hc hi.

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Trin khai Lean: C hi khc phc kh khn thnh cng to c hi trit cho vic pht hin v loi b nhng lng ph ny, cn thit phi tuyn truyn v thc hin rng khp nh my, c bit l ch trng vic hc bng thc hnh hn l vic hc ti trng lp. C th l tho lun v nhng v d c th trong cng ty v 8 c hi gim lng ph nu trn. Tin hnh phn tch chui gi tr thc s trong cng ty, thc hin cuc hp gia khch hng v nh cung cp trong ni b (cc khu trong chui gi tr) xc nh c hi ci tin sn phm (gi tr cng vic chuyn giao gia cc b phn). Tip theo l nghin cu, hc tp v thc hnh tng bc cc cng c ca Lean nh Th Kanban (Th bo gia cng on), Qun l trc quan, Heijunka (Bnh chun ha), 5 Why (Phn tch nguyn nhn ct li ca vn bng cch hi 5 ln Ti sao), Jidoka v Andon (Cng c h tr lm l din cc trc trc ngay ti ch gii quyt ngay), Kaizen v Hansei (ci tin thng xuyn v t kim im bn thn hng ngy, ngay c khi lm tt tm ra c hi lm tt hn ln sau) .v.v... iu quan trng nht l to ra c vn ha tinh gn v con ngi tinh gn trong ton cng ty. II.2.2 M hnh 4P ca Con ng Toyota

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-P1: Trit l di hn (Philosophy: Long term thinking) -P2: Quy trnh ng mang li kt qu ng (The Right Process will Produce the Right Results) -P3: Gia tng gi tr cho t chc bng cch pht trin con ngi v i tc (Add Value to the Organization by Developing Your People and Partners) -P4: Lin tc gii quyt vn , hng n vn gc r v t chc hc tp khng ngng (Continuously Solving, Root Problem Drives, Organizational Learnin g) Hnh trnh Lean l mt vng trn ci tin lin tc, hnh trnh ny chng ta phi lm tt c cc cp ca t chc (nh l 3 vng trn trn) u tin cc P ln sau thc hin cc p nh dn ti kt qu ca P ln, chng ta s c gng lm iu g? Trit l chnh ca Lean l loi tr lng ph (chi ph) nhm to ra dng chy lin tc c o lng bi thi gian u ra. Phi hiu c cc cng c Lean v phn ra thnh ba phn nhm chnh. Mt l nhm xc nh v la chn cc vn bao gm cc cng c nh: tiu chuan ha, andon, kanban, qun l trc quan. Nhm th 2 l cc cng c phn tch bao gm: phn tch dng gi tr (VSM) tiu chun ha cng vic, gii quyt vn . Nhm th ba l cc cng c tm ra li gii bao gm: 5S, ngn nga li, chuyn i nhanh. II.2.3 M hnh ngi nh cht lng ca Toyota

M hnh H thng Sn xut Toyota (Toyota Production System TPS)

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Hnh ngi nh TPS tr thnh mt trong nhng biu tng d nhn bit nht trong gii sn xut hin i, th hin s vng chc bng h thng c kt cu cht ch lin kt vi nhau. Bt k s khim khuyt no cng s nh hng n cht lng ngi nh. Bt u t phn nn tng bng trit l kinh doanh di hn, qun l trc quan, chun ha qui trnh v cn bng sn xut. Hai tr ct vng chc l Just in-Time (Va ng lc JIT) ngha l sn xut va lc cn n, khng sn xut tha; v Jidoka (T kim li): khng bao gi cho ph phm c th i qua giai on tip theo, giai on sau c coi l khch hng ca giai on trc v phi c p ng ng yu cu. Phn ni tht v trung tm cn nh l con ngi v tp th, ci tin lin tc v tch cc gim lng ph. Mi nh l tp hp cc yu t Cht lng, Chi ph, Thi gian giao hng, An tan, Tinh thn lao ng. II.3 Con ng Lean Zero Tolerance for Waste A Stable Production Environment Customer Pull / Just-in-Time

T tng Lean I : Khng c dung sai no cho lng ph tn ti Tt c cc loi lng ph c th c ngn chn v loi tr Trng thi cng vic n gin, mc tiu th hon thin

T tng Lean II : Mi trng sn xut n nh v bn vng Sn phm c cht lng tt nht c th ch t c da trn mt mi trng sn xut n nh. Cc vn to nn s n nh phi c nhn din nhanh chng v gii quyt mt cch lu di Tiu chun ha, kin nh, c th d on c, v phi c lp i lp li thc hin c cc mc tiu T tng Lean III : Khch hng ko Pull / Va ng lc/Just-In-Time (JIT)

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Mt sn phm ch c th c lm ra p ng nhu cu ca khch hng, ch lm ra nhng g khch hng mun, v bn n khi n c k vng v vi cht lng hon thin nht Cc kt qu ca tip cn ny l tt nht cho vic s dng ti a ngun lc ca cng ty, vi vic dn u c li ch cao hn v bo v ngi lao ng II.4 THNH QU T C V CC THI IM NG GHI NH CA TOYOTA -1930: Thnh lp v bt u sn xut xe ti nh. Tham quan Ford v GM hc hi cch thc lp rp sn phm theo dy chuyn. -1948: N lc tn ti trong giai on sau chin tranh. Lm pht phi m Nht Bn, khan him tin mt dn n tng s n phi thu ca Toyota ln n 8 ln vn ca Cng ty, ct gim chi ph gt gao bao gm vic t nguyn gim lng ca qun l v 10% lng nhn vin. Nh sng lp Cng ty t Toyota l Kiichiro nhn trch nhim v t chc, ng thi vi vic nhiu cng nhn t nguyn xin thi vic. -1950: To ra H thng TPS. Eiji Toyoda v cc Gim c thc hin chuyn nghin cu cc Nh my ca Hoa K trong 12 tun. Bt u thc hnh v tng bc to ra H thng Sn xut Toyota lm i thay th gii. -1960: Bt u pht trin thnh trit l mnh m cho cc Cng ty noi theo: -1973: Khng hang du m a th gii vo thi k suy thai trong Nht Bn b nh hng nng n nht v Toyota mt ln na b ri vo tnh th kh khn gia tn ti hay l cht nhng cng li vt ln sm nht v c li nhun tr li nhan h hn so vi cc cng ty khc Nht. -1980: Nht, mi ngi t ri b Toyota v cc Cng ty lin kt vi Toyota sang lm vic vi cc cng ty khc. -1989: a nhn hiu xe cao cp Lexus ra th trng v n nm 2002 c lng bn nhiu hn BMW, Cadillac v Mercedes-Benz trn th trng M trong 3 nm lin tc.

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-1997: Ra mt chic Prius ca th k mi, xe hybrid sn sut i tr u tin ca th gii, thn thin mi trng v bo tn ti nguyn thin nhin. -2003: Vt qua Ford v Chevrolet v doanh s bn hng M -2006: Vt qua DaimlerChrysler ginh v tr th 3 ti th trng M -2007: Ln u tin vt GM v Doanh s bn hng tan cu, ng thi vi vic dn trc v li nhun lin tc cho n nay. II.5 CON NG THNH CNG CA TOYOTA THE TOYOTA WAY Toyota gy c s ch ln u tin ca th gii vo nhng nm 1980 khi m khch hng bt u nhn ra rng xe Toyota c tui th di hn v t sa cha hn xe M. Ngy nay h l mt trong nhng nh sn xut xe hi c li nht trn th gii, sn xut xe hi cht lng cao, theo th hiu ca ngi dng, s dng t gi lao ng v hng ha tn kho. n ngy hm nay, Toyota vn tip tc gia tng sn xut, pht trin sn phm v han thin quy trnh II.5.1 Sc mnh tm c th gii ca Con ng Toyota Con ng Toyota: ly kh nng sn xut xut sc lm v kh chin lc. H thng sn xut Toyota (TPS) v sn xut tit kim (lean production) Toyota sng ch ra h thng sn xut tit kim vo nhng nm 40 v 50. Cng ty tp trung vo vic lai b thi gian v vt liu tha ca tng cng an trong quy trnh sn xut (t nguyn liu cho n sn phm han chnh) Kt qu cho ra mt quy trnh linh hat v nhanh m c th p ng nhng g khch hng mun, khi no h cn n, vi cht lng tt nht v mt chi ph chp nhn c. Toyota ci tin vic sn xut bng cch: Lai b thi gian v ti nguyn tha Xy dng h thng cht lng cho cc h thng lm vic Tm cch gim chi ph v cc phng php thay th cc cng ngh mi t tin Han thin cc quy trnh lm vic Xy dng vn ha hc tp phc v cho mc ch ci tin lin tc Toyota tr thnh nh sn xut tt nht th gii nh th no? Toyota pht trin h thng sn xut Toyota (TPS) sau th chin th hai. Trong khi Ford v GE vn s dng vic sn xut hng lat v kim sat theo quy m, Toyota i mt vi cc iu kin kinh doanh rt khc nhau. Th trng ca Toyota rt nh nhng phi sn xut cc lai xe khc nhau trn cng mt dy chuyn

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theo yu cu ca khch hng. Gii php cho vic ny: lm cho cc qu trnh vn hnh phi rt linh hat. iu ny dn ti s ra i ca TPS. TPS mn mt s tng ca Hoa K. tng chnh ca h thng Just in time (JIT) c c t khi nim ca h thng ko m ly cm hng t h thng siu th M. Trong h thng ko, mi mn hng s c cung cp thm khi m chng bt u vi i trn k. p dng vo cng ty Toyota, iu ny c ngha l bc u tin ca quy trnh s khng c han tt cho ti khi bc hai s dng nguyn liu hoc ngun cung cp ca bc 1. Trong quy trnh sn xut, Toyota s dng Kaban ra hiu cho bc trc khi cc ph tng cn c b sung Cng ty cng c truyn cm hng t ng W.Edwards Deming. Ngai vic nh ngha mt cch tng qut khch hng gm c khch hng bn ngai v khch hng ni b, ng cng khuyn khch Toyota p dng cch tip cn mt cch c h thng trong vic gii quyt vn , m tr thnh ct li trong vic ci tin lin tc ( c bit nh l Kaizen) Thc cht ca h thng sn xut Toyota: lai b s tha thi im chnh ca h thng TPS l gim thiu thi gian s dng trong cc hat ng khng to ra thm gi tr bng cch b tr nguyn liu v cc dng c sao cho gn dy chuyn lp rp nht c th Cc kiu lng ph chnh trong quy trnh sn xut v kinh doanh: Sn xut tha Ch i hoc.. S vn chuyn hoc di chuyn khng cn thit Gia cng tha hoc x l khng chnh xc Khim khuyt Khng s dng tnh sn to ca nhn vin Tn kho qu nhiu II.5.2 Cc nguyn tc kinh doanh trong Con ng thnh cng ca Toyota Nguyn tc 1: quyt nh ca bn phi da trn trit l di hn, ngay c khi phi tiu tn cho nhng mc ch ti chnh ngn hn. Thng ip ca Toyota rt nht qun: hy lm iu tt cho cng ty, nhn vin ca cng ty, khch hng hay x hi ni chung. Trit l di hn ny l nhim v ca cng ty m lin tc tm ti cung cp cho khch hng, nhn vin, c ng cht lng v dch v tt nht. Mc tiu di hn nn thay th cc quyt nh hay mc tiu ngn hn. Pht trin, lm vic, tng trng v hng cng ty theo mc tiu chung c ngha hn l kim tin. Nhim v cao c ca bn l v nn l nn tng ca tt c nguyn tc khc.

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*NG DNG : Toyota i theo hng lm hi lng khch hng. H tin rng nhng khch hng hi lng s quay li v em li nhiu cng vic hn. iu ny s to ra gi tr cho khch hng, x hi v nn kinh t. Mt trong nhng yu t chnh to nn thnh cng ca Toyota l n sng vi trit l tn nhim ln nhau v tinh tn t chng ta lm. iu ny c minh ha r nht khi h tham gia vo ngnh cng n ghip t hng sang. H khng mua li cng ty sn xut t hng sang. Thay vo , cng ty to ra mt b phn xe hi hng sang ring dng Lexus- t ng tp nham hc hi v hiu c bn cht ca xe hi hng sang. Nguyn tc 2: to nn dng x l lin tc gii quyt cc vn H thng sn xut hng lat m c nhiu nh sn xut s dng to nn s d tha vi khi lng ln m s dn n hng ha tn kho khng c dng n v chim ch nh my. *NG DNG :H thng sn xut tit kim ca Toyota thit k li quy trnh lm vic sao cho vic di chuyn nguyn liu v thng tin nhanh hn. ti u vic di chuyn nguyn liu sao cho nhanh hn, Toyota gim ln ca mt t sn xut v cc n v cng vic s c nhm theo sn phm hn l quy trnh. Dng x l lin tc s kt ni quy trnh v con ngi vi nhau m khi c mt vn xut hin, n s c gii quyt ngay. Li ch ca dng x l lin tc/ nguyn khi Xy dng cht lng To nn linh ng tht s To nn nng sut cao hn Ci tin an tan lao ng Nng cao tinh thn lm vic Gim chi ph hn tn kho Gii phng mt bng Nguyn tc 3: s dng h thng ko trnh vic sn xut tha H thng ko xoay quanh tng cung cp thm hng ha da trn nhu cu hng ngy ca khch hng hn l c nh theo mt lch trnh hoc h thng. N c gi l h thng linh hat theo nhu cu ca khch hng H thng just in time (JIT) s cung cp cho khch hng nhng g h mun, khi no v s lng m khch hng cn. Nguyn liu c cung cp thm ty vo s tiu th, gim thiu cng vic trong quy trnh v s sp xp hng ha tn kho. Bn ch phi d tr mt khi lng nh cho mi sn phm v thng xuyn b sung chng da trn nhng g m khch hng tht s ly i. Nguyn tc 4: Cn bng khi lng cng vic (heijunka) H thng lm theo n hng cng nhc to nn rt nhiu hng tn kho, chi ph chung, cht lng sn phm v dch v ngho nn hn, v che du cc vn . *NG DNG : lai b c nhc im ny, Toyota a ra cn bng k hach sn xut.

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Cn bng mc sn xut theo khi lng v hn hp sn phm c bit nh heijunka. Quy trnh khng sn xut ra sn phm theo n hng tht s ca khch hng. Thay vo , n tnh tng khi lng n hng trong mt khang thi gian v Cn bng ra. Kt qu l sn xut cng mt khi lng cho mi ngy. Li ch ca k hach Cn bng: Linh hot trong vic lm theo nhng g khch hng mun v khi no h cn Gii thiu ri ro ca hn ha khng bn c Cn i gia lao ng v hng ha Nguyn tc 5: Xy dng vn ha mua sm gii quyt vn , t c cht lng tt ngay ln u. Cht lng cho khch hng l mt ng lc ca bt k trit l ca cng ty no. Cht lng c xy dng trong cng ty hoc cc quy trnh sn xut. Xy dng thit b cnh bo sm trn dy truyn hoc thit b ngn khng cho s c xy ra lm ngng hat ng h thng. iu ny s gip gim chi ph v hat ng hiu qu hn l kim tra v sa cha cc s c sau khi xy ra. Bn cng nn xy h thng h tr nhanh chng khc phc s c v to ra cc tiu chun. Pht trin nguyn tc ca cng ty l ngng hoc tr han cng vic khi c s c xy ra v t cht lng tt gia tng nng sut v li nhun tron g di hn Nguyn tc 6: Chun ha cc cng vic l nn tng cho vic ci tin lin tc v trao quyn cho nhn vin S chun ha cc cng vic l nn tng cho vic ci tin lin tc, i mi, tng trng v cht lng. Khng th cao bt k quy trnh no cho ti chng c chun ha. Cht lng cng c bo m nh vy thng cc quy trnh chun ha m bo s m bo s nht qun trong quy trnh v sn phm. Khi thc hin vic chun ha, cn i gia vic cung cp cho nhn vin cc quy trnh cng ty vi li cho h t do sng to v i mi l mt vic rt quan trng. Cc tiu chun nn r rng a ra c nhng hng dn hu ch, tng qut v cho php mt s thay i. Nguyn tc 7: s dng phn iu khin c hin th khng c li no b che du Nm S lai b s lng ph: Phn lai Ch gi li nhng g cn v vt b nhng th khng cn Sp xp. Duy tr s ngn np. Lun nh rng, lun c ch cho mi th v mi th c ch ca n nh sng hc s sch s. Quy trnh dn v sinh thng l mt hnh thc kim tra m c th pht hin ra cc h hng hoc tnh trng bt thng c th nh hng n cht lng Chun ha hoc a ra cc iu l. Pht trin h thng v cc quy trnh duy tr v gim st 3 quy nh nu trn

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Duy tr. Gi gn ni lm vic n nh l mt qu trnh ang thc hin ca vic ci tin lin tc Nguyn tc 8: ch s dng cng ngh c kim ta k cng v tin cy phc v con ngi v quy trnh Vic a vo cng ngh mi phi h tr con ngi, cc quy trnh v cc gi tr ca h. Cng ngh mi khng c thay th hoc th ch chng. Ch gii thiu cng ngh mi sau khi c kim tra v chng minh vi cc bn lin quan ca cng ty ca bn. *NG DNG : Trc khi chp nhn mt cng ngh mi. Toyota u tin phi phn tch nh hng ca n i vi cc quy trnh ang tn ti. Nu h thy n cng ngh mi lm tng thm gi tr cho h thng c. Cng ty s phn tch tip xem c xung t vi trit l ca cng ty v cc nguyn l hat ng hay khng. Nu n vi phm bt k nguyn tc no, Toyota s lai b ngay cng ngh mi . Vic gii thiu cng ngh mi s c lm thng qua mt qu trnh ng tm, phn tch v ln k hach cho tt c nhn vin v ch u t lin quan ti quy trnh. Mt quy trnh cht ch nh vy s cho kt qu trin khai cng ngh mi sung s m khng c s khng c ca nhn vin hoc v quy trnh Nguyn tc 9: Pht trin cc nh lnh o hiu r han tan cng vic, tan tm vi trit l ca cng ty v dy n cho nhn vin. Pht trin cc nh lnh o t trong cng ty hn l thu mn bn ngoi. *NG DNG :Toyota khng bao gi cp ch tch hoc CEO ca cc cng ty khc. Thay vo , h tm kim cc nh lnh o ch cht trong cng t y- cc b phn bn hng, pht trin sn phm, sn xut v thit k. Trit l ca cng ty trong vic thng chc v c c cc nh iu hnh cp t trung ti cao trong cng ty xut pht t nim tin ca cng ty rng h lai b c s thay i tht thng cp iu hnh. Vic thay i vn ha khi m c mt nh lnh o mi n, mang theo s ln xn cc cp, nhn vin phi hiu chnh theo cc iu l mi. iu ny cng khng pht trin nng lc tht s hoc lng trung thnh ca nhn vin Toyota tin rng cc nh lnh o trong t chc ca h phi sng v hiu vn ha ca Toyota mi ngy. H cng mong i cc nh lnh o ca h o to cc cp di cng sng v hiu con ng thnh cng ca Toyota Nguyn tc 10: pht trin nhng con ngi ti ba i theo trit l ca cng ty S dng v hiu r thuyt ng vin. Thuyt nhu cu ca Maslow tha mn cc nhu cu cp thp hn v khch l nhn vin ln cp bc cao hn l t th hin mnh. *NG DNG : Phng php ca Toyota l tr lng cao, m bo vic lm, iu kin lm vic an tan tha mn cc nhu cu ca nhn vin. Vn ha ca vic ci

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tin lin tc ca Toyota h tr cho s pht trin v hng t th hin mnh. Toyota s dng cc thuyt ng vin khc nhau khch l v truyn cm hng cho nhn vin ca h han thnh xut sc nhim v 1. Thuyt lm phong ph cng vic ca Herberg lai b nhng ngi bt mn v thit k cng vic to ra nhng ngi tha mn tch cc l nn tng ca s pht trin chng trnh nghin cu v lao ng 5 S, qun l v tm nhn v cc chnh sch nhn s v cc tiu chun v sinh. Ci tin lin tc ca Toyota, lun chuyn cng vic v cc nh khch l hnh ng nh cc ngi tha mn tch cc 2. Thuyt qun l c khoa hc ca Taylor thit k cng vic mt cch chun ha v la chn mt cch khoa hc, cng nh o to v khen thng thnh tch theo kt qu lm vic. Toyota lm theo cc nguyn tc qun l c khoa hc ca Taylor mc nhm hn l c nhn 3. Thuyt thay i hnh vi cng c thm cho hnh vi ca vic dng chy lin tc ca Toyota s to nn thi gian lnh o ngn hn v c hi p nhanh hn. Cc vn c ch nhanh hn v cc nh lnh o c mt thng trc cho thy s ng h ca h 4. Thuyt thit lp mc tiu cn thit cho cc mc tiu r rng, o lng c, c kh nng t c. Toyota t ra cc mc tiu theo tiu chun ny thng qua hoshin Kanri ( pht trin cc chnh sch) Nguyn tc 11: nh gi cao vic m rng mng li i tc v nh cung cp bng cc a ra nhng th thch v gip h ci tin i x vi i tc v nh cung cp nh mt phn m rng cng vic kinh doanh ca bn. *NG DNG : Toyota duy tr nguyn tc hip hi. Cng ty xem cc nh cung cp nh cc i tc lm n. Toyota khng ch th thch nhn vin ca h c c kt qu xut sc v c s tin b, h cng th thch c cc nh cung cp Theo tc gi, vic pht trin nh cung cp c thc hin vi mt lat cc ch tiu v th thch gt gao. Cc nh cung cp mum lm vic vi cng ty v h bit rng h s tr nn tt hn v gia tng s tn nhim gia cc n v cung cp v cc khch hng khc Toyota lun xem xt nh cung cp mi vi mt s thn trng v t hng rt t . Tuy nhin, mt khi h c c lng tin ca Toyota, v chng minh cho thy s thnh tht ca h trong vic cam kt tun theo cc tiu chun ca Toyota v chi ph, cht lng v giao hng, Toyota s chp nhn h v dy theo cch ca Toyota. Mi quan h vi cc nh cung cp v cc hip hi thng l di hn v him khi no c s thay i nh cung cp tr khi mc phi sai lm t hi. Nguyn tc 12: t mnh i v xem xt hiu r han tan mt vn (Genchi Genbutsu) Ngh v pht biu da trn nhng thng tin v d liu c t mnh kim chng.

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i v t mnh chng thc cc thng tin. Lun nh rng bn l ngi chu trch nhim cho cc bo co v thng tin cung cp cho ngi khc. Gii quyt vn v ci tin cc quy trnh bng cch i n tn ni v t mnh xem xt v xc nhn thng tin v d liu Khng phi t suy xt v nhng g nghe hoc ngi khc ni vi bn l mt vic rt quan trng. Khi chnh bn i tm hiu th bn s hiu thu o vn hn. Nguyn tc 13: ra quyt nh phi chm sau khi cn nhc mi kh nng v c s ng tm; thc hin n mt cch nhanh chng Qu trnh ly kin ca mi ngi s gip tm ra nhiu gii php v vic thc hin cc quyt nh nhanh chng hn. *NG DNG : i vi Toyota, cch thc ra c quyt nh cng quan trng nh cht lng ca quyt nh. Khng nn vi vng ra quyt nh nu cha xem xt mi yu t, cc kh nng khc v tham kho kin ca nhng ngi chu nh hng bi kt qu ca quyt nh . Khi bn c c gii php th nn thc hin n nhanh nhng vi s cn trng. Tham kho kin s lm gip cho vic chp nhn gii php d dng hn v qu trnh thc hin c sung s hn. S xut sc ca Toyota c trnh by chi tit. Cng ty xem xt tt c yu t (chi ph, cht lng, kh khn, gii php v ch u t) 5 yu t chnh c xem xt trong qu trnh ra quyt nh : - Tm hiu nhng g tht s ang xy ra - Hiu cc nguyn nhn ca vn v t hi ti sao 5 ln - Tnh n nhng gii php thay th v chi tit ha gii php c la chn - Xy dng s ng thun ca nhn vin, nh cung cp - S dng knh thng tin mt cc hiu qu truyn t cc bc t bc 1 n 4 Nguyn tc 14: tr thnh mt t chc hc hi thng qua s suy ngh khng ngng (hansei) v s ci tin lin tc(kaizen) Thit lp mt quy trnh c s gim st v ci tin lin tc. Mt khi bn thit lp c mt quy trnh n nh v chun ha, hy s dng cc cng c ci tin lin tc tm ra nguyn nhn su xa ca vic km hiu qu p dng cc phng php ph hp To ra mt quy trnh m yu cu ti thiu ( nu c th khng) hng tn kho. iu ny s gip pht hin v sa cha cc ngun ti nguyn v thi gian tha. Bo v cht xm bng cch pht trin i ng nhn vin n nh, hc hi lin tc. o to nhn vin tr thnh nhng nh lnh o v lm vic hiu qu. Thng chc cho nhn vin ca cng ty. Chun ha quy trnh tt nht cho mi d n mi v nh qun l mi II.6 KINH NGHIM V THNH CNG TI CNG TY TOYOTA BN THNH C l Toyota Bn Thnh l cu chuyn v ng dng Lean thnh cng Vit Nam

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c nhc n nhiu trong thi gian qua. y l mt trong nhng trung tm dch v bo tr hng u ca Toyota ti Vit Nam. Nh p dng Lean, Toyota Bn Thnh rt ngn c hn ba phn t thi gian bo tr nh k cho mt chic xe, t 240 pht xung cn khong 50 pht. u tin, Toyota Bn Thnh khc phc khong thi gian cht, chim n hn mt phn t thi gian bo tr xe, ch yu do cc nhn vin phi i nhau trong lc giao v nhn ph tng gia cc cng on ca quy trnh. Tuy nhin, vn cn mt na thi gian bo tr cn phi y nhanh tin theo yu cu ca khch. ct gim lng thi gian tha ny, Toyota Bn Thnh nghin cu li vic sp xp ch ng ca cng nhn trong thao tc c th h tr nhau nhiu hn, t mt thi gian di chuyn hn; sp t li dng c theo tng thao tc ph hp cng nhn s dng c thi gian ti u trong vic la chn dng c lm vic; trang b thm cc thit b chuyn dng v hun luyn cng nhn s dng thnh tho cc thit b ny Cu chuyn ng dng thnh cng Lean ca Toyota Bn Thnh cho thy vic t chc quy trnh sn xut hp l c ngha hn l i mi thit b, cng ngh nhm tng nng sut lao ng. Trn thc t, nhiu c s sn xut cng nghip Vit Nam vn cha thy c tm quan trng ca vic quy hoch mt bng nh xng, b tr my mc thit b ph hp, rt ngn thi gian vn chuyn nguyn liu t kho vo dy chuyn sn xut s gip tng hiu sut lm vic ca cng nhn nh th no. trng hp ca Toyota Bn Thnh, vn u t cho vic mua sm trang thit b mi ch khong 10.000 la M, cn li mi th u tng t nh cc trung tm bo tr xe hi khc. Kt qu mang li khng ch l s hi lng ca khch hng m cn l li ch kinh t: Toyota Bn Thnh tng s lng xe c bo tr t su ln 16 chic/ngy. II.7 BI HC KINH NGHIM CHO CC DOANH NGHIP VIT NAM LEAN gip nhiu doanh nghip trn th gii lm nn thnh cng. Tuy nhin, vic p dng LEAN Vit Nam vn cha c ph bin v s doanh nghip p dng LEAN thnh cng ch m trn u ngn tay. Mt s doanh nghip khc c kho st c bit cht t v LEAN nhng cha dm p dng v nhiu l do, nht l tm l e ngi khi phi thay i mt cng c qun l sn xut mi m cha thy minh chng v hiu qu ca n ti Vit Nam Mt doanh nghip trong ngnh dt may cng p dng LEAN kh thnh cng. Ngi i din doanh nghip cho bit, p dng LEAN thi gian u gp phi khng t nhng nghi ng v hiu qu thit thc ca chng trnh, v n tc ng trc tip vo quan im qun tr v cch thc iu hnh hot ng ca cng ty. Gii qun l cp cao ti doanh nghip ny phn i vic p dng LEAN v n ph nhn cng lao ng gp ca h. Theo mt chuyn gia t vn v LEAN, y l tnh trng chung m phn ng cc doanh nghip t nhn Vit Nam gp phi v mt s ngi c xem l tr ct phi i mt vi nhng thay i c th tc ng n v tr v tm nh hng ca h ti doanh nghip. Trong trng hp doanh nghip dt may

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trn, ch doanh nghip mt mt phi ht sc mm mng thuyt phc nhng ngi chng i, mt khc phi tin vo vic ng dng LEAN. Sau khi thng t tng trong ban gim c, ngi ch doanh nghip ny li phi i mt vi mt kh khn khc: nhn lc qun l chuyn bit. Chng hn, trc y mi mt sn phm may mc s c mt ngi chuyn ph trch vic ct vi, by gi p dng LEAN ch cn mt ngi ph trch vic ny cho cc nhm sn phm. y l iu cc k kh khn v tc thi khng d tm, hay o to, mt ngi c k nng chuyn su nh th. Bn cnh , LEAN yu cu ch sn xut va , hn ch hng tn kho. Nhng iu ny li lm l ra nhiu tn tht tim n v tng p lc cho nh qun l nh my h khng sa kp, cng nhn bnh t xut dn n khng lm kp n hng. Tuy nhin, khi vt qua c nhng kh khn trn th LEAN thc s pht huy tc dng. Kinh nghim u tin doanh nghip trn l thc hin chuyn mu, tc b tr cng nhn ngi ng s my theo lung di chuyn hp l ca sn phm. Trc y, mi cng nhn t chn cho mnh mt ch ngi ty thch, dn n gin on chuyn sn xut v c khi hai cng on lin nhau nhng hai my li t cch xa nhau. Bi hc k tip l cch tr lng. Lu nay doanh nghip tr lng cn c theo s lng, m khng cn c vo kh ca vic to ra sn phm tng cng on nn lun c s cch bit ln v thu nhp trong cng mt chuyn sn xut. Nay lng c tr theo sn lng ca c mt chuyn sn xut, nn thu nhp ca ngi lao ng c tnh ton hp l hn. Ngi c tay ngh cao hay thm nin th doanh nghip cho nhn thm h s gi chn, ng thi khuyn khch h gip nhng ngi yu ngh hn trong chuyn sn xut ca mnh. Nhng kt qu tip theo khi doanh nghip ny p dng LEAN bao gm gim thi gian thc hin n hng t 30 ngy xung cn 15 ngy; gii quyt c tc nghn trong dy chuyn sn xut (v by gi ngi gii ngh s h tr ngi yu, ngi lm cng on n gin s c phn thm vic cho bng vi thi gian ngi lm cng on phc tp). Quan trng hn ht l gi y doanh nghip, tnh on kt ca cc b phn tng ln, t chuyn sn xut hot ng lin tc, cng vic gia cc thnh vin c cn bng v thi gian h hng my mc cng c rt ngn li ***13 li khuyn trong vic chuyn i cng ty thnh mt cng ty gn nh (LEAN) 1. Bt u hnh ng vi h thng k thut. Bt kp nhanh i vi thay i vn ha 2. Hc hi bng cng vic trc ri o to sau 3. Bt u vi ngi tin phong hng say tp trung vo h thng tit kim v a ra m hnh mu 4. S dng vic sp xp theo cp pht trin tm nhn trong tng lai v 5. p dng kaizen truyn b v to nn nhng thay i nhanh chng 6. T chc da trn dng gi tr 7. Bin mi th thnh nhng iu kin b buc

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8. Khng hong c th l bt u ca s ci tin, nhng khng nht thit lm cho cng ty thay i mt cch o ln 9. Tn dng cc c hi n nhn cc c hi c tc ng mnh v ti chnh. 10. Lin kt cc tiu chun o lng da trn dng gi tr 11. Xy dng nn tng ca cng ty v pht trin li i ring 12. Tuyn dng hoc pht trin cc nh lnh o v pht trin i ng k tha 13. Dng chuyn gia hun luyn nhm c kt qu nhanh chng

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KT LUN
Nn kinh t ton cu c nh hng bi khch hng, y cnh tranh v thay i nhanh chng ngy nay dn n mt mi quan tm mi v LEAN Loi b cc bin thin v qun l trong LEAN gip cc t chc tr nn cnh tranh hn, nhanh nhy hn v p ng c cc i hi ca nhiu th trng. Qun l vic hoch nh v tin hnh lean l nhng im mu cht gip t c kt qu trn vn. cnh tranh trong nn kinh t ngy nay, t nht bn phi phn u bng cc i th cnh tranh ton cu, nu khng ni l phi hn. iu ny khng ch ng v mt cht lng, m cn v cc chi ph, thi gian sn phm, ch bi n, giao hng, lp t, phn ng v cc vn khc. LEAN nhn mnh lm vic theo nhm, o to v hc hi khng ngng, sn xut theo nhu cu (sc ht), ch to theo yu cu khch hng trn quy m rng v gim s lng sn xut th nghim, sn xut mu, thay i h thng lm vic nhanh v bo dng nng sut ton din. Chng c g ngc nhin khi vic p dng LEAN bao gm c phng php ci tin t ph ngy cng hon thin hn. Lean l mt trit l sn xut, rt ngn khong thi gian t khi nhn c n hng ca khch hng cho n khi giao cc sn phm hoc chi tit bng cch loi b mi dng lng ph. Sn xut tit kim gip gim c cc chi ph, chu trnh sn xut v cc hot ng ph khng cn thit, khng c gi tr, khin cho cng ty tr nn cnh tranh, mau l hn v p ng c nhu cu ca th trng. Nguyn tc ch o ca Lean l gia tng gi tr cho khch hng thng qua vic lin tc loi b lng ph trong sut qu trnh cung cp sn phm v dch v. Lng ph y c hiu l tt c cc hot ng ca doanh nghip khng gip to ra gi tr mong mun cho khch hng. V th, mun p dng Lean, doanh nghip phi hiu u l nhng iu khch hng tht s quan tm, nhng gi tr t sn phm v dch v cung cp c khch hng sn sng tr tin Trn c s , doanh nghip s bit cch gim thiu, hoc loi b, nhng hot ng no lm pht sinh chi ph v ko di thi gian ch i ca khch hng.