Khái Quát Và Ứng Dung Lean Tai Viet Nam

NGU

B GIO DC O TO I HC KINH T THNH PH H CH MINH

BO CO CHUYN SN XUT TINH GN V VIC NG DNG VO CC

CNG TY TI VIT NAM

GIO VIN : H TIN DNG SINH VIN THC HIN : NGUYN THANH MINH

LP : K17 M 3 CHUYN NGNH : QUN TR KINH DOANH

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MC LC Chng 1 : Tng Quan ca Bo Co Chng 2 : C S L Thuyt

1. Lean l g 1.1 Lch s ca Sn Xut Tinh Gn (Lean) 1.2 Mc Tiu ca Lean

1.3 Cc Nguyn Tc Chnh ca Lean

1.4 Trng Tm ca Lean

1.5 Li ch t Lean

2. Cc Khi Nim trong Sn Xut Tinh Gn 2.1 Vic To Ra Gi Tr v S Lng Ph

2.2 Nhng Loi Lng Ph Chnh 2.3 Sn Xut Li Ko (Pull) 2.4 Cc M Hnh Khc Nhau ca H Thng Sn Xut Pull

2.5 V Sao Mc Tn Kho Cao Lm Tng Ph Phm v Lng Ph 2.6 Tc ng ca H Thng Pull i vi Vic Hoch nh Sn Xut 2.7 Quy Trnh Lin Tc 2.8 Phi Hp Quy Trnh Lin Tc v Khng Lin Tc 2.9 Ci Tin Lin Tc/ Kaizen 2.10 S Tham Gia ca Cng Nhn

2.11 Quy Hoch M Phng Dng T Bo 2.12 Administrative Lean (Lean cho Cng Tc Hnh Chnh)

3. Cng C & Phng Php trong Sn Xut Tinh Gn 3.1 Chun Ho Quy Trnh 3.2 Truyn t Quy Trnh Chun cho Nhn Vin 3.3 Quy Trnh Chun v S Linh Hot 3.4 Qun L bng Cng C Trc Quan 3.5 Cht Lng t Gc (hay Lm ng ngay t u) 3.6 S Chui Gi Tr

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3.7 Phng Php 5S 3.8 Bo Tr Ngn Nga

3.9 Bo Tr Sn Xut Tng Th 3.10 Thi Gian Chuyn i/Chun B 3.11 Gim Thiu Quy M L Sn Xut 3.12 Quy Hoch Mt Bng Xng v Vt T ti Ni S Dng 3.13 Kanban 3.14 Cn Bng Sn Xut

3.15 Ngi Gi Nhp 3.16 Mc Hu Dng Thit B Ton Phn

4. Trin Khai Lean 4.1 S Tham Gia ca Lnh o Cp Cao

4.2 Bt u bng Vic Trin Khai Lean Tng Phn 4.3 Bt u vi Quy M Nh 4.4 Nh Chuyn Vin

4.5 Lp k hoch

5. Kt Hp Lean v cc h thng khc 5.1 H thng sn xut Toyota 5.2 Lean v Six Sigma 5.3 Lean v ERP 5.4 Lean v ISO 9001 : 2000

Chng 3 : ng Dng Lean v Doanh Nghip Vit Nam 3.1 Vic p dng Lean ca Toyota Bn Thnh v cng ty bao b ng Nam Vit

3.2 xut cho vic p dng Lean vo doanh nghip may mc, doanh nghip thc phm Vit Nam

3.3 Cc im lu khi p dng Lean vo doanh nghip Vit Nam Chng 4 : Kt Lun Chng 5 : Ti Liu Tham Kho

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MC LC CC HNH V TRONG BO CO

Hnh 1 : Lch s pht trin ca Lean

Hnh 2 : Mc ch ca sn xut tinh gn

Hnh 3 : So snh gia cch thc sn xut theo chc nng v lin tc

Hnh 4 : Cng c v Phng Php trong Lean

Hnh 5 : Cc bc trin khai Lean Hnh 6 : Kt hp gia Lean v ERP

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CHNG 1 : TNG QUAN

1. Ni Dung Ca Bo Co Theo li kinh doanh truyn thng, ngi ta thng mua nhiu vt t tch

tr nhm phng gi tng v thiu ht vt t, ng thi ti a ha vic sn xut

tn dng kh nng my mc v sau l lu hng vo kho ch thi im bn ra. D&a va 'o th (ng k, ng'i ta th (y gia ( tri& t'n kho nhi 'u la ' m&t la ng phi( r (t l(n. T thng k , nc Nh &t a ' ra h & th(ng sa n xu (t ke (o, t(c la ' khi kha (ch

ha 'ng co( yu c 'u hay cng oa &n sau co( yu c 'u thi' nha ' ma (y ho&c cng oa &n tr(c

m(i ti (n ha 'nh sa n xu (t.

Trong giai on hin nay, mt doanh nghip hin nay mun nng cao kh nng cnh tranh ca mnh cn phi xy dng c chin lc da trn mt cht lng, m cn v cc chi ph, thi gian sn phm, ch bit, giao hng, lp t, phn ng v cc vn khc. ng thi, cc p lc i hi gim gi t khch

hng, thay i ca cng ngh mt cch nhanh chng,s mong i ca khch hng

gia tng khng ngng v s cn thit phi chun ha cc qu trnh lun t

c kt qu nh mong mun cng l cc yu t phi xem xt khi xy dng chin lc cho doanh nghip.

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 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.

Vy Lean l g v ti sao c p dng ph bin ti Hoa K t xut pht im Toyota Nht Bn. C th p dng Lean cho cc doanh nghip Vit Nam c hay khng ? chnh l ni dung ca ti ny.

2. Mc Tiu ca Bo Co - Lch s hnh thnh Lean

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- Cc khi nim v Lean

- Cng c v phng php trong Lean

- Trin khai Lean

- ng dng vo doanh nghip Vit Nam

3. Ngha Thc Tin Ca Bo Co - Cung cp thng tin v cc chc nng quan trng ca Lean

- Gp phn pht trin l thuyt v a ra hng p dng cho cc doanh nghip Vit Nam.

4. Kt Cu Ca Bo Co - Tng quan

- C s L Thuyt - Phn tch tnh thc tin khi p dng vo doanh nghip Vit Nam - Kt lun

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CHNG 2 : C S L THUYT

2.1 Lean l g 2.1.1 Lch S ca Lean

Lean trong ting Anh c ngha l s tinh gn, mch lc. Cc cp trong Lean bao gm Lean (sn xut theo Phng thc Lean), Lean enterprise (Doanh nghip thc hin Phng thc Lean), Lean thinking (T duy theo Phng php Lean).

Nhiu khi nim v Lean bt ngun t H thng sn xut Toyota (TPS) v c dn trin khai xuyn sut cc hot ng ca Toyota t nhng nm 1950. T trc nhng nm 1980, Toyota ngy cng c bit n nhiu hn v tnh hiu qu trong vic trin khai h thng sn xut Just-In-Time (JIT). Ngy nay, Toyota thng c xem l mt trong nhng cng ty sn xut hiu qu nht trn

th gii v l cng ty a ra chun mc v in hnh p dng Lean. Cm t Lean hay Lean Production xut hin ln u tin trong quyn C my lm thay i Th gii (The Machine that Changed the World) xut bn nm 1990.

Nguyn tc ch o ca Lean l lm tng gi tr cho khch hng thng qua

vic lin tc loi b lng ph trong sut qu trnh cung cp sn phm, dch v. Doanh nghip phi hiu c khch hng tht s quan tm n iu g v sn sng

tr tin cho nhng gi tr no t sn phm v dch v c cung cp. T , nhng hot ng no ca doanh nghip khng to ra gi tr mong mun s c gim thiu hoc loi b. Vic gia tng doanh thu l cn thit, tuy nhin chnh tit kim chi ph t hot ng kinh doanh s trc tip ci thin li nhun cho doanh nghip.

Lean ang c p dng ngy cng rng ri ti cc cng ty sn xut hng u trn ton th gii, dn u l cc nh sn xut t ln v cc nh cung cp thit b cho cc cng ty ny. Lean ang tr thnh ti ngy cng c quan tm ti cc cng ty sn xut cc nc pht trin khi cc cng ty ny ang tm cch

cnh tranh hiu qu hn i vi khu vc chu .

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S pht trin ca LEAN c din t nh sau :

T nm 1850 n nm 1900, El Whitney s dng phng php thay th linh kin. Sau Frederich Taylor s dng cc phng php v cng c nh Tiu chun ha cng vic, nghin cu thi gian v thao tc chun p dng cho sn xut n chic. Frank Gilbreth to ra s x l, cng cc chuyn ng dy chuyn.

n thp nin 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 qui trnh v lai b lng ph

Hnh 1 : Lch s pht trin ca Lean

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Sau Edwards Deming, Juran a ra h thng qun l cht lng SPC v TQM c tc ng ln ti h thng sn xut ca th gii.

Vo nm 1950, Sn Xut ng Gi (Just In Time Production), c xy dng bi nhng ngi sng lp ra hng Toyota, Sakichi Toyoda, con trai ng Kiichiro Toyoda v ng k s Taiichi Ohno phc tho ra h thng Sn Xut ng Gi (Just In Time Production). Khi nhng ngi sng lp ra hng Toyota n M v quan st dy chuyn lp t v sn xut hng lot m Ford to ra ti mt nh my Michida, h khng b n tng. Trong lc mua sm ti mt siu th, h quan st mt tng n gin ca vic cung cp li ung, khi khch hng cn ung, h s ly mt v mt ci khc s thay th. tng c em vo tng H Thng Sn Xut ca Toyota (Toyota Production System (TPS)) 2.1.2 Mc Tiu ca Lean

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.

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 t 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.

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Gii thch s :

Waste Reduction : Gim thiu s lng ph Intergrated Supply Chain : Tch hp knh phn phi Flow : Dng

Lean Desgin : Thit K Lean

Process Control : Kim sot s vn hnh

Synchronize : ng B

Value-creating Organization : T Chc to ra gi tr

Enhanced customer value : Ci tin gi tr mang li cho khch hng Nh vy, bng cch tch hp knh phn phi cng vi vic kt hp gia Lean, kim sot s vn hnh v ng b cc khu, t chc s to ra gi tr gia tng cho khch hng bng cch gim thiu s lng ph. C th hn, cc mc tiu bao gm:

Hnh 2 : Mc ch ca Sn Xut Tinh Gn

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2.1.2.1 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;

2.1.2.2. 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;

2.1.2.3. 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;

2.1.2.4. Nng sut lao ng

Ci thin nng sut lao ng, bng cch va gim thi gian nhn ri ca cng nhn, ng thi phi m bo cng nhn t nng sut cao nht trong thi gian lm vic (khng thc hin nhng cng vic hay thao tc khng cn thit);

2.1.2.5. 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;

2.1.2.6. 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.

2.1.2.7. 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

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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. Khi cng ty Lantech(1), 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.

2.1.3 Cc Nguyn Tc Chnh ca Lean

Cc nguyn tc chnh trong Lean c th c tm tt nh sau:

2.1.3.1. 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.

2.1.3.2. 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.

2.1.3.3. 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%.

2.1.3.4. Sn xut Li Ko Pull

(1) http://www.diendanquantri.com/quantri,1,698,print.htm

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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.

2.1.3.5. 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.

2.1.3.6. 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.

2.1.4 Trng tm ca Lean

2.1.5 Li ch ca Lean Lean c s dng rng ri nht trong cc ngnh cng nghip thin v lp

rp hoc c quy trnh nhn cng lp i lp li. Trong nhng ngnh cng nghip

ny, tnh hiu qu v kh nng ch tm vo chi tit ca cng nhn khi lm vic vi

cc cng c th cng hoc vn hnh my mc c nh hng ln n nng sut.

cc cng ty ny, h thng c ci tin c th loi b nhiu lng ph hoc bt hp

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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 loi b nhiu vn lin quan n lch sn xut v cn bng chuyn km nn Lean 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 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.

2.2 Cc Khi Nim trong Lean 2.2.1 Vic To Ra Gi Tr v S Lng Ph

Trong Lean , 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 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 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. Cc hot ng cn thit nhng khng to ra gi tr tng thm l cc hot

ng khng to ra gi tr tng thm t quan im ca khch hng nhng li cn

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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.

2.2.2 Nhng Loi 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 , nhn chung bao gm cc mc sau:

2.2.2.1. Sn xut d tha 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.

2.2.2.2. Khuyt tt

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.

2.2.2.3. Tn kho

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.

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2.2.2.4. Di chuyn

Di chuyn y ni n bt k s chuyn ng nguyn vt liu no khng to ra gi tr tng thm cho sn phm chng hn nh vic vn chuyn nguyn vt

liu gia cc cng on sn xut. Vic di chuyn nguyn vt liu gia cc cng on sn xut nn nhm ti m hnh l tng l sn phm u ra ca mt cng on c s dng tc thi bi cng on k tip. Vic di chuyn gia cc cng on x l lm ko di thi gian chu k sn xut, dn n vic s dng lao ng v mt bng km hiu qu v c th gy nn nhng nh tr trong sn xut.

2.2.2.5. Ch i Ch i l thi gian cng nhn hay my mc nhn ri bi s tc nghn hay

lung sn xut trong xng thiu hiu qu. Thi gian tr hon gia mi t gia

cng ch bin sn phm cng c tnh n. Vic ch i lm tng thm chi ph ng k do chi ph nhn cng v khu hao trn tng n v sn lng b tng ln.

2.2.2.6. Thao tc Bt k cc chuyn ng tay chn hay vic i li khng cn thit ca cc

cng nhn khng gn lin vi vic gia cng sn phm. Chng hn nh vic i li

khp xng tm dng c lm vic hay thm ch cc chuyn ng c th khng cn thit hay bt tin do quy trnh thao tc c thit k km lm chm tc lm vic ca cng nhn.

2.2.2.7. Sa sai

Sa sai hay gia cng li, khi mt vic phi c lm li bi v n khng c lm ng trong ln u tin. Qu trnh ny khng ch gy nn vic s dng lao ng v thit b km hiu qu m cn lm gin on lung sn xut thng thong dn n nhng ch tc v nh tr trong quy trnh. Ngoi ra, cc vn lin quan n sa cha thng tiu tn mt khi lng thi gian ng k ca cp qun

l v v vy lm tng thm chi ph qun l sn xut chung. 2.2.2.8. Gia cng tha

Gia cng tha tc tin hnh nhiu cng vic gia cng hn mc khch hng

yu cu di hnh thc cht lng hay cng nng ca sn phm v d nh nh

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bng hay lm lng tht k nhng im trn sn phm m khch hng khng yu cu v khng quan tm.

2.2.2.9. Kin thc ri rc y l trng hp khi thng tin v kin thc khng c sn ti ni hay vo

lc c cn n. y cng bao gm thng tin v cc th tc quy trnh, thng s k thut v cch thc gii quyt vn , v.v.... Thiu nhng thng tin chnh xc

thng gy ra ph phm v tc nghn lung sn xut. V d, thiu thng tin v cng thc phi trn nguyn liu, pha mu c th lm nh tr ton b quy trnh sn xut hoc to ra cc sn phm li do cc ln th-sai tn rt nhiu thi gian. 2. 2.3 Sn Xut Li Ko(Pull)

Khi nim trng tm ca Lean l Pull Production (Sn Xut Li Ko), trong lung sn xut trong nh my c iu tit bi yu cu t cng on cui quy trnh li ko hot ng ca cc cng on u quy trnh, vn tri ngc vi hot

ng sn xut truyn thng theo l sn phm m trong hot ng sn xut c

thc y t u quy trnh n cui quy trnh da trn mt lch sn xut nh k. iu ny c ngha rng ch khi no c nhu cu (tnh hiu) cng on sau th cng on trc mi tin hnh gia cng nguyn liu.

V d trong h thng pull, mt n t hng to ra nhu cu v thnh phm, sau ln lt to ra nhu cu cho cng on lp rp hon chnh, ri lp rp s b v i tip ngc dng chui cung cp. Vic trin khai c th c tin hnh nh sau:

2.2.3.1. n hng bt u t cng on cui cng Khi mt n hng c nhn t khch hng v thng tin cho xng sn

xut, lnh sn xut trc tin c a n cng on cui quy trnh sn xut

(nh ng gi hay lp rp hon chnh) tri ngc vi cc cng on u ca quy trnh (chng hn nh s ch nguyn liu). Cch lm ny i hi mt h thng thng tin ht sc hiu qu m bo rng cc cng on cung cp thng ngun lin tc nm bt c nhu cu ca khch hng cc cng on v sau ca quy trnh sn xut.

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2.2.3.2. 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.

2.2.3.3. 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-in-Time (va ng lc) c ngha l nguyn vt liu hay bn thnh phm c giao ng s lng v va ng lc khi khu sau cn dng n.

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

liu cn c s dng n. 2.2.4 Cc M Hnh Khc Nhau ca H Thng Sn Xut Pull

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;

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thch ng vi thc t rng vic gia cng mt vi cng on sn xut

phi c thc hin theo l do bn cht ca thit b hay quy trnh. Nhn chung, cng t kh nng d on cc n t hng, qu trnh sn xut

cng bt n nh (nh l nhng chm tr v tc nghn ngoi d tnh), hay mc tin cy ca cc nh cung cp nguyn liu cng thp th mc tn kho c yu cu

cng cao phng khi c nhng bin ng t ngt trong nhu cu ca khch hng, s bt n nh ca sn xut hay thiu ht nguyn vt liu. Trong nhng trng hp trn, cc chuyn sn xut lean c duy tr lng tn kho nguyn liu, bn thnh phm hay thnh phm lm vng m d phng trc nhng thay i khng lng trc c.

thch ng vi nhng tnh hung va nu, mt s h thng khc nhau c

th c p dng cho m hnh sn xut pull nh sau: 2.2.4.1. H Thng Pull Cp y

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.

2.2.4.2 H Thng Pull Sn Xut theo n Hng

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).

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2.2.4.3. H Thng Pull Phc Hp

Trong h thng phc hp, mt s thnh phn ca h thng cp y v sn

xut theo n hng c s dng h tr ln nhau. V d mt cng ty c th sn xut mt s sn phm trn c s cp y tn

kho trong khi sn xut mt s sn phm khc vi h thng lm theo n t hng.

Mt chn la khc, mt cng ty c th p dng h thng cp y tn kho cho mt phn ca quy trnh sn xut vap dng h thng lm theo n hng cho phn khc ca quy trnh sn xut. V d nh mt cng ty duy tr mt mc quy nh tn kho cho mt s loi bn thnh phm v ch sn xut ra thnh phm khi c khch hng yu cu. Trong trng hp ny, cng ty p dng h thng cp y tn kho cho qu trnh sn xut bn thnh phm v p dng quy trnh lm theo n hng cho phn cn li ca chuyn sn xut. Trong H Thng Sn Xut Toyota,

qu trnh sn xut c kch hot cp y mt s thnh phm chng c sn khi

c cn n.

2.2.5 V Sao Mc Tn Kho Cao Lm Tng 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:

Kim sot li km trong sn xut theo l khi sn xut theo l, s c

nhiu sn phm li c to ra trc khi b pht hin cng on sn xut tip theo. V d, nu kch thc mi l cng on in bao l ba ngn bao trc khi chuyn cho cng on k tip, ng thi nhn vin kim phm khng pht hin c li (do ch kim xc sut), s c rt nhiu kh nng l v s bao in li c to ra trc khi sai xt c pht hin cng on sn xut k tip.

H hng v lng ph do lu kho v di chuyn - mt s li pht sinh trong qu trnh di chuyn v trong thi gian lu kho. V d trong ngnh sn xut g, vic bn thnh phm b tng m do tip xc vi mi trng m trong qu trnh gia cng cng c xem l

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li. Trong khi , vic lu kho cn thm lao ng, nng lng v

mt bng.

Trch nhim trc tip khi bn thnh phm nm ch x l gia cc cng on sn xut, tc mti mi lin h trc tip gia hai cng

on. Cng on sau c rt t kh nng phn bit c mt sn phm c th do mt cng nhn hay nhm no sn xut. Khi cng nhn hay t cng on trc chu trch nhim t hn s cng c nhiu kh

nng gy ra sn phm li hay sai quy cch so vi yu cu ca khch

hng. Ngc li, vic bn giao trc tip v s dng ngay vt t/bn thnh phm bi cng on theo sau s gip m bo rng cng nhn hay t cng on trc nhn lnh trch nhim hon ton trong vic

ch lm ra nhng sn phm tt c cng on sau chp nhn.

Tuy nhin, nh cp trong phn trc, c mt s trng hp tn kho l

iu thit yu m bo iu ho sn xut v vy mt s loi tn kho nn c duy tr mc cho php qu trnh sn xut khng b gin on. 2.2.6 Tc ng ca H Thng Pull i vi Vic Hoch nh Sn Xut

Phn ln cc doanh nghip sn xut Vit Nam u s dng h thng hoch nh trung tm trong Trng Phng K Hoch Sn Xut xy dng lch sn xut v phn b lnh sn xut n cc phn xng x l theo l sn phm. y l h thng sn xut Push (thc y), c ngha rng nguyn vt liu c y i qua quy trnh sn xut da vo lch sn xut. M hnh Hoch nh Yu Cu Nguyn Vt Liu ( MRP) ca phn ln cc h thng Hoch nh Ngun Lc Doanh Nghip ( ERP) hot ng trn c s ny.

Trong mt h thng sn xut Push, nu h thng d bo sn xut khng chnh xc (vn ph bin cc doanh nghip sn xut Vit Nam) hoc Trng Phng K Hoch Sn Xut khng c thng tin y v tnh hnh sn xut v nhu

cu tng cng on hoc khng c cng c hu hiu phn tch nhu cu (y cng l trng hp c th cc doanh nghip sn xut Vit Nam), ngi ph trch c th phn b qu nhiu hoc qu t vic cho cc t v cng on khc

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nhau, v vy s d dn n tc nghn lung sn xut, d tha v tn kho, rt t kh nng trin khai sn xut trn c s quy trnh lin tc v ni chung l km hiu qu

trong vic s dng ti nguyn. Ngc li, ngoi tr vic cn bng sn xut, yu t chnh ca h thng sn

xut pull l vic phn b lung cng vic cho xng sn xut c xc nh da trn nhu cu ca chuyn sn xut ch khng phi lch sn xut hay h thng phn b sn xut c hoch nh bi h iu hnh trung tm.

Mc d cc doanh nghip sn xut p dng lean vn c mt k hoch sn xut, k hoch ny ch yu c s dng cho cc mc tiu sau:

Hoch nh yu cu nng sut thit b, bao gm nhng thay i i vi thng s ca cc chuyn hay cc cell (/ngn gia cng sn phm); Hoch nh yu cu nhn lc;

iu ho cc lnh sn xut cho xng

Hoch nh nhu cu nguyn vt liu.

2.2.7 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.

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2.2.8 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.

Hnh 3 : So snh thi gian theo cch thc sn xut chc nng v lin tc

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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. Nh 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. Khi , 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.

2.2.9 Ci Tin Lin Tc/ Kaizen Thc t, rt kh c mt cng ty no c th t n mc hiu qu tuyt i,

v vy Lean 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. Nhim v 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.

2.2.10 S Tham Gia ca Cng Nhn

Trong Lean , 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.

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Cc doanh nghip sn xut Lean nhn chung tin rng phn ln cc tng hu dng cho vic loi tr cc hot ng khng to ra gi tr tng thm xut pht t cng nhn trc thuc cc quy trnh sn xut.

m bo rng cc tng loi tr cc hot ng khng to ra gi tr tng thm c thc thi, quyn quyt nh thay i cc quy trnh sn xut c

a ti mc thp nht c th c ( l cng nhn) nhng bt k mt thay i no cng c yu cu phi p ng mt s tiu ch nht nh.

V d, Toyota cc cng nhn c khuyn khch trin khai cc ci tin cho cc quy trnh sn xut nhng vic ci tin phi th hin tnh hp l r rng ph hp vi phng php khoa hc, vic ci tin phi c trin khai di s gim st ca mt ngi qun l c thm quyn v quy trnh mi phi c ghi nhn li ht sc chi tit v ni dung, trnh t, thi gian v kt qu. Toyota trc tin trin khai cc thay i c xut quy m nh trn c s th nghim v nu vic ci tin

c hiu qu, Toyota s tin hnh thay i xuyn sut trong hot ng sn xut ca

mnh.

C hai cch ph bin khuyn khch s tham gia ca cng nhn trong hot ng ci tin lin tc:

2.2.10.1. Vng Kaizen (Kaizen Circles) Cch th nht l p dng Vng Kaizen trong cc nhm 6-8 cng nhn

c lp ra tm cc tng gip gii quyt cc vn c th. in hnh, mt Vng Kaizen s gp nhau mt gi mi tun trong sut 6-8 tun v trong thi gian s a ra mt s xut cho ngi qun l v cch gii quyt cc vn c th. S h tr v tham gia ca cp qun l l yu t tin quyt cho s thnh cng ca Vng Kaizen.

2.2.10.2. Chng Trnh Xut Ci Tin Cch th hai trong vic gia tng s tham gia ca cng nhn l xy dng

mt chng trnh xut ci tin tch cc khuyn khch vic gp ci tin v tng thng cho cc tng c p dng thnh cng. Thng th chi ph cho vic khen thng tng i nh so vi gi tr mang li cho cng ty t vic p dng

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ci tin. Mt s chuyn gia v lean cho rng duy tr s tham gia ca cng nhn mc cao trong vic lin tc xut ci tin chnh l yu t then cht trong vic

p dng lean v l iu chnh yu to nn s khc bit gia Toyota so vi cc cng ty khc v s thnh cng trong vic p dng cc nguyn tc ca lean . 2.2.11 Quy Hoch M Phng Dng T Bo

Trong b tr sn xut dng t bo, thit b v cc t lm vic c sp xp thnh nhiu cell nh (/ngn lm vic ca cng nhn) c ni kt lin lc cc cng on hay tt c cc cng on ca mt quy trnh sn xut c kh nng

din ra trong mt hay nhiu cell lin tc. B tr dng t bo mang cc c tnh sau:

2.2.11.1. Quy trnh lin tc Lung nguyn liu v ph liu di chuyn u n v hu nh khng thy c

vic vn chuyn bn thnh phm hay ch i gia cc cng on sn xut. 2.2.11.2. Lung mt sn phm

Qu trnh sn xut vi m hnh t bo p dng lung mt sn phm trong tng sn phm mt ln lt di chuyn qua tng cng on ca quy trnh sn xut.

2.2.11.3. Cng nhn a nng Ch c mt hoc vi cng nhn ng ti mi cell, khng ging nh sn xut

theo l/m m trong nhiu cng nhn cng lm vic v chu trch nhim trn

mt cng on n l, trong m hnh t bo cc cng nhn ph trch tng cng on khc nhau din ra trong mt cell. V vy mi cng nhn c hun luyn thc hin tng cng on trong cell .

2.2.11.4. M Hnh ch U

Cc Cell thng c dng ch U, vi sn phm di chuyn t u ny n u kia ca ch U khi c cng nhn gia cng. Mc ch ca cch b tr ny nhm hn ch ti a khong cch i li v vic di chuyn nguyn vt liu trong mt cell.

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B tr dng t bo gip t c nhiu mc tiu ca Lean 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(2)., 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 . 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 m khng cn a vo m hnh t bo. Chng hn nh mt s ngnh i hi vic x l cc l sn phm ln do tnh cht ca thit b hay s gin on ng k gia cc cng on sn xut v v vy khng thch hp

p dng m hnh t bo. 2.2.12 Lean cho Cng Tc Hnh Chnh

Lean p dng cho cng tc hnh chnh l dng cc khi nim v cng c ca lean ci thin cc quy trnh th tc giy t ngoi hot ng sn sut ca

xng. c bit i vi cc quy trnh hnh chnh c tnh lp li v bao gm khi lng ln cc giao dch nh nhn n hng, thu mua, k ton hay cc cng vic hu cn. Tuy nhin, vic p dng lean cho cc quy trnh hnh chnh khng ph bin bng vic p dng cho cc quy trnh sn xut.

(2) http://www.sangtaotre.com/tintucDetail.asp?catID=16&newsID=97

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2.3. Cng v v Phng Php trong Lean

Cc cng c trin khai Lean c th c gii thch bng hnh v trn nh sau Vic rt ngn chu k (short cycles), tp trung vo cht lng (Quality Focus) v lin tc ci tin (Continuos Improvement) c thc hin da trn : - Con ngi (People)

+ Vi vic huy ng tham gia ca ton b nhn lc + Kim sot thng qua trc quan

+ Qun l cng vic + Tp trung qun l cht lng

-Cng ngh (Technology) + Cu trc lung sn xut r rng

+ Sn xut theo tng l

+ Gim qu trnh khi ng

+ Ph hp s dng

Hnh 4 : Cc Cng C v Phng Php ca Lean

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- H thng (System) + Cn bng gia ti v dng sn xut + m bo vic bo tr thay th trnh vic ngng sn xut + To mi quan h i tc vi cc nh cung cp

+ Sn xut theo kiu ko

i vo chi tit, chng ta nn theo cc bc sau : 2.3.1 Chun Ho Quy Trnh

Chun ho quy trnh c ngha l cc quy trnh v hng dn sn xut c qui nh v truyn t r rng n mc ht sc chi tit nhm trnh s thiu nht

qun v gi nh sai v cch thc thc hin mt cng vic. Mc tiu ca vic

chun ho l cc hot ng sn xut lun c thc hin theo mt cch thng

nht, ngoi tr trng hp quy trnh sn xut c iu chnh mt cch c ch . Khi cc th tc quy trnh khng c chun ho mc cao, cc cng

nhn c th c nhng ngh khc nhau v cch lm ng cho mt th tc quy trnh v d a n cc gi nh sai. Mc chun ho cao v quy trnh cng gip cc cng ty m rng sn xut d dng hn nh trnh c nhng gin on c th gp phi do thiu cc quy trnh c chun ho.

Cc hng dn cng vic chun trong Lean thng c nh ngha v vit ra mc chi tit hn nhiu so vi yu cu ti thiu p ng iu khon 7.5.1. ca phin bng ISO 9001:2000 v "Kim Sot Sn Xut v Cung Cp Dch V", c th di hnh thc chun ho cc thao tc v trnh t cng vic cho tng cng nhn.

Mt t chc cn c cc ti liu sau:

Thng tin v cc c tnh ca sn phm;

Hng dn cng vic ph hp;

Thit b sn xut thch hp;

o lng v gim st thit b v h thng;

Cc quy trnh bao ph t cc hot ng hon tt sn phm, phn phi v sau phn phi.

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Vic chun ho quy trnh trong Lean bao gm mt s thnh phn chnh: 2.3.1.1 Trnh t cng vic chun

L trnh t mt ngi cng nhn phi tun th khi thc hin cng vic, bao gm cc thao tc v cc bc thc hin cng vic. Vic m t r rng gip m bo rng tt c cc cng nhn u thc hin cng vic theo cch thc tng t nhau v hn ch cc sai bit vn c kh nng gy ra ph phm. Trong iu kin l tng, vic chi tit ho cng vic ch r tng bc thao tc cho mi cng nhn. V d vi cng on ct g, trnh t cng vic chun s m t t chi tit ct v cc bc thao tc nh chun b my, chnh dao ct, cch nng gi v a vt liu qua my v thi gian x l cng vic. i vi cng on lp rp, bng m t cn lit k chi tit tng bc thao tc thc hin vic lp rp cho mi loi sn phm.

2.3.1.2 Thi gian chun

L tn xut mt sn phm c lm ra. c s dng m t r rng v theo di tc mt quy trnh cn c duy tr cc cng on khc nhau. i vi cc nh sn xut Lean, thi gian chun ca mi quy trnh sn xut c ch ng

iu phi v gim st duy tr mt lung sn xut lin tc. Thi gian chun khc vi thi gian chu k sn xut l thi gian cn quy trnh hon tt mt sn phm.

V d, mt nh sn xut g c th cch 10 pht cho xut xng mt gh sofa (takt time) nhng thc s h phi mt 3 ngy lm vic hon tt mt gh sofa (cycle time).

2.3.1.3 Mc tn kho chun trong quy trnh

y l lng nguyn liu ti thiu, bao gm lng nguyn liu ang c x l trn chuyn, cn c gi mt cell hay quy trnh hot ng cng mong mun. Mc tn kho chun nn c xc nh r rng v rt cn thit phi

duy tr lng nguyn liu ti thiu ny trong chuyn khng gy ra s nh tr cho quy trnh do thiu nguyn liu. y l yu t dng tnh ton khi lng v tn s ca lnh sn xut (hay Kanban) cho cc ngun cung cp t cng on trc.

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2.3.2 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 loi cng vic phc tp hay cc vn lin quan v an ton lao ng.

2.3.3 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 , cc hng dn cng vic chun nn c cp nht thng xuyn cng tt nhm gn kt vi cc ci tin quy

trnh ang din ra. Trong thc t, cc cng ty c khuyn khch ti a ho tc ci tin quy

trnh ng ngha vi vic cp nht lin tc cc hng dn cng vic chun. Ngoi ra mt quy trnh chun thng bao gm cc hng dn r rng cng nhn x l cc tnh hung bt thng, do thc y h ng x theo cch linh hot i vi cc tnh hung bt thng.

thc hin thnh cng vic ny, trch nhim nn c phn cng r rng

trong vic chun b v phn pht cc ti liu cn thit, cc bng hin th, cng nh m bo rng bt k mt thay i no cng u c cp trn truyn t r rng cho nhn vin bn di. Mt khi trch nhim c phn cng r rng, cc quy trnh cng vic chun c th c b sung mt cch thng xuyn. Trn thc t,

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cc cng ty p dng lean nh Toyota c bit n bi d linh hot c di hnh thc sn phm a dng v kh nng ci tin cc quy trnh sn xut mt cch nhanh chng, v vy gip cng ty phn ng nhanh hn i vi cc thay i v nhu cu

ca khch hng.

2.3.4 Qun L bng Cng C Trc Quan 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:

2.3.4.1 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...

2.3.4.2 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.

2.3.4.3 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

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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. 2.3.5 Cht Lng t Gc (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 thng nhc n t "Jidoka" trong ting Nht c ngha l cc vn nn c xc nh v loi tr ngay ti ngun pht sinh.

Mt s yu cu chnh c lin quan:

2.3.5.1. 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 ).

2.3.5.2. 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. 2.3.5.3. Trch nhim r rng ca cng nhn Vi Lean , 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

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tn kho cao gia hai cng on sn xut, cc cng nhn thuc cng on trc s

t cm thy c trch nhim c nhn i vi bt k khuyt tt sn phm no. 2.3.5.4. Phng php Poka Yoke Phng php n gin kim tra cht lng trn chuyn sn xut (khng

ch kim tra bng mt), c p dng ngn chn cc sn phm li khng cho i tip sang cng on sau. Vi Poka-Yoke, 100% sn phm c kim tra nh mt

phn cng vic ca quy trnh sn xut. Bin php ny c thc hin t ng trn

chuyn hay bi cc cng nhn (khng phi nhm kim sot cht lng). 2.3.5.5. Dng quy trnh c ch Khi c sn phm li, hot ng sn xut s b dng cho n khi nguyn

nhn gy li c khc phc. Hnh ng ny gip duy tr vn ho khng nhn nhng khuyt tt ng thi ngn khng sn phm li lt sang quy trnh sau v

gy nhiu hu qu ln hn. Chng hn Toyota, bt k mt cng nhn no cng c php dng chuyn sn xut. iu ny gip m bo trch nhim gii trnh bi cc cng nhn cng on trc. 2.3.6 S Chui Gi Tr

S chui gi tr l tp hp cc phng php gip th hin trc quan

lung sn phm v thng tin qua quy trnh sn xut. Mc ch ca phng php

ny l xc nh cc hot ng lm tng gi tr v cc hot ng khng lm tng gi

tr. S chui gi tr nn phn nh nhng g ang thc s din ra hn l nhng g c mong mun xy ra nh cc c hi ci tin c th c xc nh.

Thng c s dng trong cc d n ci tin thi gian chu k quy trnh v n th hin chnh xc cch thc hot ng ca mt quy trnh vi yu cu thi gian

v tng bc cng vic chi tit. Phng php ny cng c dng trong phn tch v ci tin quy trnh bng cch xc nh v loi tr khong thi gian lin quan n cc hot ng khng to ra gi tr tng thm.

2.3.7 Phng Php 5S Phng php 5S bao gm mt s cc hng dn v t chc ni lm vic

nhm sp xp khu vc lm vic ca cng nhn v ti u hiu qu cng vic.

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2.3.7.1. Sng lc

Phn loi nhng g cn thit v nhng g khng cn thit nhng th

thng c cn n lun c sn gn k v tht d tm thy. Nhng mn t khi hay khng cn dng n nn c chuyn n ni khc hay b i.

2.3.7.2 Sp xp

Sp xp nhng th cn thit theo th t d ly. Mc tiu ca yu cu ny l gim n mc ti thiu s thao tc m cng nhn thc hin cho mt cng vic.

V d, hp cng c cho cng nhn hay nhn vin bo tr c nhu cu cn s dng nhiu cng c khc nhau. Trong hp cng c, tng dng c c xp mt ni c nh ngi s dng c th nhanh chng ly c cng c mnh cn m khng mt thi gian tm kim. Cch sp xp ny cng c th gip ngi s dng ngay lp tc bit c dng c no b tht lc.

2.3.7.3. Sch s

Gi cc my mc v khu vc lm vic sch s nhm ngn nga cc vn

pht sinh do v sinh km. Trong mt s ngnh, bi bn l mt trong nhng tc nhn chnh gy li cho b mt hay nhim bn mu trn sn phm. tng thc v mc bi bn, mt s cng ty cho sn ni lm vic v thit b vi mu sng ng thi tng chiu sng ni lm vic.

2.3.7.4. Sn sng v chun ha

a 3 cng vic trn tr thnh vic p dng thng xuyn bng cch quy nh r cc th tc thc hin cc cng vic sng lc, sp xp v gi sch s.

2.3.7.5. Su st Khuyn khch, truyn t v hun luyn v 5S bin vic p dng tr

thnh mt phn vn ho ca cng ty. Ngoi ra vic duy tr cng bao gm phn cng trch nhim cho mt nhm gim st vic tun th cc quy nh v 5S. 2.3.8 Bo Tr Ngn Nga

Bo tr ngn nga l mt lot cc cng vic thng nht, th tc v cc

bc c thc hin nhm xc nh v gii quyt cc vn tim tng trc khi

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chng pht sinh. Lean nhn mnh cng tc bo tr ngn nga cn thit cho vic gim thiu thi gian dng my do hng hc v thiu ph tng thay th.

Khi tin cy ca thit b cn thp, cc nh sn xut buc phi duy tr mc tn kho bn thnh phm cao d phng. Tuy nhin, tn kho cao c xem l ngun chnh yu gy lng ph v sai st trong Lean .

2.3.9 Bo Tr Sn Xut Tng Th Bo Tr Sn Xut Tng Th (TPM) l phn cng cng vic bo dng c

bn thit b bao gm kim tra, v sinh, bi trn, cn chnh cho cng nhn sn xut l ngi vn hnh thit b. TPM phn nhim r rng trch nhim cng nhn ch ng v c trch nhim trong vic xc nh, gim st v khc phc nguyn nhn

gy ra s c ng my khng cn thit. Bng cch phn b trch nhim cho cc nhn vin vn hnh my, cng tc bo tr v thi gian dng my c gim thiu. Vic ny cng i hi nhn vin vn hnh my thng xuyn cp nht cho nhm

bo tr bit v tnh trng ca thit b cc vn k thut tim tng sm c pht hin v ngn nga.

Trong TPM, t bo tr chu trch nhim cho cc hot ng mang li gi tr tng thm nhiu hn nh l ci thin, i tu v ci tin hiu nng thit b, sa cha h hng v hun luyn k thut cho nhn vin iu hnh.

2.3.10 Thi Gian Chuyn i / Chun B

Lean nhm ti vic gim thiu thi gian dng chuyn bt hp l do chun b my hay chuyn i sn phm v my dng l ngun lng ph ng k. Vic ny i hi mt vn ho lin tc ci tin trong cng ty khng ngng tm cch gim

thi gian chuyn i v chun b my. Thng vic chuyn i nhanh chng c th t c phn no bng cch

xy dng cc thng s k thut tht chun (v c ti liu ho y ) cho vic sn xut tng loi sn phm ring bit khng cn s lo ngi v vic iu chnh li cc thng s trong qu trnh chuyn i sn phm trn thit b. Cc cng ty c danh mc, mu sc v quy cch sn phm a dng thng xem nh chi ph chuyn i cho mi ln quy trnh sn xut phi dng li thay khun, lau ra dn dp

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vt liu thuc quy cch trc cn ng li trn my, iu chnh li thng s thit

b.v.v... C mt s cch gim thiu thi gian chuyn i/chun b bao gm vic

thay i cch sp xp mt bng ca chuyn sn xut, chun b sn sng nguyn liu v cng c khi cn s dng hay s dng loi thit b c ngn cha i (ph) nhm trnh thi gian dng thit b lm v sinh. 2.3.11 Gim Thiu Quy M L Sn Xut

Lean nhm ti lung sn phm di chuyn trn chuyn c quy m l cng nh cng tt, vi iu kin l tng l lung mt sn phm, bn thnh phm gia cc cng on l ti thiu. Quy m l sn xut cng nh s gip cng on trc cng c nhiu kh nng sn xut ng nhng g c khch hng yu cu v

ng lc khch hng cn n.

V vy, thay th cho cch t chc vi mt vi chuyn sn xut c quy m

cc l sn phm ln, Lean thng ng h cch t chc nhiu chuyn sn xut c

quy m l nh, vi quy hoch dng t bo l mt hnh thc c trng. Nhng li ch chnh ca cc chuyn sn xut nh bao gm:

Quy m l nh ng ngha vi t bn thnh phm hn gia cc cng on sn xut v cho php cng ty hot ng gn vi m hnh quy trnh lin tc;

Nhiu chuyn sn xut c quy m l nh cho php nhiu quy cch sn

phm khc nhau c trin khai ng lot, v vy s gim thiu thi gian

cht gy ra bi vic chuyn i quy cch. Cc chuyn sn xut nh hn, cn t cng nhn hn, s nng mc trch

nhim ca cng nhn tng chuyn cao hn.

2.3.12 Quy Hoch Mt Bng Xng v Vt T ti Ni S Dng Lean nhm ti vic gim thiu cc di chuyn v vic vn chuyn sn phm

gia hai cng on sn xut. Tng t, bn thnh phm nn c gi gn k ni s dng k tip. iu ny gip gim thiu cc yu cu khing vc vt t, vic tht lc vt t, gim thiu vic vt t b h hng do qu trnh vn chuyn gy ra v i hi tn trng nguyn tc sn xut theo m hnh pull (li ko).

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2.3.13 Kanban "Kanban" l h thng cp y vt t theo m hnh pull s dng cc du

hiu tng hnh, nh cc th treo phn bit bng mu sc, ra hiu cho cc chuyn pha trc khi chuyn sau cn thm vt t. V tc dng, Kanban l mt cng c thng tin h tr sn xut theo m hnh pull. Mt Kanban c th l mt thng rng, mt th treo, bng hin th in t hay bt k hnh thc gi nhc trc quan no thch hp.

C hai loi Kanban c trng: 2.3.13.1. Kanban Cung Cp Mt du hiu t khch hng ni b n ngun cung cp ni b cho bit loi

vt t cn c cung cp.

2.3.13.2. Kanban Tiu Th Mt du hiu t ni cung cp ni b n khch hng ni b cho bit rng

vt t sng sng cho vic s dng. Trong trng hp ny, ni cung cp ni b s khng sn xut thm cho n khi vic tiu th c thc hin bi khch hng bn trong.

C nhiu bin th trong h thng Kanban v trong thc t c kh nhiu sch vit ring v cch p dng Kanban hiu qu nht. 2.3.14 Cn Bng Sn Xut

Cn bng sn xut, hay iu sn xut, nhm ti vic b tr lu lng sn xut v chng loi sn phm n nh theo thi gian nhm gim thiu s t bin trong khi lng cng vic. Bt k s thay i no v lng nn c cn bng chng din ra t t vi cng t s thay i t ngt cng tt. iu ny cho php cng ty tn dng cng sut sn xut cao hn ng thi gim thiu vic chuyn i mu m sn phm.

Yu t chnh ca cn bng sn xut l ngi chu trch nhim ra lnh sn xut cho xng phi c mt h thng t ng iu tit cc n hng khng

c s t bin v khi lng sn xut. H thng ny gip vic phn b thit b v

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con ngi chnh xc v d dng hn. p dng phng php ny, cng ty cn bit cng sut thc v tc thc hin tng cng on sn xut. 2.3.15 Ngi Gi Nhp

m bo chc nng iu ca lung sn xut lin tc trong lean , mi cng on cn sn xut vi tc ph hp khng qu nhanh hay qu chm so vi

yu cu ca cng on sau. t c iu ny, cn c mt cng on c

chn lm "ngi gi nhp". Ngi gi nhp to ra nhp sn xut cho ton

chuyn v tc sn xut tng cng on c tng hay gim ph hp vi tc

ca ngi gi nhp.

Trong H Thng Pull Cp y, ngi gi nhp thng l cng on cui

chng hn nh phn rp rp hon chnh. Trong H Thng Pull Sn Xut Theo n Hng, ngi gi nhp thng l cng on gn ni bt u quy trnh ca chui gi tr (value stream). 2.3.16 Mc Hu Dng Thit B Ton Phn

Mc Hu Dng Thit B Ton Phn (OEE) l s o kh nng tn dng cng sut tng ca cc thit b c th. OEE c chia ra hai phn:

Mc hu dng (Availability) - lng thi gian mt thit b c th hot ng ti a sau khi tr i thi gian dng my bt buc;

Hiu sut thc hin (Performance efficiency) - sn lng thc t ca my khi hot ng so vi nng sut thit k ti a hay sn lng ti a trong iu kin

hot ng lin tc.

V d, nu mc hu dng l 80% v hiu sut thc hin l 75%, vy OEE s l:

Mc hu dng x Hiu sut thc hin = OEE 80% x 75% = 60%

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

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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 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.

2.4 Trin Khai Lean 2. 4.1 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. 2.4.2 Bt u bng Vic Trin Khai Lean Tng Phn

Mt s cng ty bc u ch trin mt phn ca lean 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(3), trong s cc cng ty bt u cc chng trnh lean c 39.1% cho bit ch trin khai mt s ng dng ca lean,

(3) http://www.nangsuatchatluong.vn/nang-suat-chat-luong/16-trien-khai-lean.html

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55.0% trin khai hu ht cc ng dng v ch c 5.9% cho bit trin khai lean ton din. Mt s bc n gin ban u gm c:

o lng, theo di cng sut v sn lng ca thit b; Thit lp v ti liu ho cc quy trnh sn xut r rng hn;

Trin khai h thng 5S trong qun l nh xng; Quy hoch li cch b tr mt bng sn xut.

2.4.3 Bt u vi Quy M Nh Cc cng ty trin khai lean nn th nghim mt b phn nh trong hot

ng trc khi p dng cho ton b hot ng sn xut, nht l khi chuyn i t h thng push sang pull v s thay i ny c th gy gin on sn xut.

V d nh, c th th nghim trn mt dy chuyn sn xut hoc mt chui quy trnh nh v iu ny s gip gim thiu ri ro lm gin on cng vic. Tin

hnh hun luyn nhn vin v cc nguyn tc ca lean, ng thi thuyt phc

nhng ngi khc trong cng ty v li ch ca lean.

2.4.4 Nh Chuyn Vin

Nn s dng dch v t vn t mt chuyn vin v lean hng dn trin khai h thng lean. c bit s chuyn i t h thng sn xut push sang pull c th gy gin on sn xut, do qu trnh ny nn c s hng dn ca mt chuyn vin c nhiu kinh nghim lin quan.

2.4.5 Lp k hoch Cng ty nn thit lp mt k hoch trin khai chi tit v r rng trc khi

tin hnh chuyn i sang lean.

Chng ta c th s dng hnh v sau thuyt minh :

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C bn bc trin khai Lean trong mt doanh nghip : Bc 1 : Phi xc nh r rng Chin Lc v cc Trng Hp Thay i

tp trung vo mc tiu kinh doanh v cc mc tiu c th Bc 2 : Cung cp cc kha hut luyn c c nn tng v s hiu r

cc c tnh, phng php v cng c

Bc 3 : Xc nh cc im ca d n, s chui gi tr v thnh phn thng qua Kaizen

Bc 4 : ng dng cc cng c v phng php nng cao thng qua vic chuyn giao cc k nng v tip tc ci thin vic chuyn gia trong doanh nghip

Hnh 5 : Trin khai Lean trong doanh nghip

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2.5 Kt Hp Lean vi Cc H Thng Khc 2.5.1 H Thng Sn Xut Toyota

Mc d bt ngun t H thng Sn xut Toyota (TPS), Lean 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:

Chun ho quy trnh Tt c cc quy trnh sn xut u rt c th v ni

dung cng vic, chui s kin, thi gian v kt qu. Mc tiu l loi tr nhng khc bit trong cch cng nhn thc hin cng vic.

Bn giao trc tip Mi im kt ni gia khch hng vi nh cung cp

phi hon ton trc tip, v phi lun lun c th hin mt cch r rng,

c-hay-khng, truyn t yu cu sn xut gia nh cung cp v khch

hng. iu ny m bo nh cung cp phi chu trch nhim ti mc ti a v lung thng tin c ti u.

Lung sn xut - ng i ca mi sn phm v dch v phi tht n gin v r rng, vi lung sn xut nh trc. iu ny c ngha l sn phm

khng c a ti nhn vin hay my cn trng k tip, m c a ti

mt nhn vin hay my c th nh v nhn vin hay my ny nn c

t v tr cng gn ngun cung cp cng tt.

Giao quyn cho cng nhn trong ci tin quy trnh - Tt c cc ci tin phi c thc hin da theo phng php khoa hc, di s gim st ca mt chuyn vin, nhng nn bt ngun t cp thp nht trong t chc. Toyota khuyn khch cng nhn xut cc ci tin cho quy trnh sn xut bng cch trin khai th nghim, nhng bt c thay i no trong quy trnh sn xut u phi c nh ngha chi tit theo chun mc ca Toyota v

Chun Ho Cng Vic, nh m t trn. 2.5.2 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

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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 nn cc cng c v thng k v gii quyt vn ca Six Sigma c

th c s dng khi trin khai Lean . Thng thng khi hai phng php ny c trin khai ng thi, ngi ta gi l Lean Six Sigma.

2.5.3 Lean v ERP ERP l mt phn mm hot ng trong mi trng cng nghip, gip

doanh nghip iu hnh mt cch d dng v hiu qu cc cng vic ca qu trnh sn xut. H thng ERP lin tc cp nht thng tin gia cc phng ban. Khi c yu cu, cc thng tin s c chuyn ti nh qun l di dng cc bo co mt cch ngn gn v gn nh tc thi. Vi h thng ERP, nh qun l c th kim sot v iu phi tt c cc hot ng trong cng ty. Hu ht cc phn mm ERP

u c thit k cho h thng sn xut theo m hnh push v c hoch nh

tp trung.

ERP l mt phng php gip cho vic hoch nh v kim sot c hiu

qu nhng ngun lc cn mua vt t, ch to, vn chuyn, giao hng trong mt

cng ty sn xut, phn phi hoc dch v. Mt h thng tch hp ERP qun l cc qu trnh kinh doanh cn cho mi n hng v nh gi tc ng ca vic thc hin n hng n tn kho v sn xut. Module sn xut ca mt gii php ERP, chng hn, gip gim thi gian hoch nh/ ti hoch nh v v vy lm cho

h thng linh hot hn gip cng ty sn xut nhanh hn v hiu qu hn. Module phn phi qun l gip kim sot mi th t mua sm vt t cho n vic ng gi, vn chuyn thnh phm.

ERP cung cp chnh xc, ng lc v nhanh chng nhng thng tin nh

hng sn xut cho vic lp k hoch v kim sot tc v. Nhng kh nng tng

hp, so snh, phn tch v a ra thng tin cht lng cao lm cho vic ra quyt

nh tt hn. ERP hnh thnh xng sng giao dch ca mt doanh nghip v lm vic nh l mt cht bi trn thng tin, thc y vic trao i d liu gia b phn ca doanh nghip thng qua s thng nht v cc qu trnh ch cht.

44

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

p dng nguyn tc Lean 8 lng ph vo ERP Sn xut tha: Ch iu nhng g cn thit da trn iu sn xut

tng th (MPS) v Hoch nh nhu cu vt t (MRP). Thi gian ch: Gim thi gian iu (lp k hoch v iu hng ngy

hoc mi ca). Tn kho: - Loi b lng tn kho an ton.

- Lm theo n t hng.

Vn chuyn: S dng nhng k thut tinh gn khng phi kim sot phn xng bng thng k (SFC).

Thao tc: - Ti thiu ha cng vic iu .

- Ti thiu ha hoc loi b vic bo co v sn xut v lao ng.

Qui trnh: Loi b vic s dng SFC, thay bng JIT v Kanban. Sai st: - C s d liu chnh xc.

- Thng tin:

Lp k hoch v iu t hiu sut v hiu qu cao.

45

Vic ng dng nhun nhuyn cc nguyn tc ca Lean c th bin i ERP thnh Lean ERP vi cc c im nh sau :

ERP truyn thng Lean ERP

Lp k hoch sn xut da vo s kt hp cc n t hng thc t v

d bo bn hng

Sn xut ch da vo n t hng thc t nhn c

Thi gian lp k hoch v sn xut

c th ngn trong vi tun nhng

cng c th di trong mt nm hoc hn. Trung bnh thng vo khong 12 tun

Lp k hoch v iu sn

xut da trn nng lc sn xut hng ngy v cc n t hng

thc t nhn c

Cc sn phm c sn xut hng lot ln t c hiu sut cao

Sn xut theo m hnh hn hp trong hng ha c th c

Hnh 6 : Kt Hp Lean v ERP

46

v lu v di sn xut theo lot nh hoc n chic

Cc sn phm c di chuyn xuyn sut nh my theo lot vi

nhng nguyn cng ring r c

hon thnh trc khi di chuyn n nguyn cng tip theo

Do mi nguyn cng c

hon thnh trn mt b phn n l, mi b phn c di chuyn n nguyn cng tip

theo trong dng cng vic lin tc

Vn hnh da trn khi nim cc trung tm gia cng

Yu cu chuyn sn xut phi

c cn bng vi cc thi gian nh mc v chu k sn

xut c ng b ha

Mua sm vt t da vo iu sn xut d bo thng qua h thng ERP truyn thng

Kanban c s dng xc nh nhu cu mua vt t v ph

tng

2.5.4 Lean v ISO9001:2000 ISO9001:2000 l mt h thng qun l cht lng gip m bo rng cng

ty c mt h thng c bn p ng yu cu cht lng ca khch hng mt cch nht qun. So vi ISO9001:2000, Lean 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.

47

Nhn chung, ISO9001 c xem nh mt nn tng tt cho Lean v c hai phng php u b sung cho nhau.

48

CHNG 3 : NG DNG LEAN TI VIT NAM 3.1 Toyota Bn Thnh v Bao B ng Nam Vit 3.1.1 Toyota Bn Thnh

Cch qun l Lean da trn nn tng TPS ca Toyota nn s rt ph hp cho ca (c cng ty sa n xu (t xe hi va ' xe g(n ma (y y.Ngoa 'i ra m&t s( nga 'nh c khi(,

i &n t, i &n gia du &ng, la 'm ' g, la 'm ha 'ng tiu du'ng, gia 'y de (p, may xu (t kh u, tu(i xa (ch, ' chi, ' nh&a, bu(t bi

C s l lun ca Lean ti Toyota Bn Thnh : Xi( nghi &p t Toyota B (n Tha 'nh c thnh lp nm 1993 v tr thnh i

l chnh thc ca Cng ty t Toyota Vit Nam vo nm 1999. Cng ty cung cp dch v: kinh doanh xe t Toyota, trm bo dng, sa cha xe t Toyota v kinh doanh ph tng Toyota chnh hiu. Hin ti, x nghip c ngun nhn lc mnh vi gn 200 cn b, nhn vin, trong c 64 ngi lm vic ti b phn sa cha thn xe v sn. Toyota Bn Thnh lun l mt trong nhng i l c hot ng kinh doanh xut sc nht trong h thng i l ca Toyota Vit Nam. Trong nm 2006, Toyota Bn Thnh n 44.000 lt xe vo sa cha, d tnh con s ny s tng ln 48.000 lt xe trong nm nay, tng 10% so vi nm 2006.

Toyota Bn Thnh ng dng Lean thnh cng Vit Nam v 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.

Kt qu mt cuc thm d kin khch hng do Cng ty Toyota Vit Nam tin hnh cho thy, gn 90% ch xe mun ch ngay ti trm nhn li xe ngay sau khi bo tr xong v c n 67% ni rng h ch mun ngi ch khong 60 pht. Trong khi , vic bo tr bnh thng ti Toyota Bn Thnh mt khong 240 pht. Nh vy lm th no rt ngn thi gian ch nhm tha mn nhu cu

ca khch hng.

u tin cng ty cho quay phim li ton b quy trnh bo tr chic xe, k t lc tip nhn cho n khi bn giao xe cho khch. Qua phn tch bng hnh, cng ty pht hn trong 240 pht c n 70 pht l thi gian cht do nhng ch tc gia

49

cc cng on ca quy trnh m ch yu l ch i giao v nhn ph tng. Thi

gian bo tr thc s ch c 150 pht v phn cn li l thi gian cho cng tc lin quan nh chun b ph tng bc trc khi bo tr, kim tra li sau khi hon tt cng vic, th tc bn giao xe cho khch.. Nh vy, ch cn loi b thi gian cht, trung tm c th rt ngn thi gian bo tr mt chic xe xung cn 170 pht.

Phn tch tip thi gian 150 pht thc hin cng tc bo tr ca cng nhn, nhm ci tin tip tc pht hin nhng bt hp l trong cch thc lm vic, nh vy sp xp dng c v la chn dng c khng ph hp, ch ng ca cng nhn cha ti u nn mt nhiu thi gian di chuyn. Ch ring s di chuyn thiu hp l ny chim hn mt phn ba thi gian ca hot ng bo tr.

Do , 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... 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.

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 6 ln 16 chic/ngy. iu ny 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.

50

Trn thc t, nhiu c s sn xut cng nghip Vit Nam vn cha thy

c tm quan trng ca vic quy hoch mt bng nh xng, b tr my mc thit b ph hp, rt ngn thi gian vn chuyn nguyn liu t kho vo dy chuyn sn xut... s gip tng hiu sut lm vic ca cng nhn nh th no.

3.1.2 Cng ty Bao B ng Nam Vit

Cng ty TNHH Bao b ng Nam Vit l cng ty con ca cng ty Liksin, c thnh lp vo nm 2003 vi nh my t ti tnh Bnh Dng.

Lnh vc hot ng l sn xut thng carton 3 v 5 lp cht lng cao, in nhiu mu, phc v cho nhu cu trong nc v xut khu, c bit l cc thng carton in offset vi cht lng cao. Cng ty c cp giy chng nhn ISO

9001:2000 thng 2 nm 2006, Cng ty tin hnh cc hot ng nhm nng cao hiu qu trong cng tc qun l nhm gim gi thnh, a n bn hng nhng sn phm cht lng tha mn yu cu. tin hnh hot ng 5S, thc hin p dng sn xut tinh gn (LEAN),v tin ti thc hin ISO 22.000 tch hp gia phin bn ISO 9001:2008 v ISO 14.000. Cng ty lm cc thnh vin trong Hip hi Bao b Vit Nam (Vinpas) bt ng khi trin khai thnh cng 5S, ng thi tr thnh n v u tin ca Vinpas p dng th im thnh cng h thng sn xut tinh gn (Lean ) vo thng 4/2009. Mc tiu ca vic p dng ny l tng nng sut lao ng 8-10%, gim tn kho 30%, xy dng h thng qun l theo 5S v qun l trc quan. C s l lun ca Lean ti cng ty ng Nam Vit

Ban u, nh my, kho xng u c sp xp thong ng, mi trng

lm vic sch s, ngn np, tm l ca cn b cng nhn lm vic thoi mi hn trc, nng sut tng ln.

K tip, lnh o cng ty c mt s thnh vin ban gim c tham gia ban d n sn xut tinh gin, ng thi tham gia kha hun luyn hai ngy mi tun vi nhn vin, trng cc b phn. b sung cho phn l thuyt hc c, ban d n cn quay phim, chp nh quy trnh lm vic trc v sau khi vn dng sn xut tinh gin. Hng tun, ban u c bui hp v Lean rt kinh nghim

51

v xy dng k hoch cho tun sau, ng thi cn t chc chm im cc hot ng 5S v qun l trc quan, xy dng tiu chun lm vic cho nhn vin.

Tuy nhin, cng ty vn cha tha mn. Bi l vn mt nhiu thi gian cho

quy trnh sn xut, cng nhn tn nhiu thi gian di chuyn trong lc lm vic, cc cng on sn xut phi ch i nhau, cha c tiu chun ha cng vic Sau

khi c hng dn l thuyt cch ci tin ti t my sng bi cc chuyn gia, ban d n v nhn vin th hin s sng to ca mnh. H chuyn i ca v chun b thi gian sn xut hng ngy, gip hiu sut s dng my tng 8,95%, to ra gi tr lm li trn 500 triu ng/nm. Nhng hiu qu ca vic p dng c th c nhn thy qua chn thay i di y :

Mt bng nh xng nay thng thong cho vic SX ch khng cn rc ri ba bi hay dn ng nhng c khng cn thit. So vi khi cha thc hin 5S, doanh s hin nay tng gn gp 2 ln, mc d khng xy thm kho nhng vn din tch cho SX, kho vt t, thnh phm, ngoi ra cn b tr 350 m2 kho cho thu to thu nhp cho Cty.

Sn lng SX gia tng l do iu kin SX c ngn np trt t ca Cty, kim sot SX c d dng hn, mt bng nh xng thng thong v nht l BG Cty khng phi lo lng trong vic v sinh nh xng khi c khch

n thm quan cng ty.

Khu kim sot SX c thc hin d dang hn.

Vt t v ph tng c bo qun, tn dng. Tt c vt t, ph tng khng dng, ph liu . . . u c di i ti nhng ni thch hp.

Thi gian c tit kim. Vic mt cng i kim nguyn vt liu, dng c, dng . . . c chm dt. Cng nhn c ch rng hn lm vic thoi mi v khng cn mt th gi cho vic dn dp tm ch lm vic.

Vic bo tr bo dng, sa cha thit b c tin hnh thun li. Cng nhn c in khng phi lo lau chi bi bm, du nht, li cn c ch trng thun tin cho thao tc.

52

Ch bo qun an ton c thc hin vng chc hn. Xa b khng gian cht chi gip cho vic vn hnh my mc thit b c an ton. Nn nh xng thng thong sch s lm gim bt va chm, trt ng nhng ni c du m, li i thng thong cng gip gim thiu cc v ng xe, ng vo ngi nhau, ng vt t, bn thnh phm ng . . .

Cng tc phng chy cha chy c tng cng. Ri ro ha hon c

gim thiu. Mt bng thng thong gip thot him nhanh.

Tinh thn o c c nng cao. Cng nhn quan tm n nh my hn. Sau ba thng p dng sn xut tinh gin song song vi 5S, nng lc sn

xut c ci thin rt nhiu, t 4.000-5.000 thng/ca, p ng yu cu v thi gian ca khch hng so vi nng sut ca nh my ch sn xut c 2.500 thng ng thanh long/ca nh trc y.

Ti nh my ca ng Nam Vit, cc b phn thnh phm, bn thnh phm, t my sng, kho bi u th hin c s i mi v s lng, thng tin c cp nht, cng khai mi ngy, gp phn lm gim ng k lng hng tn

kho, tit kim khng gian v tng kh nng quay vng ca ng vn C th, sau

khong ba thng thc hin sn xut tinh gn ti cc b phn, kt qu l gim tn kho giy cun, gim tn kho vt t, kho thnh phm, tng nng sut b phn dn hng v ng kim thng carton, t my sng, t my in gi tr lm li t gn 1

t ng/nm.

Tnh n cui thng 8-2009, nng sut lao ng ti ng Nam Vit tng 5-10% theo tng khu, gim tn kho t 30,56-52,41%, xy dng hon chnh h thng qun l 5S v h thng sn xut tinh gin. Nm 2009, cng ty t k hoch doanh thu 70 t ng. Theo ng Cao Hng Quang, Ch tch Hi ng thnh vin kim Gim c cng ty : Kt qu t c ln nht, l xy dng c tinh thn t gic ca mi cng nhn, thc tit kim, v sinh cng nghipThc hin sn xut tinh gn khng phi l b ra tht nhiu tin mua my mc, iu quan trng l doanh nghip phi bit cch tn dng nhng g ang c tht hiu qu. Lean khng s nhng ngi khng bit lm m ch s ngi khng mun lm.

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3.2 Xut S Dng Lean 3.2.1 Ti Doanh Nghip May Mc :

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.

Vic u tin thc hin l vic 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 may mc p dng Lean s gip gim thi gian thc hin n hng; 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 s 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. 3.2.2 Ti Doanh Nghip Thc Phm

54

Vn ca Doanh Nghip Thc Phm chnh l s lng hng tn kho v

iu ny nh hng rt ln n chi ph ca doanh nghip. Bn cnh , ngoi vic c nhiu loi sn phm v tranh th c hi trn th trng, khi sn xut lun

mong mun c chu k sn xut tht di nhm gim thiu t l ngng my v hao ph cho mi t chy.

Do , hng p dng Lean vo trong nh my thc phm l gim chu k sn xut trung bnh xung cho tt c sn phm. c th t c, chng ta cn phi thay i vic sn xut cc sn phm nhiu ln. Mi pht ngng my cho cho

mt ln chuyn i, mi sn phm li c sn xut ra khi khi ng li my v

c vic duy tr tc my thp trc khi tng dn n tc mong mun, u tr nn rt quan trng. iu ny dn n mt yu cu bc bch cho khi sn xut l lm sao phi thc hin chuyn i tht nhanh v hiu qu: thi gian ngng my

ngn, sn phm li trong qu trnh khi ng thp v quy trnh tng tc sau khi

ng tht nhanh.

Bn cnh , cn phi trang b cho khi sn xut c tht nhiu kin thc v k nng cho vic chuyn i sn phm nhanh. Vi cc k nng c trang

b cng vi h thng pht huy sng kin ci tin, rt nhiu thao tc chuyn i sn phm c rt ngn i nhiu ln. Ngoi ra, cn lu n cc dy chuyn a nguyn liu vo nh my. iu ny s gip tng nhanh thi gian sn xut v gim

thiu thi gian ch.

Mt yu t rt quan trng khc chnh l vic thu thp thng tin v nhu cu

ca khch hng trn th trng. Thng tin ny s gip cc nh sn xut hoch nh

sn lng sn phm sn xut ra trn th trng nh trnh c tnh trng lu

tr tn kho.

3.3 Nhng vn khi ng dng LEAN vo Vit Nam 3.3.1 thc ca ton th thnh vin trong t chc.

Mc ny c xp u tin v trong Lean, chng ta ch ni n s vn hnh

ca c mt h thng (system) da trn n lc ca tp th, i nhm ch khng phi c nhn.

55

3.3.2 i ng cng nhn vin

H thng sn xut Lean i hi ngi lao ng phi c thc v tinh thn trch nhim cao trong mi cng vic. V d in hnh, trong Lean, i ng lm cng vic kim tra sn phm (QC hay KCS) c xem l lng ph. Chnh ngi thc hin cng vic ti ca mnh (cell layout) chu trch nhim kim tra cht lng sn phm mnh lm ra. Hay trong vic rt ngn thi gian lp t hay iu

chnh my mc, ngi lao ng phi tun th nghim tc quy trnh chuyn i th

mi c hiu qu. Vi thi quen lm vic thong dong v chm ri ca ngi Vit Nam chng ta, liu chng ta c tinh thn ch ng tun th quy trnh tit kim thi

gian tng nng sut hay s ngh n vic c nhiu thi gian, mnh phi lm

nhiu vic hn?

3.3.3 i ng qun l y li chnh l nhng ngi nh hng rt ln n tin trnh ng dng

Lean. i vi nhng ngi lm qun l, nht l nhng ngi c t tng lm vic c, da vo kinh nghim v thch n nh trong cng vic th s l mt th thch ln nu yu cu h thay i cng vic g , d rng lm vic ny s tt hn cho ngay chnh bn thn hn. Hin nay, nhng ngi c t tng lm vic ny c mt ti a s cc t chc. H rt t tin vo kinh nghim, kin thc hay k nng lm

vic ca mnh. C ngi bn yu cu thay i ng dng phng thc mi, h s ng , nhng ch ngoi mt, khi thc hin li d d ng ng. C ngi li phn ng ngay khi cho rng, chng ta khng gp vn g rc ri, ti sao phi

thay i.

3.3.4 Ban lnh o

c th ng dng thnh cng Lean, i hi phi c mt Ban lnh o ti nng v bn lnh; kho lo trong x l quan h v sng sut khi quyt nh s vic xy ra trong qu trnh ng dng Lean.

Ban lnh o cn phi c nhng t cht quyt nh sau:

56

3.3.5 S dng cm Qu trnh ng dng Lean l qu trnh chuyn i cch lm truyn thng

sang cch lm chuyn nghip, khoa hc v quan trng nht l hnh thnh mt vn

ha t chc mi. l qu trnh ny sinh nhng th thch v kh khn i hi s

dng cm rt ln ca Ban lnh o t chc. Dng cm loi b nhng c nhn, tp th d l nhng con ngi ti nng

v c v tr quan trng trong t chc khi h nht nh khng theo ch trng Ban

lnh o t ra.

Dng cm i mt vi nhng thch thc xy ra trong qu trnh chuyn i

(thng gp trong giai on u ca qu trnh ng dng) c th nh hng n li nhun ca t chc. Chng hn nh s chuyn i quy trnh, cch thc lm vic, sp xp b tr li my mc thit b, nh xng. thm ch l i ng i kim tra cht lng.

3.3.6 S cng quyt Trong thc hin Lean, tm nh hng ca Ban lnh o i vi ton th

cn b cng nhn vin l rt quan trng, l nhng ngi ng vai tr u tu trong sut con ng i. Ban lnh o phi lun thng nht v cng quyt trong mi

hnh ng thc hin Lean, iu cho mi ngi thy c quyt tm ca Ban

lnh o. Khng ch mt th h m qua nhiu th h, iu phi lun c duy tr thc hin.

3.3.7 S kin tr

xy dng mt h thng sn xut Lean hiu qu trong ton t chc, i hi s kin tr thc hin rt ln. Ban lnh o phi kin tr thc y cc hot ng

ng dng Lean lun c thc hin mt cch lin tc, ngay c khi c kh khn. Kinh nghim cho thy, s ng dng Lean mt cch mit mi, khng b gin

on s to nh hng rt ln n tp th ngi lao ng. H thy c s chuyn

i v quyt tm ca nhng ngi lnh o. S khng lin tc trong qu trnh ng

dng s lm chm tin trnh v ngi lao ng nhanh chng qun i nhng g va mi chuyn vo trong tm tr h.

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3.3.8 Kh nng, nng lc ca t vn vin hay t chc t vn

ng dng h thng sn xut Lean c thnh cng, kh nng, nng lc ca t chc t vn v t vn vin ng vai tr rt quan trng. l ngi dn ng cho chng ta. Thc hin Lean phi l nhng ngi xut thn t sn xut v

thc hnh. Lean lun i vi thc tin.

Qu trnh thc hin Lean mt thi gian rt di v nh hng n c h thng ca doanh nghip (quy trnh, th tc, hng dn v ISO), do , ngi t vn phi c trnh , kin thc thc t nht nh v ng dng Lean. Nu bn chn phi mt nh t vn ni gii v khi nim Lean m cha ln no thc hnh, bn c nguy c thnh vt th nghim vi c h thng vn hnh ca mnh. Ngay c nhng

nh t vn c uy tn khi p dng Lean vn vp nhng sai lm nh thng.

58

CHNG 4 : KT LUN

c th a cc nh sn xut Vit Nam ngang tm vi cc nh sn xut

khc trn th gii, chng ta cn phi p dng nhng dy chuyn sn xut hin i. Bn cnh , vn qun l cht lng cng mt h thng sn xut tinh gn l vn rt ng c quan tm. H thng sn xut Lean v ang c p dng rng ri trn ton th gii nhng thp nin va qua. Cc doanh nghip Vit Nam c th tin hnh hc hi v p dng vo doanh nghip mnh nhm to ra c mt li th cnh tranh cng nh chin lc kinh doanh ng n cho doanh nghip mnh.

iu quan trng nht by gi l cn phi c mt i ng t vn trnh v kinh nghim thc t, am hiu vn ha v ngn ng Vit Nam, nhm gip

nh hng cho cc doanh nghip trong nc tip cn theo mt l trnh bi bn v chnh thng khi trin khai p dng Lean. ng thi cn truyn b v thng t tng cho cc doanh nghip gip cc lnh o doanh nghip bit c tm quan trng ca vic trin khai p dng Lean v hiu qu li ch tht s t vic ny.

59

TI LIU THAM KHO

1. http://www.diendanquantri.com/quantri,1,698,print.htm 2. Qun Tr iu Hnh i Hc Kinh T TPHCM TS. H Tin Dng 3. http://www.sangtaotre.com/tintucDetail.asp?catID=16&newsID=97 4. http://www.nangsuatchatluong.vn/nang-suat-chat-luong/16-trien-khai-

lean.html 5. http://www.dongnamvietpackaging.vn 6. www.samco.com.vn 7. www.leansigmavn.com 8. http://thuvien-ebook.com/forums/showthread.php?t=1479 9. www.cis.tennessee.edu/library/pdf/2009_Lean.pdf 10. www.leanconstruction.org/lcj/V2_N2/LCJ_05_011.pdf