库存的浪费 Inventory

原因 (Cause) 對策 (Action plan)

因顧及安全或基準沒改導致採 庫存意識的改革 Inventory

購過多的物料 Due regard to safety consciousness reform
or baseline did not change too much 運用看板管理調節生產節奏
material procurement lead Regulating the use of Kanban
因積習難改或候鳥作業的備料 production rhythm
流程 Because old habits die hard or 平穩化及平準化的”一個流”
migratory job preparation process 的生產模式 Smoothing and leveling
因產能不均、消化不良或討厭 of "a flow" mode of production
換線的生產型態 Uneven due to 突破思維建立快速換線機制
capacity, indigestion or hate changing Breakthrough thinking a rapid
production patterns, lines changeover mechanism
因預測錯誤或月底趕貨造成過 優化生產排程計劃，優先考慮
多的成品庫存 Predict the end result 庫存消化 Optimizing production
of an error or cause excessive rush scheduling plan, prioritize inventory
finished goods inventory digestion
 库存的浪费 Inventory
 零件物料、半成品及成品的存货是不會產生任何附加價值，反而增
加了管理成本
Part of materials, semi-finished and finished products inventories will not
generate any additional value, but increased management costs

庫存
萬惡 是
根源 的
 不良品的浪费 Defects
不良品的浪费 : 是指產品在生產過程中無法第一次就完成作業，
必須再過維修、返工或重工流程作業
waste of defective product refers to the product can't be finished first time in the process
of production, must after repair, rework , or repeat process operations
松動
 表現形式 ( Phenomenon type) ： Lossen

線上堆積待維修的不良品 Defects that wait

rework on the product line 毛刺
burr
產品需回流或重测 the product that need NG
rework and re-test
Switch 靠
線外有過多的维修人员 over many repairers 近 Flex
側
at offline Switch
near the
報廢倉存放大量的待處理材料或待拆解 Flex

機台 rejection warehouse have more materials OK

waiting for being dialed with or machines waiting Switch 遠
離 Flex 側
for being assembled Switch far
from the
OQC 、 OBA 或客户退貨重工 OQC 、 OBA Flex

or comeback rework NG
不良品的浪费 Defects
原因 (Cause) 對策 (Action plan)
產品設計不成熟 必須有效執行新產品開發階段的 DFX 設
計檢討機制 Must be effective implement
product design is not mature
of new product development phase of the
制程設定不合理或不穩定 DFX design review mechanism
process to set unreasonable or unstable  建立 PFMEA 及 VA/VE 手法研究快速 ,
人員操作不當、品質意識不佳或培 高效 , 有效的自働檢驗設備和技術
訓不足 establish PFMEA and VA/VE technique
study fast, efficient , effective automatic
improper operation , poor quality
inspection equipment and technology
consciousness or lack of training
品質控制點設定不恰當或品質要求
 落實體現品質三不政策
過當
the implementation of the three-no policy
the quality control point setting that reflect the quality
inappropriate or unsuitable quality  建立完整的技能培訓考核追蹤機制 ,
requirements
收集相關不良品樣本進行實體化訓練
檢驗設備和檢驗技能不完備
establish complete skills training
incomplete inspection equipment and assessment tracking mechanism, collect
skills the sample of defective product for
materialization training
 搬運的浪费 Transportation
搬運的浪费 : 是指產品、半成品或材料在生產過程中必須藉由人力、料
車、載具等進行傳送作業
Transportation waste is that product 、 semi finished or
materials in producing must be transport by manpower 、 buggy or fixture

 表現形式 ( Phenomenon type) ：

1. 生產線上多人次的取放或傳遞動作
the motion of taking or putting and transport by
manpower on product line
2. 前後工序的銜接轉移搬運
the transport at two stations
3. 過多的材料點交移轉搬運
Overmuch check and hand over

4 材料或產品因故造成四處暫存及多次出入库的搬運
the NG materials and product result that transport of
stores and un-store
搬運的浪费 Transportation
原因 (Cause) 對策 (Action plan)
平穩化及平準化的”一個流”的
生產流程規劃不合理
生產模式
product process re-layout smooth and balanced producing mode
illogically
建立 JIT 及後拉式生產系統 Create
物流設計怖置不合理
JIT(Just in time) and Pull system
physical distribution designed 簡化收料、備料流程及上料供貨
illogically
模式
複雜的收料入庫點料
Simplify receiving and stocking flow
發料備料上料… .. 等流程
必須有效執行新產品開發階段的
storeroom flow is complicated
生產排程不穩定，產品或制程
DFX 設計檢討機制
品質成熟度不夠 Must be effective implement of new
product development phase of the DFX
the non-smoothly schedule and design review mechanism
non-Ripley quality
搬運的浪费 Transportation
從大的托盤移到小的托盤，從倉库到車間的搬運也是浪费！
Transportation from a big plate to a small plate ， or from war-house
to workshop are waste

1. 通過物流布局的修正，消除搬運，缩短距離
Through correcting the logistics layout, eliminate handling and shorten the
distance

2. 通過逐步線内化來消除物品暂放的浪费
Dismiss the wastes of materials Placement pro tempore by on line

3. 通過縱向生產線來消除工序間搬運
Through the vertical line to eliminate the handling between processes 
Thank You