Ukuphathwa Kokukhiqiza Okungaxubile
Ukuphathwa kokukhiqiza kwe-Lean kuyindlela ehlelekile yokuthuthukisa ukusebenza kahle kwezinqubo zokukhiqiza ngokuqeda imfucuza, ukuthuthukisa inani lamakhasimende, nokwakha isiko lokuthuthuka okuqhubekayo. I-Lean ingaphezu nje kweqoqo lamathuluzi asezingeni lokukhiqiza; ingumqondo oqondisa izinkampani ukuthi zikhiqize imikhiqizo esezingeni eliphezulu, zinciphise izikhathi zokucubungula, zilawule izindleko, futhi ziphendule ngokushesha ezidingweni zemakethe. Empeleni, i-lean ingasetshenziswa ezimbonini ezisukela ekukhiqizeni, izinsizakalo, ezokuthutha, ezempilo, ngisho nasekuthuthukisweni kwesofthiwe, ngoba izimiso zayo eziyisisekelo zisebenza emhlabeni wonke: gxila enanini futhi unciphise imisebenzi engangezi inani.
Izisekelo Ezilula: Inani Nokuchitha
Enhliziyweni ye-lean kukhona umbuzo olula: “Yini eyigugu ngempela kumakhasimende?” Inani lichazwa ngokombono wekhasimende—lizimisele ukukhokhela imisebenzi eguqula umkhiqizo/insizakalo ukuze ihlangabezane nezidingo zalo, ngekhwalithi efanele, ngesikhathi esifanele. Imisebenzi engaphezu kwalokho ingaba yimali.
I-Lean ihlukanisa imfucuza ngezigaba eziningana, ezivame ukwaziwa ngokuthi imfucuza engu-7 (evame ukunwetshwa ibe yimfucuza engu-8). Nasi isifinyezo:
1. Ukukhiqiza ngokweqile: ukwenza okungaphezu kwalokho okudingekayo noma okusheshayo kunokufunwa, okubangela ukunqwabelana kwempahla.
2. Ukulinda (ukulinda): isikhathi sokungasebenzi ngenxa yokuma komshini, imigqa yenqubo, noma ukungalungi kwezinto ezibonakalayo.
3. Ezokuthutha: ukunyakaza okungadingekile kwezinto/imikhiqizo, okwandisa ingozi yomonakalo nezindleko.
4. Ukucubungula ngokweqile: izinyathelo zenqubo eziyinkimbinkimbi kakhulu, ukuhlolwa okuphindwe kabili, noma imininingwane ikhasimende elingayidingi.
5. Isitoko: isitokwe esiningi sezinto zokusetshenziswa, i-WIP (umsebenzi osaqhubeka), noma izimpahla eziqediwe.
6. Ukunyakaza: ukunyakaza okungasebenzi kahle komqhubi, ukwakheka okungekuhle, amathuluzi afinyeleleka kalula.
7. Amaphutha: amaphutha okukhiqiza abangela ukulungiswa kabusha, ukulahlwa, izikhalazo, kanye nezindleko zewaranti.
8. Ithalente elingasetshenziswanga (amandla ezinsizakusebenza zabantu angasetshenziswanga): imibono namakhono abasebenzi awamukelwa ngoba isiko alisekeli ukuhlanganyela.
Ngokufunda izinqubo ngeso lokuchitha imali, izinkampani zingabona amathuba okuthuthukisa avame ukuba nomthelela osheshayo ezindlekweni, ekhwalithini, nasesikhathini.
Izimiso Ezingenamsebenzi Ekuphathweni Kokukhiqiza
Ngokuvamile, i-lean isekelwe ezimisweni ezinhlanu eziyinhloko:
1. Chaza Inani (thola inani): chaza izidingo zamakhasimende ngendlela eqondile (izici, ikhwalithi, isikhathi sokulethwa, intengo).
2. Ukuhlela Inani Lomkhiqizo (hlela inani lomkhiqizo): hlela zonke izinyathelo kusukela ezintweni zokusetshenziswa kuya kumkhiqizo otholwe yikhasimende, bese uphawula izingxenye eziyigugu nalezo ezingelona.
3. Dala Ukugeleza (dala ukugeleza): zama ukwenza inqubo ihambe kahle ngaphandle kwezithiyo, ngaphandle kwemigqa emide, ngaphandle kokunyakaza okungadingekile.
4. Sungula ukudonsa (sungula uhlelo lokudonsa): ukukhiqiza okusekelwe ekudingweni kwangempela (hhayi nje izibikezelo), ukuvimbela ukukhiqiza ngokweqile.
5. Phishekela Ukuphelela: yenza intuthuko eqhubekayo ngesiko lama-kaizen kanye nokulinganisa okuvamile.
Ngomongo wokuphathwa kokukhiqiza, lesi simiso sihunyushwa ezinqubweni zokusebenza: ukuhlela okuvumelana nezimo, amalungiselelo okuhlelwa asekela ukugeleza, amazinga acacile omsebenzi, ukulawulwa kwekhwalithi emthonjeni wezinkinga, kanye nokuqinisa ukubambisana kwemisebenzi ehlukahlukene.
Amathuluzi Nezindlela Ezisetshenziswa Kakhulu Ezingenamsebenzi
I-Lean yaziwa ngokuceba kwayo ngamathuluzi. Kodwa-ke, amathuluzi akuwona umgomo; akhethwa ngokusekelwe enkingeni. Ezinye zezindlela ezisetshenziswa kakhulu zifaka:
1. Imephu Yokusakaza Intengo (i-VSM)
I-VSM isiza ukubona ngeso lengqondo ukugeleza kwezinto kanye nolwazi. Kusukela kule mephu, amaqembu angalinganisa isikhathi sokuhola, isikhathi somjikelezo, i-WIP, izithiyo, kanye namathuba okunciphisa imfucuza. I-VSM ivame ukuba yisinyathelo sokuqala ngaphambi kwamaphrojekthi amakhulu okuthuthukisa.
2. 5S (Seiri, Seiton, Seiso, Seiketsu, Shitsuke)
I-5S ihlela indawo yokusebenza ukuze icoceke, ihlanzeke, futhi ihambisane. Umthelela udlula ubuhle: I-5S inciphisa isikhathi sokusesha amathuluzi, inciphisa amaphutha, ithuthukisa ukuphepha, futhi yenza kube lula ukwenziwa kwezindinganiso. I-5S iyisisekelo sokusebenzisa ezinye izindlela eziyinkimbinkimbi neziyinkimbinkimbi.
3. I-Kaizen (Ukuthuthukiswa Okuqhubekayo)
I-Kaizen ikhuthaza ukuthuthuka okuncane nokuqhubekayo, okubandakanya abaqhubi kanye nabaphathi abaqonda kangcono imininingwane yenqubo. Uhlelo lwe-kaizen olunempilo luvame ukufaka indlela yokuthumela imibono, ukuhlolwa okusheshayo, kanye nokulinganisa uma ukuthuthuka sekubonakale kusebenza kahle.
4. I-Just In Time (JIT) kanye ne-Kanban
I-JIT ihlose ukuhlinzeka "ngenani elifanele, isikhathi esifanele" sezinto ezibonakalayo. I-Kanban uhlelo olubonakalayo (amakhadi/amasiginali) lokuphatha ukugcwaliswa kabusha ngokusekelwe ekusetshenzisweni kwangempela. Nge-Kanban, izinkampani zingalawula i-WIP, zinciphise isitokwe, futhi zithuthukise ukuzinza kokugeleza kokukhiqiza.
5. Umsebenzi Ojwayelekile
Umsebenzi ojwayelekile usungula ukulandelana komsebenzi okwaziwa kakhulu njengamanje, isikhathi somjikelezo, kanye ne-WIP encane. Umsebenzi ojwayelekile awuhloselwe "ukunciphisa ubuhlakani," kodwa kunalokho ukusebenza njengesisekelo lapho noma yikuphi ukuthuthuka kungalinganiswa futhi kuphindwe khona.
6. I-SMED (Ukushintshaniswa Kwama-Dies Omzuzu Owodwa)
I-SMED igxile ekunciphiseni izikhathi zokusetha/zokushintsha. Ukusetha okusheshayo kuvumela ukukhiqizwa kwezindawo ezincane, kwandisa ukuguquguquka, futhi kunciphisa izidingo zempahla. Amaphrojekthi amaningi e-lean athole impumelelo enkulu ngokunciphisa izikhathi zokushintsha—isibonelo, kusukela kumaminithi angu-90 kuya kumaminithi angu-15.
7. I-Poka-Yoke kanye ne-Jidoka
I-Poka-yoke iyindlela yokuvimbela amaphutha, kuyilapho i-jidoka isho "ukwenza izinto ngokuzenzakalela ngokuthinta komuntu": umshini noma inqubo iyama ngokuzenzakalelayo lapho kutholwa into engavamile. Kokubili kuqinisa ikhwalithi evela emthonjeni, kunokuthembela kuphela ekuhlolweni kokugcina.
Ukusetshenziswa Okulula: Izinyathelo Ezingokoqobo
Ukusebenzisa ukuphathwa kokukhiqiza okungenamsoco kudinga indlela ehlelekile yokugwema ukuba yisiqubulo nje. Izinyathelo ezilandelayo zivame ukusebenza kahle:
1. Ukuzibophezela kwabaphathi kanye nemigomo elinganisekayo: isibonelo, umgomo wokunciphisa isikhathi sokuhola ngo-30%, ukwanda ngo-10% ku-OEE, noma ukwehla ngo-50% kwamaphutha.
2. Ukuqeqeshwa okuyisisekelo kanye nokwakhiwa kwamaqembu asebenza ngezindlela ezahlukene: ukukhiqiza, ikhwalithi, ukulungiswa, i-PPIC, indawo yokugcina impahla, ubunjiniyela, ngisho nokuthenga.
3. Khetha indawo yokuhlola: qala ngomugqa onezinkinga ezisobala kakhulu noma umkhiqizo onomthamo ozinzile wokufunda okusheshayo.
4. Ukuxilongwa kwenqubo ngedatha: sebenzisa i-VSM, ukulinganisa isikhathi somjikelezo, amaphutha e-Pareto, kanye nokuhlaziywa kwesikhathi sokungasebenzi.
5. Ukwenziwa kokuwina okusheshayo: isibonelo i-5S, ukuphathwa okubonakalayo, ukuthuthukiswa kwesakhiwo, ukunciphisa amabanga okuphathwa kwezinto.
6. Ukulinganisa nokulawula: ngemva kokuthuthukiswa okuphumelelayo, bhala phansi umsebenzi ojwayelekile, ukuqeqesha kabusha, kanye nokuhlolwa okuvamile.
7. Ukwandisa: ukuphindaphindwa kwezinye izindawo ngenkathi kwandiswa amakhono eqembu.
I-Lean ephumelelayo cishe isekelwa njalo uhlelo lokuphatha lwansuku zonke: amabhodi okusebenza okubonakalayo, imihlangano emifushane esitolo, ukucaca kokwanda kwezinkinga, kanye nokusetshenziswa kwe-PDCA (Plan–Do–Check–Act).
Izinkomba Zokusebenza Ekukhiqizeni Okunganciphisi
Ukuqinisekisa ukuthi i-lean inethonya langempela, izinkampani zidinga ama-KPI afanele. Ezinye izinkomba ezibalulekile yilezi:
– Isikhathi sokuhola: isikhathi kusukela ekwamukelweni kwe-oda kuze kube sekuqedweni.
– Isikhathi sokujikeleza nesikhathi sokuthatha: ukuqhathanisa isivinini senqubo nezidingo zamakhasimende.
– OEE (Ukusebenza Kahle Kwemishini Yonke): inhlanganisela yokutholakala, ukusebenza kanye nekhwalithi.
– Isivuno Sokudlula Kokuqala (FPY): iphesenti lemikhiqizo edlula ngaphandle kokulungiswa kabusha.
– I-WIP kanye nokushintsha kwempahla: kulinganisa amazinga empahla kanye nokushintsha kwayo.
– Ukulethwa ngesikhathi (OTD): ukunemba kokulethwa.
– Isikhathi sokungasebenzi, isikhathi sokushintsha, kanye nesilinganiso sokulahlwa: ukuqapha ukuzinza kwenqubo.
Okubalulekile, ama-lean KPI awazimele wodwa. Isibonelo, ukunciphisa impahla kumele kulinganiswe nokuqina kwenqubo kanye nokuthembeka komhlinzeki ukuze kugwenywe ukushoda kwezinto ezibonakalayo.
Izinselele Ezivamile Nendlela Yokuzinqoba
Imizamo eminingi engenamsebenzi ayiphumeleli ngoba umqondo unephutha, kodwa ngoba ayisetshenziswa kahle. Izinselele ezivamile zifaka:
– Ukumelana namasiko: Abasebenzi bakhathazeka ngokuthi ukungabi namali kuzosho ukuncipha kwabasebenzi. Isixazululo ukuxhumana ngokwethembeka nokugxila ekwandiseni umthamo kanye nokuphepha emsebenzini.
– Gxila kumathuluzi, hhayi ezinkingeni: Ukusebenzisa i-5S noma i-Kanban ngaphandle kokuqonda izidingo zenqubo kungaba umsebenzi womkhosi. Qala ngezinkinga zangempela kanye nedatha.
– Ukuguquguquka okuphezulu kanye nekhwalithi engazinzile: I-Lean idinga izinqubo ezizinzile. Ngakho-ke, ikhwalithi nokugcinwa (TPM) kumele kuhambisane.
– Ukuntuleka kokuhlelwa kwezindinganiso: ngaphandle kwezindinganiso zokusebenza, intuthuko kunzima ukuyigcina.
– Uchungechunge lokuhlinzeka ngempahla alukasekeli okwamanje: I-JIT idinga ukuthi abahlinzeki baziphathe kahle mayelana nekhwalithi kanye nezikhathi zokuhola. Ukubambisana kanye nentuthuko yabahlinzeki ngokuvamile kuyingxenye yoshintsho olungenamsebenzi.
Isiphetho
Ukuphathwa kokukhiqiza kwe-Lean kuyisu eliphelele lokukhulisa ukuncintisana ngokunciphisa imfucuza, ukuthuthukisa ukuhamba komsebenzi, nokuqinisa ikhwalithi emthonjeni. Ngezimiso ezicacile—inani, ukugeleza kwenani, ukugeleza, ukudonsa, kanye nokuthuthuka okuqhubekayo—i-lean ingaletha imiphumela ebalulekile: izikhathi zokuhola ezimfushane, izindleko eziphansi, ikhwalithi engcono, kanye nokuguquguquka kokukhiqiza okwandisiwe. Kodwa-ke, impumelelo ye-lean incike kakhulu ekusetshenzisweni okuhlelekile, ubuholi obuqhubekayo, kanye nesiko elibheka intuthuko eqhubekayo. Uma i-lean isetshenziswa njengohlelo lokuphatha, hhayi iphrojekthi yesikhathi esisodwa, izinkampani zizoba nesisekelo esiqinile sokusinda nokukhula endaweni encintisana kakhulu.
