【精益生产英文】谈谈七大浪费之过度加工浪费今天分享的是精益生产英文

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谈谈七大浪费之过度加工浪费

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谈谈七大浪费之过度加工

什么是过度加工

Overprocessing is one of the seven wastes of lean manufacturing (or 7 mudas); Overprocessing is adding more value to a product than the customer actually requires such as painting areas that will never be seen or be exposed to corrosion.

过度加工，是精益生产七大浪费（或者七大muda）之一；过度加工，指的是向某种产品增添了超出客户实际所需要的多得多的价值，比如，喷涂区域绝不会被看到或者受到腐蚀。

1

加工浪费的成本

By adding work that is not required, Overprocessing costs you money with regards to the time of your staff, the materials used and the wear on your equipment. These costs can amount to a considerable sum over a period of time, they will also reduce your efficiencies as the operators that are Overprocessing could be performing other value adding tasks that the customer is willing to pay you for.

由于增加了不需要的工作，过度加工，会让你为相关员工的工作时间、物料使用以及机器磨损而买单。这些成本在一段时间内能达到相当可观的金额，也会降低工作效率，因为操作员过度加工了客户愿意去买单的其他增值的任务。

2过度加工的原因

Overprocessing as one of the seven wastes is caused by having unclear standards and specifications, many operators will try to do the best job possible and will not always be aware of what truly adds value to the product or even the end use. They will therefore often expend time polishing and finishing components that do not require it.

过度加工，是七大浪费之一，是由于标准和规范的不明确所导致，许多操作员会尽力把工作做到最好，并不会一直清楚真正为产品或者最终用途增加价值的是什么。因此，他们通常会花时间去抛光和整理不需要这么加工的零件。

Another issue is the one of non-standardized working practices, unless you have standardized working then you will have differences in methods between different shifts and different people.

另一个问题是：非标准化的工作方法，除非有标准化的工作，否则，在不同的班组和不同的人之间都会有不同的方法。

The most common issue is to do with design, often designers specify tolerances that require precision machining when in reality looser tolerances that could be produced by significantly less expensive methods could be employed.

最常见的问题是与设计有关，设计者往往明确指定需要精密加工的公差，而在实际情况下，公差放宽一些，可以通过使用非常经济的方法来加工。

请看例子

Painting areas that will never be seen or be affected by corrosion.

喷涂区域绝不会看到或者受到腐蚀。

Over polishing an area that does not require it.

过度打磨无需打磨的区域。

Tolerances that are too tight.

公差过于收严。

Within a company that I used to work in many years ago, we produced rubber components for the automotive industry, we cut these components to length (anywhere from 1M to 3M) with a tolerance of +/- 1mm. These then had to be measured and documented on SPC charts to ensure that capability was maintained. Engineers worked hard on trying to design machines that could cut these products to the tolerances required.

多年前服务过的一家老东家，是为汽车行业生产橡胶部件，我们将这些部件切割成一定的长度（从1m到3m），公差是+/-1mm。这些必须在SPC图表上进行测量和记录，以确保能力能维持在一定的水平。工程师们努力去设计能让产品达到所需要的公差的机器。

These products were then joined together end to end to form a circular seal, this in use was stretched around another component; stretched far beyond its actual length at rest like a rubber band.

然后，将这些产品的接头接在一起，形成一个圆形的密封件，这种密封件在另一个部件上进行拉伸；而静下来时，拉伸远远超出其实际长度，就像橡皮筋一样。

The tolerance was a joke and the measuring also, as long as the piece of rubber was at least 10%-20% smaller than the final component it would work fine in operation. The measurements conducted were also a sham as the operators could either stretch or compress the components to get any measurement they wished! All of this is relative to the waste of Overprocessing.

公差与测量简直就是笑话，只要橡胶件至少比最终部件小10%到20%，就可以在工作中运行良好。所实施的测量也是虚假的，因为操作员可以拉伸或压缩部件，用以得到希望得到的任意测量值，所有这些都与过度加工的浪费有关。

3如何消除或者减少过度加工

To prevent the waste of overprocessing there are a number of simple steps that can be undertaken, as part of your initial 5S implementation instigate the use of Standard Operating Procedures (SOP) to provide written instructions for all of your employees. This is extremely easy in today’s age of digital cameras and word processing packages.

为了防止过度加工的浪费，可以采取一些简单的步骤，作为最初的5S实施的一部分，促成使用标准操作程序（SOP）为所有员工提供书面的指南。在当今这个数码相机和文字处理软件包的时代，这是相当容易的。

These SOPs will ensure the standardization of methods across shifts and personnel, combined with on the job training they are a highly effective way to improve the quality of your product as well as ensuring the reduction in Overprocessing. These SOPs combined with quality standards can also help with regard to clarifying specifications and acceptance standards.

标准操作程序（SOP），将确保不同班组和人员的方法的标准化，结合在职培训，标准操作程序（SOP）是改进产品质量的有效途径，还能确保过度加工的减少。这些标准操作程序（SOP）与质量标准相结合，也有助于澄清规范和验收方面的标准。

Review designs with techniques such as value engineering and value analysis to identify opportunities to remove tolerances that are too tight.

使用诸如用价值工程和价值分析等方法来查阅设计，以找出消除公差过于紧密的机会。

Examine your process routes, are you using expensive processes where there are simpler cheaper methods?

请检查加工路径，你在用的是否相对较贵，而在实际上却有更简单与更经济的方法？