One
The current domestic manufacture enterprise produces the
question which exists
Cuts off at present, changes the system, the strategic
plan through the enterprise, the CIS system, the organizational
structure combs with management promotion work and so on marketing
system design, the very many Chinese enterprise has basically solved
enterprise development and the organization operation question and so
on development localization, organization movement mechanism, market
development and enterprise idea localization. But along with the
Chinese green economy development localization, WTO further docking as
well as the policy edge gradually vanishes, the Chinese enterprise is
facing the competition day by day intense market. Says regarding
the very many manufactures enterprise, the delivery tows the time, the
stock fund massively occupies, the product quality not not stably, has
the order form but not to be able to make, the production system
efficiency is low and so on the undesirable tendency, has become
hinders its survival and the development fatal factor.
Therefore, embarks from the fine profit management angle, the
very many Chinese manufacture enterprise decided through introduces
5S, the fine profit production management and the production process
makes again strengthens the production management the process control,
the enhancement manufacture system flexibility, the reasonable layout
production system movement process, the promotion enterprise market
reaction rate, to the whole enhances the enterprise the competitive
ability and the profit level.
Through ours research, the Chinese manufacture enterprise's
production system saves generally exists in the below aspect either is
light or the heavy question:
Foundation "5S" management aspect
The reorganization, the reorganization still had is
short of, the scene existence very many questions spot, the
installment management was chaotic.
Nearly does not have the visual management, the visual
management is not clear about, lacks marking, the goods seeks wastes
the time. Has when the question cannot promptly discover.
The standard standardization management does insufficiently, the
production work lacks the standardization, the work standard is
imperfect, the standard formulation is unreasonable.
The maintenance of equipment maintenance mechanism is not
perfect, breakdown more, the breakdown engine off number of times
quite is frequent.
The production operation with produces the scene
The partial personnel produce the idea to be backward,
has not formed take the order form as the central production operation
idea.
The production counts and analyzes the system not to be
imperfect, effectively appraised with difficulty the company produces
the system the condition.
The production pattern created the middle goods in process to be
bigger, has taken an greater fund and the production space.
The color thick liquid disposition and the sample trial
manufacturing operation was not standard, causes to waste the mass
productions time.
To the date of delivery continual readjustment, covered in
manufacture process many questions, in the production question has not
been able promptly to expose the solution, created the system reaction
speed to be slow.
The scene lacks the work standard, the staff work is not
standard, is at will strong, creates the quality not to be good.
The scene non- standard work management visual tool, the
management is chaotic, the scene flows the management to lack the
standard, creates the thing to flow chaotic.
Quality control aspect
The quality guarantee system insufficiently is perfect,
inspection system and so on inspection, manufacture inspection, QC
inspection, independent inspection must strengthen.
The quality process control ability is weaker, causes the
massive quality cost losses.
The quality visual management, beforehand the quality project
diagnosis, the prevention management, afterwards the quality
countermeasure improvement does insufficiently.
The quality data analysis is not thorough, is unable to carry on
the work behavior improvement.
Management atmosphere and personnel ability aspect:
The basic unit superintendent's accomplishment and the
management ability wait for the enhancement, manages the technology to
have to strengthen grasps, specially found the problem, solves the
problem, the alone handling ability. Simultaneously needs
advanced to manage the idea training.
Needs further to build the improvement the climate atmosphere,
carries on the environment to exaggerate, for example: The staff
trains, method and so on slogan slogan, present situation board
improves the environment, obtains from the staff accomplishment
promotion, development improvement proposal activity, thus causes the
company overall level promotion.
Second, implements the income which 5S and the fine profit
production can bring
5S and the fine profit production management technology
took modern enterprise production management method the
representative, in the effective implementation and under the
reasonable utilization premise, can give the domestic manufacture
enterprise to bring the huge benefit and the production improvement.
According to ours experience, if the method is appropriate, the
implementation arrives, through 5S and the fine profit production
implementation and the development, at least may give China the
manufacture enterprise in following three aspects to achieve the
anticipated income and makes a profit the goal:
1st, organization culture income
We thought through 5S and the fine profit production
advancement work development, at least must strengthen in the
enterprise interior following three aspects cultural idea and the
deepening:
The strengthening strives for perfection process quality
consciousness, but is not controls quality consciousness. Very
many enterprises take own quality good as proud, but its behind is
grieved is this kind of quality is depends on the massive waste
products to take the price. Certainly is not makes the process
the active control, the realization quality enhancement and the waste
product drops the dual goal.
Fine, thin, is strict, regardless of 5S or the fine profit
production, all emphasizes is the detail leaves the benefit, this the
custom which fails to search for deep understanding regarding the
China traditional culture in is a very good improvement.
The true realization take the customer as the attention focal
point, very many enterprises thought the delivery postpones is the
behavior which one kind may accept, specially when through lets the
customer with the customer communication when not postpone the
delivery gets angry, enterprise's production personnels postpone the
delivery to regard as the satisfied matter.
2nd, economic efficiency income
Moreover, according to ours research, regarding the
domestic very many manufactures enterprise, through 5S and the fine
profit production advancement work development, at least must obtain
the efficient income or the improvement in following several aspects:
The mass defect reduces 30%.
The stock reduces 30% (not including reasonable raw material and
end product).
The production cycle reduces 25%.
The equipment failure engine off rate reduces 30%.
3rd, staff quality income
We thought through 5S and the fine profit production
advancement work development, the third aspect income is must realize
the staff quality enhancement in following several aspects:
Selects can impel the enterprise development and the progress
talented person.
Raises consciousness which the overall staff strives for
perfection.
Enhances the staff to find the problem, solves the question
ability.
Enhances the staff to modern management technology grasping with
the utilization ability.
Fosters the staff standard to work with the good custom
Certainly, this work development inevitably can meet the
very big resistance, the key is must change the staff idea through
training, with careful and the explicit standard determine to the work
request, takes on the work main force with the most appropriate
talented person, forms the formidable propelling force with the
effective drive, last is the company all levels of leaders' value
above, lacks any, all will cause the work the execution and the income
greatly gives the discount.
Third, implements 5S and fine profit production some keys
The domestic manufacture enterprise needs to want very
good to carry out the fine profit production management, we thought
has four keys:
1st, the goal is clear about, also must to the goal which
finally achieves be clear about, also must be clear about to the
middle process goal, therefore must explicitly formulate each kind of
standard, including efficiency improvement standard, work standard,
condition standard, inspection standard and so on;
2nd, the change idea, only has each staff to change originally
regards the question, the development work method can carry out the
work the tangible;
3rd, the personnel arrives, regarding this work, must guarantee
"who can work who to do";
4th, links up appropriately, wants reasonable linking up
regarding each part of contents, avoids creating the foundation jail
but the next step of work with difficulty not to develop, but
simultaneously also must avoid wasting the excessively much time to
cause the result finally let it go at that.
In view of above understanding, in order to guarantee in Chinese
manufacture enterprise fine profit production project solid foundation
and work advance simultaneously realization, we thought 5S, the fine
profit production management and the flow make three parts to be
allowed again to adopt the overlapping 独立?project operation
way, also the preceding part of work took the latter part of work the
foundation, simultaneously the latter part of work development also is
the preceding part of consolidated processes.
When does each part of work, first must establish the explicit
goal, including efficiency goal, quality goal and cost goal. And
to affects each kind of behavior factor which the goal achieves to
carry on the system the analysis, and take optimizes the production
work system, the promotion company whole operation ability as the
basic starting point, but is not the simple localization to the scene
management and the improvement.
Under this localization premise, first is the staff which
carries on the system trains, the establishment perfect work standard,
causes each post when the improvement work can have Zhang Kexun.
Looks at the board way during the realization standard work in
the production system realization information transmission.
Looked the board is the fine profit production method visible
part. On the one hand needs to have a set to suit the enterprise
actual situation the scene policing method; On the other hand it
needs to grasp by the scene all operating personnel with the
implementation. Based on the Chinese manufacture enterprise's
special details, according to the goal establishment corresponding
servosystem, the perfect scene quality control and the TPM maintenance
of equipment, induct the production improvement and the thin each
supervisory work. Therefore the entire project operation must
draw by the ultimate objective achievement. Draws the operation
project in the project ultimate objective under the way, must work the
content structure according to below to complete the project.
Following chart:
Fourth, the enterprise develops 5S and the fine profit
production main work content
5S and the fine profit production system establishment
and the deepening are a practical greatly strengthened work, in the
plan each partial analyses, the design, the implementation, examines \
to adjust \ to deepen inevitably also carries on, moreover inevitably
is the result which the enterprise all staff joint effort, consultant
firm not impossible charge d'affaires to take care of everything,
consultant firm's function lies in uses own experience, the
specialized knowledge and the specific work technology provides the
experience for the enterprise to counsel, the knowledge service and
the opinion consultation:
1st, investigation and study and analysis diagnosis
Grasps the enterprise to produce the operation system
present situation, from the enterprise value flow is the starting
point, discovered must improve the method of work and the work
mentality, excavate creates a production operation system question
intrinsic reason; Forms "Enterprise To appraise, Diagnosis
Report", objectively describes the enterprise to realize looked in the
board management process involves the scene foundation management, the
equipment management, the quality control, the cost control, the
material management data material and the main improvement spot,
complete produces 能效?the analysis, the q analysis and the cost
element analysis, will prepare for full for the later effective
impetus.
2nd, training work content
Production management improvement goal completing very
is important with the realization on the one hand is the enterprise
leader's determination and the participation degree cannot separate;
On the other hand also cannot separate with the enterprise whole
personnel's participation motion. The preliminary enterprise
idea, idea training are extremely essential.
In the implementation process, must change person's some
习惯?thinking mode and 习惯?the behavior, creates a
humanities environment for the fine profit production smooth
implementation; On the other hand, also is most important,
raises one batch for the enterprise to understand the person which the
idea can operate.
According to need which improves, should establish the training
curriculum includes:
1) 5S management and visual management
5S elementary knowledge and idea training
5S advancement main point
Office 5S
Produces scene 5S
5S standard hypothesis and inspection
2) the fine profit production - constructs the fast
flexible manufacture system
Fine profit production idea and theory training
Value flow analysis
Standardized work
JIT immediate production
Fast cut
Fault prevention and question solution
3) looked the board management and the fine profit
flows the management
The low effect flows the heavy loss, the enterprise
interior thing which brings to the enterprise flows the improvement,
looked the board the basic concept, the establishment draws production
system, reduction in storehouse classical method, transporting method
hypothesis and implementation
The immediate purchase and the supplier manage
4) TPM comprehensive productiveness maintenance
The equipment six big losses, about the equipment crops
pace analyses, the equipment performance deterioration analysis, the
equipment preserves with the quality, the cost, the TPM connotation
and the significance, the fault analysis method, the equipment 5S
implementation, the TPM advancement method, the TPM implementation
skill
5) fine profit quality control actual combat
Fine profit quality control idea and technical
training
Quality control statistics technology application
QC seven tools
6) highly effective field operation management
The work design basic principle summarizes the method,
the industrial engineering concept and the principle, the movement
analysis and the elimination movement waste, the standard work
definition, the standard work three essential factors which, the work
expands: The metre time, the work order, the standard grasp, the
standard work to the quality condition request, the standard work
application three tools, the establishment qualities is highest, the
labor number lowly has the foreword security the work method, first
enters first leaves may trace the natural, the reduced labor number
production layout, person of many machine works methods with the
product.
7) works the guidance method
The guidance importance, not the correct guidance
method, the correct guidance method four stages, the correct guidance
method implementations train the function and the method, the guidance
method which, the work decomposes in the practical work application
3rd, project implementation work content
In the implementation, for the reduced project risk,
reduces to the enterprise present pattern impact, generally uses the
method which fans out from point to area, each stage all starts by the
experiment site region, meets the requirements after the pilot area,
again big area promotion.
General main content as follows:
Carries out 5S and the visual management
Founds the transparent scene. Establishes the
scene management the fundamental rule, discovered the scene invalid
with the waste, in particular three decides the management through the
material to appear the thing to flow the trace, effectively the
exposition flows the waste, gradually trains the staff to observe
decides the rule the custom.
The scene depositing material discrimination, establishes the
depositing standard (position, time standard and scene margin);
According to standard processing not thing;
The material deposits the region installment marking, the
construction section marks, channel discrimination marking;
The dirty dirt source search and the government, sweeps clear
the responsibility area the establishment, sweeps clear the standard
the establishment implementation;
5S 点检 standard and evaluation criteria establishment.
Optimized equipment spare parts management, including necessary
reserve management, non- necessary purchase channel and vulnerable
cyclical management.
Establishment standard work and establishment perfect work
standard
The establishment consummation work instruction book,
the unification makes and examines the standard, enable the scene the
quality control to have 严肃? strengthens the quality the process
control, eliminates the waste operation, sharpens the productivity.
The establishment work standard and carries on the work training
to the staff, completes many can labor training;
Recarries on the work to optimize, rational distribution work
load;
Optimized work standard, realization standardization work
Establishment transporting route and transporting
standard work
Uses the reasonable mode of transport to achieve the
small batch multi- frequency mix carry the transportation among,
reduces in the system, enhances the system reflection the sensitivity,
the realization flexibility manufacture goal.
Use fixed time indefinite quantity or quota indefinite tense
transporting method;
The determination fixedly transports the personnel and the
transporting frequency;
Sets reasonable smallest among in the storehouse;
The implementation looks at the board system
Establishes in the production system looked the board
management system management system, the use looked the board draws,
realizes the high efficiency class, the entire marking gauge current
events produce, achieved among the reduction in the system, reduces
goal of the manufacture cycle.
The investigation flows the present situation;
The plan present situation flows the chart;
The analysis flows the route, the plan looks at the board flow
chart;
The establishment looks at a board number.
Establishment equipment preventative maintenance system
Causes the equipment the breakdown service gradually to
transform as the equipment preventative maintenance, enhances the
equipment the processing precision and the processing ability,
gradually reduces the equipment failure engine off number of times and
the engine off maintenance time. This part of work massively is
covered as a result of the scene in the system; But revolves to
look the board management carrying out, the equipment preventative
maintenance importance appears extremely prominently.
The equipment appraised, determination essential equipment;
(Essential equipment hypothesis rests on a comprehensive
parameter)
Equipment existing breakdown removing
Implements the equipment to be independent 点检;
Implementation equipment plan maintenance mechanism, including
week, month, 点检 and engine off maintenance;
Equipment operation standard determination
Optimized equipment spare parts management, including
necessary reserve management, non- necessary purchase channel and
vulnerable cyclical management.
Establishes the fine profit quality guarantee system
The quality idea transforms, is clear about the scene
quality control method, causes the quality question to appear, grasps
the quality control the tool to improve the quality of the product may
trace the nature
Quality problem analysis method;
The scene quality may the tracing application;
QC seven tools descriptions and solution;
Scene quality control method and QCC tube ring activity.
Creativity proposal system and topic improvement
Through produces the scene quality production topic
improvement, the establishment proposal system, fans out from point to
area, gradually thin optimized improvement effect, maintenance and
enhancement improvement ability
Proposal system establishment;
Improvement topic choice and consummation
Improvement achievement issue summary appraisal;
Fourth, gradual appraisal
In the implementation process, regarding each stage,
the enterprise internal personnel must fully link up, guarantees the
work the actual effect. At the same time, according to the work
progress, arranges pointed method training, strengthens the staff to
improve the skill and consciousness. After each sub- project had
ended, after the enterprise personnel (or consults consultant) the
full communication, separately aims at before the implementation in
the production condition and the implementation advancement effect
carries on the appraisal, and appraises based on the stage to the
concrete implementation plan carries on the corresponding adjustment,
guarantees the project implementation the validity.
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