Site management is too confusing, how to change? Please do these 9 aspects
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Many companies' production sites, looking at it is a word: chaos! Managers are helpless and even accustomed to it.
In fact, there are only a few basic elements in the field management: people, things, places; the situation on the scene is ever-changing, and it comes down to only "two streams": logistics and information flow. The site manager must make a detailed analysis and research on these three elements and two streams, discover problems, analyze the causes, and find answers to the problems.
NO.1
Process check
To find a problem in a company or department, we should start from the process, analyze the whole process of production and work, what process is unreasonable, where is there to be reversed, where is there to pause, which process routes and links can be Cancel, merge, simplify, analyze and judge whether each link of the flow chart is in a controlled state, check whether it can play a check role, whether the horizontal contact of each department is in place, whether it is smooth, whether it is necessary to construct or add a new channel, by the flow chart All links and delivery routes, whether the existing functions of the various departments are in place, whether to adjust or reorganize the existing institutions.
NO.2
Calculate on the assembly line
Production lines and assembly lines should be in accordance with consistent tempo, and production can be balanced. Some enterprises often produce "front work, look behind, go ahead, and work overtime". One reason is that the way of moving is unreasonable, and the other is that the beat is not balanced. If the sequential movement mode is adopted, each batch of work is carried out and then moved to the next process, which causes waiting for the next process and work. If you pass it in parallel, that is, if you do one job and pass one to the next process, it will often double the efficiency.
On the assembly line, the slowest person is the one who determines the ultimate efficiency of the assembly line. Balance efficiency of production line or assembly line = total of net operation time of each process / operation time of the longest process × number of personnel. The balance rate of many production lines is often less than 50%. If the long-time process is simplified, the method of speed increase, substitution, or splitting is used to balance the assembly line by cutting, adding, etc. The production efficiency of the entire production line will be greatly improved, and the labor and accumulation caused by the slow individual processes will be eliminated.
NO.3
Action factor minus one minus
Any operation is based on manual movements, especially labor-intensive enterprises, assembly processes, processing operations, etc., which are manual labor-based processes. Actions are a very important factor in generating benefits.
For the purpose of motion analysis, the main purpose is to eliminate redundant movements, invalid movements or slow movements, such as bending work, standing on the stool, squatting, poor working place, no suitable station equipment, people and things. In the search for status, etc., the most efficient way to achieve maximum efficiency. This research can greatly increase production efficiency without spending a penny. For example, in real life, why do some people make dumplings much faster than the average person? Why are some people transplanting a lot faster than the average person? That's all because they have mastered certain flaws and completed the task with the most economical action.
Action analysis should follow the following most important principles of action economy:
1. Do not use your right hand to do it with your feet or your left hand. Work as much as possible with both hands, start at the same time, and end at the same time.
2. Make your hands move symmetrically in the opposite direction at the same time.
3, materials and tools should be placed as far as possible to reach the location, and determine the appropriate location in the order of the basic operating elements.
4, reduce all unnecessary movements, we must know: work without benefits can only be called action, and effective action is work! The action distance should be the shortest and try to improve efficiency.
5, try to use inertia, gravity, natural forces and power devices, rather than relying on manpower, of course, can reduce people's fatigue, which helps to improve work efficiency.
6. In order to reduce fatigue, the working point should maintain an appropriate height, and this height can be measured. Through measurement and careful calculation, it is possible to make the movement as comfortable as possible, and to reduce the fatigue of the work.
7, standing walk around the homework. From the perspective of lean production, in order to adjust the production cycle, it may be necessary for one person to operate two or more devices at the same time, which requires the operator not to sit and work, but should use the walking and walking mode to improve work efficiency. .
NO.4
Up the floor plan
Some have not carefully designed the site layout and equipment layout at the beginning of the construction, or because of the continuous development of production, the continuous addition of equipment, disrupted the layout, or caused the plant or equipment layout due to changes in product structure. Unreasonable, so that the product and the workpiece in the production of the transport route is too long, which is a waste of manufacturing waste at all times, must be determined to change. In the process flow chart, the plane route is not visible. An arrow on the flow chart may actually go tens of meters, so it is necessary to further find the benefits on the floor plan.
By analyzing the operation mode and the configuration of equipment and facilities, according to the flow direction of the production process, whether there are repeated routes and backflow conditions, find out the unreasonable parts, rationally adjust and design a new layout to shorten the process route and operators. Walking distance reduces unnecessary waste of resources. Sometimes, the movement of a device can bring savings of tens of meters or even hundreds of meters, sometimes saving more space.
NO.5
Carrying air pressure and pressure
According to statistics, 25% to 40% of the processing fee is the handling fee; 70% to 80% of the time of the process is the time of handling and stopping; 85% of the factory disasters occur during the handling process. It can be seen that it is very important to compress the handling. Improvement of handling is optimized for handling, and the number of handling, handling space, and handling time are improved.
First, reduce the number of handling and the number of handling.
Secondly, the handling distance should be shortened as much as possible, and the handling route and number of times should be reduced.
Thirdly, it is necessary to shorten the time and reduce the number of times in the handling time; in the method, pay attention to management coordination, try to use non-power, such as using gravity to slide on the slope or transport on the conveyor belt.
The principle of rationalization of transportation is to make almost no loss to the materials being transported; the handling method should be scientific, civilized, and savage and brutal; the handling environment should be safe, suitable, and prevent risks; reduce the chance of temporary placement, try to do it once. In place; reasonable planning of the factory layout can effectively shorten the handling distance. When the factory planning has been finalized, the transportation distance can be effectively shortened by rationalizing the planning process.
NO.6
Human-machine efficiency
People and equipment are a pair of contradictions. If they are not handled well, it will happen that machines such as people are machines and others. Human and equipment constitute the relationship of ergonomics. In the analysis, it is necessary to analyze the work situation of the operator and the machine at the same time, whether there is work, waiting, invalid time, improve the man-machine coordination by adjusting the work order, and seek reasonable The method is to coordinate the operation of the person with the operation of the machine, reduce the waiting time to the maximum, and fully utilize the efficiency of the person and the machine. It is like squeezing water to squeeze out the time waiting for each other, which is to benefit from the joint operation of human and machine.
NO.7
Key route shrinks
Almost any product is made up of several parts, usually produced by several lines or several processes, and the parts are assembled one by one in the later stage, which will inevitably occur in the process of forming parts and components. The amount of work in each process varies. This will bring mutual restraint in the later production, there will be a lot of free time in the small workload, and there will be no rest time in the process with large workload, in other words, the time difference is zero, and it becomes production. The bottleneck on it. The process with zero time difference is called the key route. It restricts the production capacity and delivery time of the enterprise or workshop. After finding the key route, we need to transfer people and property from non-critical routes, strengthen the key route, or adopt parallel operation. Cross-cutting and other forms, shortening key routes, continually modifying and optimizing plans, and achieving the best goal of reducing schedule savings.
The basic skill of a production supervisor is to calculate and find key routes based on planning and production capacity. The second is to continuously compress key routes and other routes to achieve comprehensive optimization of time and cost.
NO.8
Visual management to take a look
The human brain has up to 80% of visual information. Therefore, the method of communicating and directing with vision is more straightforward. Organize on-site production with visually sensible and visually appropriate visual perception information, using charts, drawings, photographs, text annotations, logos, symbols, and tools for visual management. It is easy to achieve functions such as interpretation, cognition, warning, judgment, and action. Therefore, visual management can also be called "visible management" and "visual management".
NO.9
Find the root of the problem
Finding the gap every day to do better the next day—this is a very important point in the originality of the Haier model. It is constantly looking for problems, analyzing problems, and constantly improving the site. This is quality improvement. The commonality of activities such as 8D work method and CIP. It is this that drives the management process and keeps the company in a virtuous cycle of continuous upwards.