On the premise of ensuring product quality, the essence of enterprise competition is the competition between efficiency and cost. How to continuously improve production efficiency is not only the key to the sustainable development of enterprises, but also the fundamental way to reduce manufacturing costs.
Of course, we must operate strictly in accordance with the process standards (SOP). In order to enable the operator to better understand the production process and improve work efficiency, the upper and lower processes should be subdivided, and the principles of continuous improvement of the process should be achieved in a feasible way. The most reasonable way to work.
When working, you should consider the following issues:
Why: Is it necessary to do this action? Is there a better way?
Where: Why do it here? Is there a more suitable place?
When: Why do it now? Is there a more suitable time?
So, on how to improve productivity, the author puts forward some opinions based on experience:
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Improve our working habits
1. Maintain a good sitting posture, so that the body and the workbench are more reasonably combined, which is conducive to work.
2. Try to use both hands for production work during the production process.
3. Within the operating range, try to keep movements as short as possible to improve time utilization.
4. Improve employees' production skills (conduct time-based training and skill assessment).
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Properly allocate workplaces
Pay attention to the placement of raw materials
1. The movement path of the hands and arms should be within the normal working area (the range that can be reached by the hand in a normal sitting position).
2. For work that requires visual attention, normal vision should be ensured and the situation at the work site can be clearly seen.
3. Tools and materials should be placed in a fixed location so that they can be easily accessed at one time. You can also place the most commonly used and highly reusable materials nearby and place them in order according to the assembly order of the materials.
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tools and equipment
1. Tools and equipment should be placed within easy reach.
2. Design and use simple auxiliary tools or tooling to make production smoother, more reasonable, and convenient for operations.
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Material handling
1. In order to facilitate access, good design must be done in advance.
2. Consider arranging some tooling designed based on the principle of gravity to transport materials to the place of use.
3. Preset and classify materials and parts required for the next process.
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save time
1. You should concentrate while working, which can improve the problem of manual hesitation or temporary stoppage. At the same time, it can also avoid safety accidents, such as burns caused by blowing wind, injuries caused by objects, etc.
2. Analyze the actions we take while working, which actions are necessary and which actions can be combined. This can not only reduce steps, but also shorten time.
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Encourage employees to self-check and check each other
In production management, generally speaking, as long as the quality is good, the efficiency will naturally be high. Repair of defective products often affects efficiency by more than three times. In previous consultations on production rationalization, it was found that most companies spend a lot of resources on first and last parts, full inspection and special inspection, but ignore the self-inspection and mutual inspection of employees.
"Quality is manufactured." How can this sentence be implemented at the execution level?
1. Employees must conduct self-inspections during the production process
- Confirm the processing quality of parts in the previous process;
- Confirm the technology, process requirements and processing quality of this process;
- Confirm the quality of finished products delivered to the next process.
2. There are generally two quality management principles for employee mutual inspection.
- The downstream process has the right to make index claims against the upstream process
When the first process provides products to the second process, if the second process detects defective products, for example, 10 products are provided, and the second process detects that 9 are qualified and 1 is unqualified. Then, the second process has the right to make an index claim against the upstream process. The claims index here is quite astonishing, increasing geometrically.
- If defective products are not detected in downstream processes, there must be corresponding penalties.
After the first process provides products to the second process, if the second process does not detect the existing defective products and flows to the third process, the third process will deduct the second process. bonus……
By designing a series of systems to allow employees to conduct self-inspections and mutual inspections, not only can efficiency be greatly improved, but quality inspectors can also be significantly reduced.
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Establish a flexible production organization system
Establishing a flexible production organization system can enable the development of all personnel while ensuring the completion of production tasks with good quality.
- The function of the production organization assigns overall tasks to each unit or individual and establishes a relationship that includes both division of labor and cooperation.
- Arrange work stations according to the flow chart, determine the spacing and complexity according to the amount of work time, configure the work stations according to the instructions, and do a good job of inputting materials, marking defective products, and placing tools, fixtures, and equipment.
- Determine the balance of work stations and the smoothness of the assembly line, and arrange employees reasonably according to their proficiency so that the production line does not pile up materials and leaves a certain amount of space.
- Personnel position replacement, reasonable allocation of personal strengths, fast players and slow players know what to do.
- Pay attention to the management of new employees, designate specialized personnel responsible for guidance, clarify responsibilities, and conduct regular inspections and confirmations.
- Determine effective production capacity and qualification management, divided into internship period, independent period, autonomous period, proficiency period, level period and development period.
- The lines of authority should be clear: employees (complete tasks, report problems) - team leader (execute tasks, handle problems, report results) - squad leader (execute plans, report production, handle problems) - director (supervise execution, summarize plans, report results) ).
- Cultivate generalists, distinguish employees' strengths, pay attention to cultivation, use and recruitment, and cultivate them consciously in daily work.
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Precautions
To achieve the plan and increase production, managers should pay more attention to:
1. Preparation work before production must be sufficient (personnel, machines, equipment, materials, processes and sites).
2. Control the pulling speed properly, maintain a moderate sense of urgency when working, and do not relax.
3. Confirm the output in time and fill in the Kanban.
4. Control defective products, correct them in time, stop work if correction is ineffective, find another suitable person or find the correct way to operate.
5. Incoming defective products and generated defective products must be confirmed in a timely manner to return, replenish and change materials.
There are many reasons that affect production efficiency, such as "acquired imbalances caused by congenital deficiencies" in design and development, insufficient procurement of materials that lead to production line changes or shutdowns for materials, etc. By grasping the main contradiction of the problem and solving it in a targeted manner, production capacity efficiency is greatly improved. Not too difficult.
If one employee can save one minute a day through effective methods, then 400 employees in the workshop can save 400 minutes a day. By analogy, how many more products can the company produce in a year?
If everyone makes a little progress every day and thinks more every day, not only will they improve themselves, but the company's development will also be more stable and rapid.
