The factory lost a big order because the workshop was dirty, messy and poor! This is so wrong.

"I received a big order some time ago, and we talked very well on the phone, but after the customer came to the site for inspection, he suddenly decided not to cooperate with us!" A dry casting boss said. It took a long time for the foundry owner to know that the uncooperative customers chose to cooperate with other enterprises because they felt that the workshop was not clean enough and were afraid that the product quality could not be guaranteed!

In fact, whether the management of an enterprise is in place, the most intuitive and effective observation is to take a look at his work site. A good management site must be neat and orderly, so that the product quality of the enterprise can be guaranteed, and the cohesion and centripetal force of the personnel will be much better than that of the chaotic enterprise. ...

So, how to control the chaos of workshop management?

1. staffing: whether there are enough equipment, suitable management level and management personnel, and whether there are various production personnel and related personnel (production planner, purchasing, quality control, warehouse management, technicians, plumbers, etc.). ) reasonable?

2. Operation process: Have you worked out the operation process (production schedule, procurement process, quality inspection procedures and standards, warehouse management measures, on-site management measures, etc.)? )? Do all departments follow the operating procedures?

3. Order arrangement: Is it reasonable for the production planner to arrange production, and is the production capacity overloaded without corresponding measures?

4. Quality management: Is there a corresponding written quality standard, and is the inspection and final inspection of quality personnel carried out in full accordance with the standard? Is the problem handled and improved in time?

5. Production management: Is the design of work assembly line reasonable? Are the job requirements clear? Is the production plan comprehensive? Can material procurement and material preparation keep up with production needs? Is there a special person in charge of warehouse management, and is the material account clear? Can technicians deal with temporary problems in a timely and effective manner? Is the production site neat, messy and disorderly? Failure to effectively distinguish between defective products and good products caused confusion?

In inventory management: the following practices are for reference only.

1, now using ERP system, including warehouse management system. However, before using ERP, the invoicing system was always used. After purchasing the original, the company's information personnel revised it according to the actual production needs of the company and the feedback results of various departments. The overall operation of the company can be presented by each subsystem. From receiving orders to production, purchasing, picking, scrapping, assembly and shipment, detailed data are presented in the company, and all departments can know the inventory situation and the quantity to be produced, purchased and shipped in real time. MRP can directly extend production scheduling.

2. Partition management of good and bad products from the production site to the warehouse.

3. Establish a unified material code.

4. The warehouse should be partitioned and managed on demand, and the materials should be charged with cards, and the entry and exit details should be clearly recorded.

5, material packaging volume quantitative, orderly, easy to find and count.

6. Use ABC classification to strengthen the management of key materials.

Let me show you the 5S management standard of the workshop production site, so you don't have to worry about the mess of the workshop in the future!

20 5S management standard for workshop production site

A, general standards (workshop)

Behavior discipline

1、? In and out of the workshop hall

Standard: Please close the door behind you when entering or leaving the workshop hall. When opening or closing the door, gently push and put it down, and don't hit it violently, so as not to damage the glass door.

2、? Walking in the workshop aisle

Standard: Go to the middle of the right passage when commuting. Don't play or run. Two or more people can form a formation and consciously walk in formation.

3. Private shoe cabinet

Standard: after changing shoes, the private shoe cabinet should be locked, not for convenience. The door of the shoe cabinet should be opened at will. I lost the key of the shoe cabinet, so I have to register with the security officer and lock it with a spare key. Don't pry open the lock of the shoe cabinet at will, or you will have to pay the original price.

4, the use of drinking fountains

Standard: When receiving hot water, be careful not to be scalded by hot water. The faucet marked in red on the left is hot water. After receiving the water, gently close the door of the drinking cabinet. Besides, if there is tea in the cup, don't pour it into the pool. Please pour it into the next bucket.

5. The floors in the pantry and shoe changing area are clean.

Standard: Snacks and fruit dander eaten in the teahouse should not be thrown on the ground, but in the trash can.

6. Books and periodicals management in the teahouse

Standard: After the books on the bookshelves are lent out, put them neatly on the bookshelves, and don't take them out of the tea room.

7. Personal clothing

Standard: Work clothes should be worn at work, shorts and cropped trousers should not be worn into the workshop, rings, necklaces, earrings and other jewelry should not be worn, boys should not have long hair, girls should tie their hair tightly in their hats, electrostatic clothes should be worn when entering the workshop, and zippers should be pulled to the end.

8, homework sitting posture

Standard: Knees are naturally close together, legs are upright or sideways, and legs cannot be crossed. Chairs should be at least 2/3 full, the distance between people should be at least 20cm, and stools should be about 5cm away from the yellow line.

9. Brand

Standard: labels issued by the company should be filled in as required, and the handwriting should be neat. In the department column, write "Pottery Overseas Workshop" uniformly, and do not scribble on it, and attach my one-inch photo. At work, you need to hang the factory label on the right side of your corresponding work instruction and get it back after work.

10, stool placement

Standard: When working, the surface formed by the feet on the outside of the stool should be parallel to the yellow line, and the distance between the feet and the stool should be kept at about 1cm. Don't press the yellow line. After work, push the stool into the assembly line and pull it in. The stool should be close to the trachea below.

1 1, towel cleaning

Standard: Towels should be thoroughly washed with washing powder or detergent after 5 seconds every day, and there should be no obvious stains on the washed towels.

12, personal belongings management

Standard: Personal items, such as drinking water, snacks and skin care products, are not allowed to be brought into the workshop. Don't play mobile phone at work.

13. Company parts distribution management

Standard: Accessories issued by the company, such as electrostatic bracelets, electrostatic gloves, electrostatic shoes, etc., shall be properly kept, and shall not be scribbled or damaged at will.

14, operation flow

Standard: Don't talk, laugh or discuss things that have nothing to do with the work.

Logo management

1, material identification

Standard: The logo is 7.5cm long and 1.5cm wide, and is uniformly placed in the slot on the front of the magazine.

2. Identification on the assembly line

Standard: the width of the logo is 1cm, and the length depends on the actual content of the logo, which is stuck in the middle of the positioning line.

3. Ground marking

Standard: the width of the logo is 4.5cm, the length is determined according to the actual content of the logo, and it is stuck in the middle of the positioning line.

4. Identification card

Standard: The logo is 9.5cm long and 8.5cm wide, which is clamped on the turnover box to identify the state of the inner plate of the turnover box.

5, sign in and out of the house

Standard: The diameter of the sign is 10cm, and the "push" plate is stuck at 5cm above the door lock, and the "pull" plate is stuck behind the door with the same height.

6. Safety signs of electrical cabinets

Standard: The sign is 6 cm long and 8 cm high.

7. Fire extinguisher indicator light

Standard: the sign is 30cm long and 15cm high.

8, flue gas purifier equipment stop, run logo

Standard: sign length 1.5cm, width 1cm.

9, flowerpot positioning signs

Standard: Use a green adhesive with a length of 1cm and a width of 1cm to evenly place the panel in a circular area and label it.

Kanban/card

1, stop sign

Standard size: 20 cm long and 15 cm wide. ?

2. Line body label

Standard size: 58 cm long and 35 cm wide.

3. Kanban method

Standard: The height of kanban in workshop aisle is 150cm, and the length is determined according to the actual content. Uniform PVC board mounting, black edge, uniform Logo, shading background.

4. Test equipment status identification card

Standard size: 20 cm long and 15 cm wide.

Color management method

1, yellow

Standard: The yellow area is used for placing products to be repaired, turnover vehicles, turnover boxes, etc. It can also be used as the logo of the main channel of the workshop.

2. Red

Standard: Red areas are used to locate defective products, such as trash cans, fire extinguishers, fire hydrants and dangerous areas.

Second, the implementation standard of 5S in AI workshop

1, grounded

Standard: Do not drop materials, garbage, paper scraps, etc. On the floor and keep the floor clean during working hours. Regularly (at least once every 3 days) clean the dead corner area of the workshop, such as fire extinguishers and under the shelves.

2. Equipment maintenance

Standard: after work every day, maintain the equipment and wipe the surface of the equipment with a towel, subject to no obvious dust by hand. The air conditioner and shelves in the workshop should be maintained at least once every three days.

3. Material placement

Standard: Materials should be neatly placed outside the shelf, and different materials should be placed separately. They should not be mixed and have accurate material identification. When the shelves are not in use, corresponding dustproof measures should be taken.

4. Maintenance area

Standard: During maintenance work, the countertops should not be misplaced, but should be placed neatly on the L rack, and the maintenance records should be updated in time. When the maintenance platform is not in use, the lighting power supply should be turned off, and the garbage falling on the ground in the maintenance area should be cleaned up in time.

5, homework area

Standard: Please wear earplugs at work and work according to the requirements of the work instruction. The desktop should be placed neatly. The garbage left by the unopened box should be separated from the board that wants AI, and cannot be put together. Desktop electrostatic skin grounding.

6. Checklist

Standard: Check the routine checklist before starting operation every morning. Check the temperature and humidity checklist at 9: 00 am and 3: 00 pm every day, and make a temperature and humidity curve.

7, semi-finished products area turnover car put.

Standard: when not in use, the turnover car should be placed in the designated area, keeping the principle of being parallel or symmetrical to the designated area, and not skewed, beyond the planned area or under pressure.

8. Empty turnover box.

Standard: turnover boxes (including empty boxes and in-use turnover boxes) should be placed in the planning area, and the outside should be aligned with yellow lines, with a height limit of 2 floors.

9. Garbage bin area

Standard: Garbage bins should be cleaned regularly, and garbage should not fall on the ground. The garbage in the box should not exceed the horizontal line of the garbage bin, and it should be cleaned up in time when it is full. Towels need to be thoroughly cleaned after 5S cleaning every day.

10, PCB temporary storage area

Standard: The height of the board in the temporary storage area is limited to 2 floors. Don't put the unpacked board directly on the carton, put it back in the turnover box again and take it out when using it.

1 1, riveting machine area

Standard: The materials in the material box on the desktop should be clearly identified, and the physical objects should be consistent with the identification. Please pay attention to 5S on the desktop when you are not working, and irrelevant items should not appear on the desktop.

12, feed area

Standard: Because there are many pins in the feeding area, you need someone to help you clean the floor once an hour.

Third, the implementation standard of 5S in SMT workshop

1, grounded

Standard: No materials, garbage, paper scraps, etc. It should fall to the ground, and there should be no stains on the ground. The ground should be kept clean during working hours. Regularly (at least once every 3 days) clean the dead corner area of the workshop, such as fire extinguishers and under the shelves.

2. Equipment maintenance

Standard: after work every day, maintain the equipment and wipe the surface of the equipment with a towel, subject to no obvious dust by hand. The air conditioner and shelves in the workshop should be maintained at least once every three days.

3.SMT preparation frame

Standard: The material preparation rack after material preparation should be placed in the planning area, and documents such as BOM should not be placed on the flight.

4. Temporary placement area of 4.SMT tray

Standard: The pallet of each compartment on the cabinet is limited to 10 pallets. Trays in each compartment should be placed neatly up and down and marked with materials. The use of pallets should follow the principle of first in first out.

5, semi-finished products placement area

Standard: The semi-finished products in the preparation area should be put on the car in a unified way, and placed neatly by the yellow line outside. The semi-finished products in the non-preparation area are placed on the ground and aligned against the wall, and the distance between different models is about 10cm.

6. Red glue/silk screen printing area

Standard: When operating, the board should be placed on the L-shaped rack piece by piece, not directly on the desktop. Due to the nature, special attention should be paid to the cleanliness of the desktop in this area.

7. Connection desk

Standard: The boards on the L-frame should be placed according to the standards in the drawings, and the report on the table should be updated in time.

8. Visual inspection post

Standard: Except for L-shaped frame, transparent adhesive, wiring card and wiring card, no other items can be placed on the desktop of visual inspection area. The above items should be placed in the designated position.

9. Steel mesh placement area

Standard: Steel mesh should be placed in one-to-one correspondence with the numbers on the form, and each mesh should be placed neatly and cleaned up after use.

10, freezer

Standard: The use of red glue and solder paste in the freezer should follow the principle of first in first out. Red glue should be placed in the steel ring in a unified order. When you take it out for use, you should register the check number to ensure that the data on the card is consistent with the actual data. At the same time, the temperature and humidity should be controlled and recorded regularly.

1 1, thawing area

Standard: The thawed red glue and solder paste should be placed in the designated area, not at will, and the random inspection records should be made.

12, received by trash can.

Standard: the material belt in the dustbin should be cleaned every two hours, and the material belt should not exceed the dustbin. If there is any material outside the box, it should be sorted out in time to avoid leakage outside the box.

13, sitting posture

Standard: When operating, the operator should approach the yellow line uniformly and keep it parallel to the yellow line. When you leave the operating area, you need to put the stool back in its original position, close to the docking station.

Four, rice workshop 5S implementation standards

1, production information kanban

Standard: the daily production situation on billboards needs to be updated in time, the hourly production capacity needs to be updated within half an hour, and the skill matrix needs to be updated once a month.

2. filing cabinets

Standard: Materials and PCB boards are not allowed in filing cabinets. SOP, reports, attachments, notebooks, calculators, etc. Can be placed. All items to be placed should be clearly located and marked according to the marked content. ?

3. Placement of fixture segmented turnover car

Standard: Only one turnover car can be placed in this area. When there is only the last box left in this car, the material engineer can come from the SMT lead plate. After the turnover car is replaced, the turnover car with empty boxes should be pulled to AI workshop immediately. The turnover car should be placed according to the positioning, and the line pressing is not allowed.

4, SOP, grape brand and tag

Standard: Grape brand is hung on the left side of the corresponding area of each station, factory label is hung in the middle, SOP is hung on the right side, and it is hung in strict accordance with the positioning point.

5, electrostatic bracelet to wear

Standard: the electrostatic bracelet is loosely worn, and the contact between the metal surface and the skin is not complete, which can not achieve the effect of electrostatic grounding. The electrostatic bracelet should be properly worn at the fixed station and checked in time (to ensure good grounding), and the floating personnel on site should wear electrostatic gloves.

6, turnover box handling

Standard: dragging the turnover box will cause the materials in the turnover box to collide, and it is easy to scratch and damage the floor. The turnover box should be lifted or consigned by a turnover car to avoid vibration and wear caused by direct friction between the turnover box and the ground.

7, tool placement

Standard: foam is used to carve out the models of tools needed for daily production, such as brushes and scissors, which are securely fixed. When placing tools, they should be placed according to the track.

8. Material identification

Standard: For materials in use, each material must have at least one material identification, which needs to be printed by computer and cannot be changed manually.

9, work instructions

Standard: Work instructions need to be issued for every job position. Without work instructions, you can't do any work on the job position, except for new employees who have just come in to study.

10, table update

Standard: Routine check lists that need to be updated every day, such as electrostatic bracelet routine check list, assembly line maintenance list, soldering iron maintenance list, ICT maintenance list, FCT maintenance list, etc., should be completed before 9: 00 am that day. Grape cards need to be updated before the end of the day, and cannot be delayed until the next day.

1 1, PCB board placement

Standard: PCB boards that are too late to operate should be picked up and placed neatly on the L-shaped rack, and illegal operations such as stacking, pushing, throwing and throwing boards are not allowed, which may easily lead to bad phenomena such as cracking of pads, falling off of patches and components, and bring hidden dangers to quality.

12, chemical control

Standard: chemical products should be placed in designated containers and marked. It is easy to be drunk by others, and chemical products such as washing water and moisture-proof oil in beverage bottles are misused, endangering personal safety.

13, power cord binding

Standard: The power cords of various power instruments and equipment are placed in disorder, which is easy to be touched by people nearby, and there are potential safety hazards. The power cord should be folded neatly and tied tightly with a tie.

14, soldering iron, batch management

The soldering iron temperature and batch parameters cannot be adjusted privately, but should be adjusted by professional spot inspectors to avoid poor operation quality caused by too high or too low parameters. If any abnormality is found, the equipment management personnel shall be notified to make adjustment or maintenance.

15, Material Management

Standard: Good materials should be separated by different black boxes, and mixed materials are not allowed. Digital tube height limit 10 layer, relay height limit 6 layers. The defective products should be put in red boxes and can be put together. The defective products (including defective boards) of the day should be cleaned up before work.

16, assembly line maintenance

Standard: the assembly line needs maintenance after work every day, and towels and rags can be used. Towels are mainly used to clean the dust on the surface of the equipment, not to clean the oil inside the equipment. Wipes are used to clean oil stains and other stains that are difficult to clean in equipment. Towels need to be cleaned after use and hung in designated areas.

17, on-site items placement

Standard: the items on the site should be placed according to three principles, that is, there should be a clear positioning (L rack, soldering iron, turnover box, etc.). Should be placed in the location area, not beyond the area or line pressing), should be marked, the number of items placed should not exceed the standard (the upper limit of L rack is 8), and large items should not be placed on the stool. The pursuit of Excellence.

Use of towels and rags.

Standard: Towels can only clean the dust on the surface of the equipment, but not the dirt that is difficult to clean, such as oil stains. You can wipe the oil stains with a rag.

19, large material placement

Standard: height limit of large digital tube 10 layer, and height limit of transformer and relay is 6 layers. The garbage in the trash can should be recycled in time.

20. Post-MI finished product staging area and mantissa position

Standard: the temporary storage area in the back section of MI line body is divided into 8 grids. If any finished product is not put into storage temporarily due to abnormality, it should be placed in the positioning area, and it is not allowed to press the line or put it on the channel. The height limit is 6 floors, and it should be placed neatly. The board in the mantissa area should be cleaned on the same day.

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