If you are a workshop manager, how will you do a good job in production safety?

It is often said that safety is the eternal theme of enterprises. For Daqing Petrochemical, a refining and chemical enterprise, safety is life and benefit. In the past eight months, the company's security situation is very grim: two accidents occurred on 27 October, 2004 and 3 March, 2005, respectively, which caused six employees to die, not only causing great economic losses, but also causing great fluctuations in employees' emotions! Learn from a painful experience, and the realistic and severe task is before us. As the workshop director, I want to do a good job in the following aspects of safety production in this workshop. First, strengthen the safety awareness of employees. Every employee of ours has received safety education since he stepped into the door of this industry. Everyone is familiar with the safety policy of "safety first, prevention first". Safety activities every Tuesday are an effective way to learn safety documents, rules and regulations and accident cases. Then why do security accidents happen frequently? And accident analysis is "illegal"! What kind of thinking will have what kind of work attitude, and work attitude determines a person's work behavior. If you want to do any work well, you must first attach importance to it ideologically. Analysis of the root causes of the above two accidents is the result of long-term accumulation of paralysis of safety thinking and hidden dangers in technology, equipment and management. It can be said that the hidden danger in safety thought is the biggest hidden danger and the source of safety accidents. My company's brother factory has a problem in safety production, which not only causes the company to suffer economic losses, but also affects the company's image, which is ultimately reflected in the loss of employees' interests. Therefore, the workshop director should establish the idea of attaching importance to safety among employees, so that employees can understand that attaching importance to safety production is to safeguard their own interests; Ignoring the safety of enterprises means ignoring the interests of employees. Establishing the idea of safety first is not achieved overnight, but requires long-term safety education in the workshop. Safety experts have come to the conclusion that any accident can be prevented by analyzing a large number of accidents. There are signs behind the accident and signs behind the signs. There are no unavoidable and avoidable accidents. As a workshop director, we should constantly instill in employees through various effective ways to strengthen this prevention-oriented safety awareness and concept. Employees should be made aware that ideological contempt and behavioral inertia are the main causes of accidents. The most taboo in safety work is the style of treating the headache and the foot pain. In practical work, we should give priority to prevention and nip all accidents in the bud. Prevention first means changing post-event treatment into pre-event analysis, accident management into hidden danger management, and passive management into active management, and jumping out of the bad cycle of "an accident is rectification and re-inspection, and an accident is rectification and re-inspection". The realization of the goal of safe production, the elimination of hidden dangers, and the formulation and exercise of emergency plans are all manifestations of the work idea of putting prevention first in practical work. Second, standardize the work behavior of employees. Safety work focuses on implementation, and the weakness of safety is only words and no deeds. The purpose of studying and analyzing many cases of safety accidents is to grasp the safety work around us, draw lessons from others and implement the measures we should take. The foothold of workshop safety management is the team, and the terminal of accident prevention work is every employee. The overall safety of the workshop depends on the safety behavior of everyone and each post, so we must start with standardizing the work behavior of employees to do a good job in safety production. As the water quality workshop of the service department of the water and gas plant, the post safety responsibility system, the analysis regulation and the post safety operation regulation are the work instructions of employees, and their contents are the summary of many years' practical experience and lessons. The workshop should pay special attention to the study and practice of these three instructions by employees. In the daily training of the workshop, there should be not only theoretical and practical contents, but also the training of employees' safety responsibilities and procedures. Make employees understand the safety responsibilities shared by their posts, the risks in their work and the correct methods of operation, control and reduction. In management, we should persistently correct the deviation in our work through weekly inspection, so that it can be done in strict accordance with "one rule and two regulations" and form a standardized habit. The daily safety management of the workshop should also focus on key positions. The key positions of water quality workshop are sewage, instrument and circulating water analysis class. Because the work of these three teams involves on-site explosion detection, oxygen detection, poison detection and the use of organic toxic reagents. On February 9, 2004, an employee of a sewage analysis class was poisoned, and similar lessons must not be repeated. Workshop safety management should go deep into the grass roots, supervise and inspect the correct use, maintenance and repair of protective equipment and the correct use, protection and disposal of toxic and harmful reagents, so that employees can deeply understand the concept of "poisoning is against the rules" and resolutely become the backbone of "anti-three violations". Responsible for the first level, ensure the first level, and the safety of our enterprise will be guaranteed. In a word, safety is the foundation of all work and the top priority of all work. Only when employees do not forget their safety awareness before work, abide by various safety operation procedures at work, and sum up safety experience at any time after work can they not make mistakes, and our enterprise can strive for better results! The author once worked in a Japanese electronics company in Shenzhen, witnessed and implemented the daily management of the Japanese, and deeply realized this: the quality of Japanese products comes from strict daily management!

First, the quality requirements for management cadres

The Japanese have high requirements for the quality of management cadres and pay attention to practical work ability. Let's take the position of workshop director as an example to talk about the Japanese demand for this position.

The workshop director must be familiar with the performance and operation methods of the equipment, instruments and meters used in the workshop, and the auxiliary equipment needed to ensure product quality (designed or manufactured by himself if necessary). He must be able to confirm the causes of adverse phenomena in the production process in time and accurately, and take corresponding countermeasures (solutions and implementation plans) to solve them immediately.

Second, the concept of total quality of disciplines

Quality is not only for production workers, but also for production workers, office workers, secretarial finance and management cadres. In order to enhance and strengthen the quality consciousness and concept of all employees, Japanese enterprises should regularly organize all employees to concentrate on learning the basic knowledge about quality, and conduct cognitive training on new products before they are put into production-what products they are, what functions they play, how to make them, what equipment, instruments and tools they should use, how to operate them correctly, what bad phenomena may appear in production, what countermeasures they have, and so on. In cognitive training, when all employees understand it, product design engineers and production engineers will personally show it to the workers, and if necessary, they will teach them to do it by hand until they can do it.

Third, the quality assurance system and measures

The quality assurance organization of Japanese enterprises is called "Quality Control Department". They are directly responsible to the top leader of the factory. The quality control department consists of three parts (or groups): QA, QC and IQC. QA (Quality Assurance) is a management method of quality assurance. Its function is to continuously evaluate the adaptive elements of the specification, verify and audit the manufacturing, installation, debugging, inspection and inspection, formulate and publish the quality standards and inspection means and methods of various products in the manufacturing process, and inform the product quality status. Analyze the quality factors detected by QA, review and confirm the unexpected incidents of defective products on the production site together with the technical design department and the production management department, find out the reasons and countermeasures, and implement them quickly. Qc (quality com TRD quality inspection) refers to the back testing department, which reports the work results to QA department. IQC(imyports Quality Control) is a means and department to check and control the quality of all raw and auxiliary materials, purchased parts and outsourced parts purchased by the factory. It permeates all aspects of production. In the implementation, whether it is the first feeding or the supply or processing by an old customer with high reputation, it must undergo strict inspection every time. Those who are qualified can be put into storage with the pass seal. If it is unqualified, it will be returned unequivocally. After layers of "IQC", the product quality rate naturally increases.

Four, 5S management (civilized production)

Japanese enterprises pay special attention to civilized production. They call the five management methods of civilized production "5S" management, namely "arrangement", "rectification", "sweeping", "cleanliness" and "beauty".

1. Being sorted. Finishing is to completely separate what you want from what you don't want, put what you want in a designated position and make it clear, and implement target management; Get rid of the unwanted things resolutely. These discarded items include raw and auxiliary materials, semi-finished products and finished products, equipment and instruments, fixtures, management documents, lists and documents.

2. correct. When dealing with those unnecessary things, the important things should be placed according to the target management orientation, and all the things that are littered or not specially specified and need not be placed temporarily should be investigated by the on-site management cadres (team leader, workshop director, deputy director of production department, section chief, etc.). This kind of rectification is equally important to every department.

Clean up. It is used to clean and wipe the dust, dirt, debris, mud and sand on the workplace, environment, instruments and equipment, materials, work fixtures and measuring tools.

4. clean. Cleaning is the most common daily maintenance activity after "sorting", "rectifying" and "sweeping". For example, there is no falling objects (parts) on the ground, no oil pollution, no garbage and paper scraps, things are not placed in disorder, operators do not leave their nails (special process), and female workers wear long hair in work hats and only work slippers (special occasions). The implementation of this management means is that every employee always reviews and confirms whether the above unhealthy phenomena exist in his work area, and if so, immediately corrects them (not after work! )。 3 minutes before work every day (or 5 minutes as the case may be), all staff shall participate in the cleaning operation to keep the overall environment in good condition at any time.

5. Beautiful figure. Physical beauty is to cultivate good manners, work habits, organizational discipline and professionalism of all employees.

"5S" for 3-5 minutes every day, "5S" for 0/5 minutes on weekends/kloc, "5S" for half an hour every month and "5S" for two hours at the end of the year. If we persist in this way, civilized production and product quality can reach a new level. 5S Editor's Note: Literally speaking, 5s refers to five words in Japanese that begin with the Roman pinyin "s", namely: cleaning, rectifying, cleaning, neatness and self-cultivation. These five words and their meanings sound simple, but they will have a far-reaching impact on the company's culture ... K company is a printing enterprise, mainly engaged in corrugated boxes for packaging, screen printing and traditional offset printing. Two years ago, the company launched a set of "printing management information system", which really played a great role in the highly competitive printing market. At this time, Mr. Hou, the general manager of the company, began to look to the field of all-digital printing.

Accept the 5S challenge

The joint venture project that K Company is negotiating with a company in Hong Kong is to introduce new digital printing equipment and technology in K Company and transform its printing information system at the same time.

However, the joint venture negotiations with Hong Kong businessmen are not smooth. The other party put forward many opinions on the factory management of K company, and Mr. Hou thought it was too "picky": for example, the paper, ink and tools in the warehouse and workshop were not arranged neatly; The ground is not clean enough, and the oil on the printing press is "unbearable"; Workers' work clothes are also "unsatisfactory" ...

Later, in the joint venture clause, the investor insisted on "introducing the 5S method of on-site management of modern production enterprises" as a necessary condition and wrote it into the contract text.

At first, Mr. Hou and the management of the company thought that Hong Kong was a bit "fussy". "Don't just do sanitation, make the environment more beautiful." Teacher Hou always thinks that these things are too "naive" and have nothing to do with modern management and information management.

However, for the smooth progress of the joint venture, Mr. Hou still readily promised.

A few months later, Mr. Hou recalled these "trivial things" and "had a feeling of being reborn".

The shock of "trivial"

The popularization of "5S Management Law" popular in Japanese manufacturing enterprises in 1950s requires a lot of preparation and training.

Literally speaking, 5S refers to five words in Japanese that begin with the Roman phonetic symbol "s", namely, Seiri, Seiton, Seiso, Seiketsu and Shitsuke.

These five words and their meanings sound simple. At first, everyone was very disapproving.

A few days later, Mr. Mai, who was sent by Hong Kong to guide the implementation of 5S, gave a strong shock to the leaders and employees of K Company through on-the-spot investigation and a large number of on-site photos and investigation materials.

Mak found that there are always different kinds of papers piled on the floor of the printing workshop, some of which are used now, and some of which are "I don't know who moved here"; Waste ink and the removed roller and screen are lying in a corner of the workshop, covered with greasy; The tools used by workers are not clearly marked, so it is very troublesome to find a suitable tool.

The situation in the warehouse is not much better.

There is only a narrow, non-isolated passage between the shelves where paper, ink and accessories are stacked and the finished goods shelves, and the article number often does not match the goods. Sometimes, the extra paper returned by the workshop is mixed with the new paper ordered, and no one can tell how much is used.

Mr. Mai also looked at Mr. Hou's proud MIS system and several computers in the planning department, sales department and purchasing department, and found that the files on the hard disk were equally chaotic. There are arbitrary subdirectories and arbitrary files everywhere. Some subdirectories and files don't open, so I don't know what's inside. Moreover, Mr. Mai found that there are many versions of files, such as expired files, temporary files, wrong files or multiple copies of a file.

In k company, people have long been accustomed to this phenomenon: what they want is always hard to find; Unwanted things are not thrown away in time, as if they were "in the way" at any time; In workshops, desks, filing cabinets and computers, there are such "I don't know" everywhere-I don't know whose it is; I don't know when it was put here; I don't know if it is still useful; I don't know if it should be removed; I don't know how many. ...

"In this case," Mr. Mai asked Mr. Hou bluntly, "how do you ensure the quality of the products? How to make sure that the data in the computer is true? How to boost morale? Enhance employees' sense of honor and mission? " Finally, Mai pointed to a dusty slogan posted on the wall, "regard users as God and quality as life".

Clean up, rectify, sweep

Mak divides the promotion of 5S into two steps. The first step is to advance the first three "s", that is, cleaning, rectifying and cleaning.

Cleaning is to make clear what is useful, useless, rarely used or damaged for everyone and every production site (such as workstations, machines, places, walls, shelves, etc.). ), every desk, every computer.

Cleaning is to sort out the defective products and non-necessities mixed in good materials, tools, accessories and documents. It is a pity to deal with it on the spot and abandon it. "Especially electronic' garbage'," Mak warned managers, "will greatly reduce your work efficiency; The constant search, confirmation and comparison of files will waste a lot of working time. "

Rectification means that every "useful" article, tool, data and electronic document that has been cleared out should be identified and distinguished in an orderly manner, and placed in an "easy-to-take" and "eye-catching" place according to the reasonable layout of the workspace and the actual needs of the work, so as to ensure that it can be taken at will.

"Rectification" sounds simple, but judging from Mak's experience, it is actually a very detailed job. For example, the computer file directory is the best example.

"Generally speaking, time, version, nature of work and document owner may all be key factors in document classification." Mak introduced "what is electronic office" in detail with his own experience. For a company that gradually uses computers and networks for production process management and daily affairs, how to deal with the relationship between paper documents and electronic documents is an important part of developing the good habit of "electronic office".

"In the process of electronization, if the bad habits of' dirty, messy and poor' in the manual work environment are brought in, the harm is enormous," Mak said.

Cleaning, in short, is to do a thorough cleaning. Find problems and correct them in time. But there are still some differences between "cleaning" and "cleaning" that everyone used to say in the past. "Cleaning" only solves the problem of "environmental sanitation" truthfully, and the foothold of "cleaning" lies in "finding the source of garbage". In Mak's words, it means "check, check, check while cleaning".

resilience

With the gradual deepening of 3S (cleaning, rectification and cleaning), the windows of workshops and offices have been cleaned, and the sanitary corners have also been cleaned. The "key rectification targets" such as warehouses, filing cabinets, file directories on computer hard disks, various forms and ledgers have also been completely renewed. However, including Mr. Hou, everyone has no special feeling about the "panacea" introduced by Mr. Mai.

However, Mr. Hou admits that there have been some subtle changes in everyone's mental outlook: people's mood seems to be much better than in the past, and some "informal" people's loose habits have converged; The statistical data submitted are no longer the "unreliable" "confused accounts" as before, and the workbench and office environment are indeed much more relaxed.

This is certainly not the whole of 5S management. Combining the results of the previous stage of rectification, Mr. Mai said to Mr. Hou: "The focus or difficulty of 5S management is not only to correct some mistakes or clean up some garbage; The core of 5S management is to shape meticulous professionalism and cultivate diligence, pragmatism and discipline through continuous and effective improvement activities. "

According to Mak's suggestion, the company started the second step of implementing 5S management: implementing the last two "S", one is Seiketsu and the other is Shitsuke.

The basic meaning of neatness is "how to keep clean", that is, how to stick to it and make a clean and orderly workplace the standard of daily behavior; The basic meaning of literacy is "cultivating sentiment and improving self-cultivation", that is, consciously and voluntarily implementing these very basic norms and guidelines in daily work, restraining one's own behavior and forming a fashion.

Mak further stated that Ming Dow's last two "S" are actually the concentrated expression of company culture. It is hard to imagine that customers will trust a company full of garbage and dust; It is also hard to imagine that employees will have a great sense of responsibility to ensure production quality and labor efficiency in a working environment with lax discipline, harsh environment and waste everywhere; In addition, not to mention that in a "dirty, chaotic and poor" enterprise, information systems will play a huge role.