How to Realize Lean Production Management in China Enterprises

However, with the development direction of China's green economy, the further connection with WTO and the gradual disappearance of policy advantages, China enterprises are facing increasingly fierce market competition. For many manufacturing enterprises, the bad phenomena such as delayed delivery, a large amount of funds in stock, unstable product quality, unable to make orders, and low efficiency of production systems have become fatal factors that hinder their survival and development. Therefore, from the perspective of lean production management, many manufacturing enterprises in China have decided to strengthen the process control of production management, improve the flexibility of manufacturing system, reasonably arrange the operation process of production system, improve the market response speed of enterprises, and thus improve the overall competitiveness and profitability of enterprises. Through our investigation, the following problems generally exist in the production system of Chinese manufacturing enterprises: ◆ There are still some deficiencies in the layout and rectification of the basic "5S" management, many on-site problems and chaotic fixed management. There is almost no visual management, visual management is unclear, lack of identification, and it is a waste of time to find things. When there is a problem, it cannot be found in time. The standardized management of standards is not done enough, the production work lacks standardization, the operating standards are not perfect, and the standard formulation is unreasonable. Equipment maintenance mechanism is not perfect, there are many faults and frequent downtime. ◆ The production concept of some personnel in production operation and production site is backward, and the order-centered production concept has not been formed. The production statistics and analysis system is not perfect, so it is difficult to effectively evaluate the status of the company's production system. This mode of production leads to larger intermediate products and takes up more capital and production space. The color paste configuration and sample trial run are not standardized, which leads to a lot of production time waste. The constant adjustment of the delivery date covers up many problems in the manufacturing process, and the problems in production cannot be exposed and solved in time, resulting in the slow response speed of the system. There is a lack of working standards on site, and the staff's work is not standardized and arbitrary, resulting in poor quality. There is no visual tool for on-site standard operation management, which leads to management confusion, and on-site logistics management lacks standards, resulting in logistics confusion. ◆ The quality assurance system in quality management is not perfect, and inspection systems such as parts inspection, manufacturing inspection, QC inspection and independent inspection need to be strengthened. The quality process control ability is weak, resulting in a large number of quality cost losses. Visual management of quality, quality engineering diagnosis beforehand, preventive management afterwards and improvement of quality countermeasures are not enough. Incomplete analysis of quality data can't improve operation behavior. ◆ Management atmosphere and personnel ability: The literacy and management ability of grass-roots managers need to be improved, and management skills need to be strengthened, especially the ability to find problems, solve problems and handle problems alone. At the same time, it needs training in advanced management concepts. It is necessary to further create an improved climate atmosphere, render the environment, such as employee training, slogans, status cards and other methods to improve the environment, and start with the improvement of employee literacy to carry out improvement proposal activities to enhance the overall level of the company. Second, the benefits brought by the implementation of 5S and lean production. As the representative of lean production management methods in modern enterprises, 5S and lean production management technology can bring great benefits and production promotion to domestic manufacturing enterprises on the premise of effective implementation and reasonable application. According to our experience, if the methods are properly implemented, the implementation and development of 5S and lean production management can at least achieve the expected benefits and profit targets of Chinese manufacturing enterprises in the following three aspects: 1. Organizational cultural interests. We believe that in order to promote the development of work through 5S and lean production management, at least the following cultural concepts should be strengthened and deepened within the enterprise: △ Strengthening the process quality consciousness of Excellence, rather than checking the quality consciousness. Many enterprises are proud of good quality, but the bitterness behind it is that this quality is at the expense of a large number of waste products. It is not an effective control of the manufacturing process, achieving the dual goals of quality improvement and waste reduction. △ Fine, meticulous and strict. No matter 5S or lean production management, it emphasizes details to obtain benefits, which is a good improvement on the habit of not asking details in China traditional culture. △ To be truly customer-centric, many enterprises think that it is acceptable to delay delivery. Especially through communication with customers, customers are not angry because of the delay in delivery, and the production personnel of enterprises regard the delay in delivery as a matter of peace of mind. 2. Economic Benefits In addition, according to our research, for many domestic manufacturing enterprises, through the development of 5S and lean production management, at least the following aspects should be achieved: △ quality loss is reduced by 30%. △ Inventory is reduced by 30% (excluding reasonable raw materials and finished products). △ The production cycle is shortened by 25%. △ The downtime rate of equipment failure is reduced by 30%. 3, employee quality benefits We believe that the third benefit of promoting the development of work through 5S and lean production management is to improve the quality of employees in the following aspects: ◆ Selecting talents that can better promote the development and progress of enterprises. △ Improve the staff's awareness of Excellence. △ Improve employees' ability to find and solve problems. △ Improve employees' ability to master and apply modern management technology. △ Cultivate employees' standardized work and good habits. Of course, the development of this work will inevitably encounter great resistance. The key is to change employees' ideas through training, determine the requirements for work with meticulous and clear standards, use the most suitable talents as the main force of work, form a strong driving force with effective incentives, and finally attach importance to the leaders at all levels of the company. Lack of any of the above will greatly reduce the execution and efficiency of the work. Thirdly, some domestic key manufacturing enterprises that implement 5S and lean production management want to implement lean production management well. We think there are four keys: 1, clear objectives, clear objectives, whether the final objectives or intermediate process objectives, we must clearly formulate various standards, including efficiency improvement standards, operation standards, status standards, assessment standards and so on. 2, change the concept, only each employee changes the original way of looking at problems and carrying out work, the work can be implemented; 3, personnel in place, for this work, to ensure that "who can do things who will do"; 4, properly connected, for each part of the content should be reasonably connected, to avoid a weak foundation, the next step is difficult to carry out, but at the same time, we should avoid wasting too much time, so that the result will eventually go away. In view of the above understanding, in order to ensure the solid foundation and work progress of lean production management projects in China manufacturing enterprises at the same time, we believe that 5S, lean production management and process reengineering can adopt cross-independent project operation mode, with the former part of the work as the foundation of the latter part, and the development of the latter part is also the consolidation process of the former part. In each part of the work, we must first establish clear goals, including efficiency goals, quality goals and cost goals. It also systematically analyzes various behavioral factors that affect the achievement of the goal, taking optimizing the production and operation system and improving the overall operation ability of the company as the fundamental starting point, rather than simply positioning on-site management and improvement. Under the premise of this positioning, the first thing is to carry out systematic staff training and establish perfect operating standards, so that every post can find the law when improving its work. While realize standardized operation, realize that Kanban mode of information transmission in the production system. Kanban is a visible part of lean production management. On the one hand, it is necessary to have a set of on-site management methods suitable for the actual situation of enterprises; On the other hand, it needs to be mastered and executed by all operators on site. According to the specific situation of domestic manufacturing enterprises, corresponding auxiliary systems are established according to the objectives, site quality management and TPM equipment maintenance are improved, production improvement is introduced, and various management tasks are refined. Therefore, the operation of the whole project must be driven by the ultimate goal. With the ultimate goal of the project driving the project operation, complete the project according to the following work content structure. Four. The main work content of 5S and lean production management in enterprises The establishment and deepening of 5S and lean production management system is a very practical work. The analysis, design, implementation, inspection, adjustment and deepening of all parts of the scheme must be carried out at the same time. In addition, it must be the result of the joint efforts of all employees of the enterprise, Qi Xin, and it is impossible for a consulting company to do it for them. The role of consulting companies is to provide experience guidance, knowledge services and suggestions for enterprises by using their own experience, professional knowledge and specific working technology: 1. Investigate and analyze the present situation of enterprise production and management system, find out the working methods and ideas that need to be improved from the perspective of enterprise value flow, and explore the internal reasons for the problems in production and management system; Form an enterprise evaluation and diagnosis report, objectively describe the data and main improvement points involved in the process of realizing Kanban management, such as on-site basic management, equipment management, quality management, cost control and material management, and complete productivity efficiency analysis, quality factor analysis and cost factor analysis, so as to make full preparations for effective promotion in the future. 2. Content of training: On the one hand, the determination of business leaders is closely related to the degree of participation; On the other hand, it is also inseparable from the participation of all employees in the enterprise. It is very necessary to cultivate the ideas and concepts of enterprises in the early stage. In the process of implementation, we should change some habitual ways of thinking and behavior, and create a humanistic environment for the smooth implementation of lean production management; On the other hand, it is also the most important to cultivate a group of people who understand the concept and can operate for the enterprise. According to the needs of improvement, the training courses to be set up are: 1)5S management and visual management 5S basic knowledge and concept training 5S promotion essentials office 5S production site 5s standard formulation and assessment 2) lean production-building a fast and flexible manufacturing system lean production management concept and theory training value process analysis standardized operation JIT instant production quick switch to prevent mistakes and solve problems 3) Kanban management and lean logistics management inefficient logistics bring great impact to enterprises. Big losses, logistics improvement within the enterprise, basic concept of Kanban, establishment of pull production system, classic method of reducing inventory, setting and implementation of handling method, real-time procurement and supplier management 4) Six major losses of TPM overall productive maintenance equipment, equipment productivity analysis, equipment performance deterioration analysis, equipment preservation and quality, cost, TPM connotation and significance, fault analysis, equipment 5S implementation, TPM promotion method, TPM implementation skills 5) Concept and technical training of lean quality management in actual combat, application of seven tools of quality management statistical technology QC 6) Efficient field operation management methods, basic principles of work design, methods of work expansion, concepts and principles of industrial engineering, action analysis and elimination of action waste, definition of standard operation, three elements of standard operation: takt time, operation sequence, standard handheld, and requirements of standard operation on quality conditions. The three tools used in standard operation establish an orderly and safe operation method with the highest quality and the least number of operations, a first-in first-out and product traceability, a production layout with reduced number of operations, and an operation method with one person and multiple machines. 7) The importance of working teaching method, incorrect teaching method, four stages of correct teaching method, the exercise of correct teaching method, the function and method of work breakdown, and the application of teaching method in practical work. Contents of project implementation. In order to reduce the risk of the project and reduce the impact on the existing model of the enterprise, a point-to-area approach is generally adopted, and each stage begins with a pilot area, and then it is widely promoted after the pilot area meets the requirements. The general contents are as follows: Carry out 5S and visual management to create a transparent construction site. Establish the basic rules of on-site management, discover the ineffectiveness and waste of the site, especially show the logistics traces through the three-level management of materials, more effectively expose the logistics waste, and gradually cultivate the habit of employees to abide by the established rules. Distinguish the materials stored on site, and establish storage standards (location, time standard, on-site reserve); Dispose of supplies according to standards; Location identification, workshop identification and channel identification of material storage area; The search and treatment of pollution sources, the establishment of cleaning responsibility area, the formulation and implementation of cleaning norms; Establishment of 5S spot inspection standard and evaluation standard. Optimize the management of equipment spare parts, including the reserve management of key parts, the procurement channels of non-key parts and the management of vulnerability cycle. Establish standard operation, establish and improve operation standards, establish and improve operation instructions, unify manufacturing and inspection standards, seriously manage on-site quality, strengthen quality process control, put an end to wasteful operation and improve production capacity. Establish operation standards, conduct operation training for employees and complete multi-functional training; Re-optimize operations and rationally allocate workload; Optimize operation standard, realize standardized operation, establish handling route, and use reasonable handling methods to realize mixed transportation in small batches for many times, so as to reduce intermediate production, improve the sensitivity of the system and realize the purpose of flexible manufacturing. Use irregular or quantitative timing modes of transportation; Determine the fixed handling personnel and handling frequency; Set a reasonable minimum intermediate library; The implementation of kanban system establishes a kanban management system in the production system, and realizes efficient logistics and just-in-time production of the whole line by using kanban pull, thus reducing intermediate production and shortening the manufacturing cycle. Investigate the current situation of logistics; Draw the current logistics map; Analyze the logistics route and draw the flow chart of Kanban; Establish the number of kanban. The establishment of equipment preventive maintenance system will gradually transform equipment fault maintenance into equipment preventive maintenance, improve the processing accuracy and processing capacity of equipment, and gradually reduce the number of equipment faults and downtime. This part of the work is covered up because of a large number of field systems; But around the implementation of Kanban management, the importance of preventive maintenance of equipment will be very prominent. Equipment evaluation, determine the key equipment; (The setting of key equipment is based on a comprehensive parameter) Troubleshoot the equipment and conduct independent spot check on the equipment; Implement the planned maintenance mechanism of equipment, including weekly maintenance, monthly maintenance, spot inspection maintenance and shutdown maintenance; The determination of equipment operation standard optimizes the management of equipment spare parts, including the reserve management of necessities, the procurement channels of non-necessities and the management of vulnerability cycle. Establish a lean quality assurance system, change the concept of quality, clarify the on-site quality management methods, make quality problems visible, master the tools of quality management, improve the traceability of quality and analyze quality problems; On-site quality traceability application; Description and solution of seven QC tools; On-site quality management methods and QCC quality control circle activities. Creative proposal system and project improvement Through the improvement of high-quality production projects on the production site, the proposal system is established, the improvement effect is gradually refined and optimized, and the improvement ability is maintained and improved. Improve the topic selection, improve the release, summary and evaluation of the improvement results; 4. In the process of phased evaluation, for each stage, the internal staff of the enterprise should communicate fully to ensure the effectiveness of the work. At the same time, according to the work progress, we will arrange targeted method training to strengthen employees' improvement skills and awareness. After each sub-project, after full communication, enterprise personnel (or consultants) respectively evaluate the production status before implementation and the effect during implementation, and adjust the specific implementation plan according to the stage evaluation to ensure the effectiveness of project implementation.