Outline of Ten Sharp Tools for Improving the Production Site in Chen Peng

By studying this course, you will be able to:

● Skillfully use ten sharp tools for improvement in production site; ● Grasp the reasonable treatment measures; ● Understand and understand the handling convenience coefficient; ● Understand the impact of environmental indicators on work efficiency.

Ten sharp tools to improve the production site

First, the weapon: check the process.

The work of an enterprise has a practical process. By drawing a flow chart, it is easier to find problems and improve them.

1. Flowchart

Composition of flow chart

A flowchart consists of lines or squares, which is called a decision box. After the tasks are listed in order, check, review, review or approve the tasks.

There are two kinds of results when checking the flow chart: qualified and passed; Unqualified recovery and redo. Drawing method of flow chart

When drawing the flow chart, the diamond should be regarded as the check flow, and the square should be regarded as the actual operation link, which is connected by a set of arrows and has links such as technical standards, process regulations, user requirements and related documents. It should be marked with wavy lines. That is, the simplest symbols are used to explain the most complicated process.

The application of flow chart is relatively simple, just like repairing bicycle inner tube, it can also be drawn to solve problems faster, which is the importance of flow chart.

2. Process jingle

In manufacturing enterprises, this process has been adapted into a jingle:

"It's a treasure to use a diamond box with lines. No matter how complicated your process is, as long as you have a clear perspective, you can't escape. Adding one plus one, strictly ensuring the customs is more secure, reducing one, the efficiency will be greatly improved, and the departmental functions cannot be empty. There are certain rules and regulations. "

Interpretation of Tinker Bell

In manufacturing enterprises, as the jingle says, some places are flooded with disasters because of loopholes in the places where checks are made, and this part needs strict control; Departmental prevarication lies in solving problems horizontally without bridging.

Dingdang's solution to horizontal problems

Try to solve the problems in the enterprise horizontally, and don't report to the leaders. Reporting problems to leaders has two disadvantages:

First, the route is too long. It could have been solved by itself, but it was reported around the detour and then conveyed one by one. The route was too long; Second, it is easy to cause disgust. For example, when leaders accuse employees of always having problems, the first thought of employees is who to complain to, which is particularly easy to arouse employees' resentment.

3. Process case

situation

Simplify workshop process

The sieve produced by a steel plant is huge, especially the flange. Thick steel needs to be made into a square structure, and bending and blanking are required before welding. After completion, there are two flanges at both ends, with holes in the flanges, and then welded.

Figure 2 shows the flow of a workshop.

Fig. 2 Workshop process flow chart

As can be seen from Figure 2, the process flow of the workshop is: blanking in the blanking workshop, sending it to the equipment workshop for assembly, then submerged arc welding, sending it to the flange, checking again, coming back for welding and checking again, and finally sending it to the processing workshop. During this period, due to the involvement of two units, in order to clarify the responsibilities, there are many inspection links.

Horizontally, the two workshops are more than 50 meters apart. According to the above regulations, it takes more than 200 meters to go back and forth, and there is still a lot of distance in the internal workshop. Because it involves two units, the units often pass the buck, one side is urgent and the other is slow. It seems unreasonable for two people to do a simple job for the past three days.

So the enterprise changed the process, which was completed by the blanking workshop from beginning to end, namely blanking, bending, submerged arc welding, flange alignment, flange welding, inspection and delivery to the workshop. This 200-meter-long road does not need to go back and forth, and the situation of buck-passing will no longer happen. Now it only takes two people to finish it in one day, and the work efficiency has been improved by three times.

Product production process of foreign trade enterprises

The production process of foreign trade enterprises is divided into the following four main steps:

First of all, foreign customers put forward sample requirements. If it is a new product, it will be specially reviewed and approved by the general manager, and the technology department will put forward a new product development plan. If the plan is qualified, horizontal tools and samples will be developed. After the sample is qualified, it will be sent to the marketing department and distributed to customers. If it is the original product, the production department will make a sample and send it to the customer after inspection. After receiving the product, the customer will propose amendments.

Secondly, sign an intentional contract and conduct a formal review of the intentional contract. Execute if there is profit, and give up if there is no profit.

Thirdly, after making a decision to execute the contract, sign a formal contract order.

Finally, after being audited by the general manager, the production plan is made. Before making a production plan, it is necessary to make inventory analysis, capacity analysis and determine suppliers. , and decomposed into sub-plans of each workshop, such as stamping workshop plan and welding workshop plan. After each workshop gets the plan, it will pick, cut and cut materials. After a series of working procedures, the workshop director's first inspection was put into storage. In addition, the products in these two workshops are ready for pickling, and will be degreased and pickled in the pickling workshop. At the same time, suppliers continue to deliver goods, and packaging materials, standard parts, plastic parts and raw materials are inspected and put into storage. The assembly workshop began to assemble products with one hand and packaging materials with the other. After passing the inspection, we will determine the delivery date with foreign investors through sampling inspection, and then make warehouse reservation, customs declaration, delivery and tax refund.

This is a huge system flow, in good order.

As can be seen from the case, through the flow chart, enterprises can find faults from top to bottom and from left to right, and make improvements. Consider the problem from the whole process, don't dwell on only one aspect. It can be seen that the process is the most effective way to solve the problem as a whole.

Second, the weapon 2: adjust the tone of the plan.

1. Adjustment reason

The site layout, plant layout and equipment arrangement of an enterprise are very reasonable in the early stage of building a factory, but with the increase of orders, equipment and output and the expansion of the plant, the original arrangement will become more and more unreasonable, and it is especially necessary to readjust and clean up at this time to avoid reducing efficiency.

situation

Improvement of process layout

Figure 3 shows the unreasonable production process layout of an enterprise.

Figure 3 Unreasonable process layout

As shown in fig. 3, it takes a lot of time to collect raw materials, pass through lathe A and lathe B, and reach milling machine 2, lathe 3, grinder 4, grinder 5, grinder 6, grinder 7, grinder 8, etc. And transportation and transportation will not produce benefits and increase the value of products.

Figure 4 Improved process layout

Modify the drawings, move the material warehouse and semi-finished product warehouse to the factory building, and then rearrange the installation order of machine tools. In this way, the raw materials are taken out from the raw material warehouse, passed through the lathe A and the lathe B, and then sent to the milling machine 2 and the lathe 3, so that the route is short, the occupied area is small, the local material acquisition efficiency is high, and a lot of costs are saved.

2. The principle of adjustment

The most important principle for manufacturing enterprises to adjust the floor plan is "U-shaped layout method", which is also the most advanced layout method. U-shaped layout method, that is, in the factory building, all equipment is arranged in a straight line according to the direction of logistics, and transportation is realized by the shortest route. U-shaped layout method plays a very important role in plant and equipment layout.

3. Cell production

The production of manufacturing enterprises has gradually changed from mass production to multi-variety and small batch production, so small assembly lines have replaced long assembly lines. Among them, the small assembly line is also called "cell". The so-called cell production is to put several devices together and combine several people to form a small production unit.

The advantage of unit production is that it can adapt to the changes in the current world market and turn a long assembly line into a small combat unit.

Third, weapon three: counting on the production line

1. Change the movement mode

At present, the movement mode of production work is mainly the connection between one process and another, which leads to inconsistency between the previous processes. The reason is not the workers, but the production plan and the usual mode of transportation.

Fourth, weapon four: the action elements are reduced by one.

1. Action analysis

For labor-intensive enterprises or enterprises with assembly as the main body, many processes are completed by manual operation. However, the action of the inspection operator is measured by labor attitude, and it is found that half of the labor action is redundant. Therefore, enterprises need to analyze actions.

The role of action analysis

As a production unit, the effect of completing the whole action with three actions is very remarkable. For example, Suzhou Su Ayi Food Company specializes in selling handmade wonton and jiaozi. After adopting the method of jiaozi's Three Action Packages, each worker's daily package of jiaozi was increased from 50 boxes to 300 boxes of jiaozi, and the efficiency was improved by six times.

The appearance of action analysis first appeared in America.

situation

The process of action analysis

Peter found that when workers lay bricks, everyone moves differently. Some people need 18 movements to build a brick, while others need 6 movements to build a brick. One of the six movements is redundant, that is, only five movements can build a brick. Peter popularized the five-step bricklaying method throughout the construction site. Under his guidance, the workers became more and more skilled, and the bricklaying speed rose linearly, from the original average per person per hour 120 bricks to 350 bricks, and the efficiency increased nearly three times.

Peter's friend Taylor was very encouraged. Three months later, he did a shovel test in an American steel company. It turns out that steel workers' shovels come in different sizes and are all brought by employees from their own homes. There is no uniform standard. Taylor wants to know whether the efficiency of coal mining depends on the size of shovel. In order to improve the efficiency, if the shovel is made very large, one shovel is 50 kg, two shovels 100 kg and three shovels 150 kg, the efficiency is high, but it is easy to twist the waist; If the shovel is made smaller, it will be light and as small as a cooking spoon. After a day's work, the waist will not be tired, but the efficiency is not high.

After repeated experiments, the famous spade answer was obtained, and it was found that the efficiency of the spade was the highest when it was 2 1 lb, which was so high that it needed 400 ~ 600 people to work, and 140 people could complete it.

It can be seen from the case that through the study and analysis of actions, the work efficiency can be improved linearly without any local factors.

2. Basic principles of action elements

Among the elements of action, there are ten basic principles: try to do things with your feet and left hand, work with both hands at the same time, move your hands in the opposite direction, do it with small gestures as much as possible, put materials and tools where you can get them, and the fewer basic operations, the better. Combine more than two tools into one, use fixers, keep the operating point at an appropriate height, and waste the interpretation of songs.

Try to do things with your feet and left hand.

Being used to doing things with your right hand makes the left hemisphere more developed. You should think with your right hemisphere, free your right hand and use your left hand and feet more. For example, some switches can be stepped on with their feet, which frees up two hands to work.

Work with both hands at the same time

Work with your hands at the same time. Don't rest your hands at the same time. Try to get your hands to do something else in your spare time.

Move your hands in the opposite direction

Hands should do symmetrical movements, not in one direction, so as to avoid excessive impulses and problems.

Do as little as possible.

In manufacturing, the human arm is divided into five grades: first, it needs enough fingers to move 25 mm; Second, move 50 mm and move your wrist; Third, move 150 mm, move the forearm;

Fourth, move 300 mm, and the middle part of the boom should participate in the activity; Fifth, if you move 450 mm, you should move the whole arm.

According to scientific calculation, as long as it moves 25mm M 1, where m is MOD, that is, the number of movements of a person is the time taken by the most basic and smallest movement of a person's body, which is 0. 129 seconds. Therefore, the smaller the action, the faster it will be completed, and the greater the action, the more time will be wasted, so it is necessary to complete the task with the smallest action.

Materials and tools should be kept where they can be obtained.

Don't put materials and tools far away, put them in the nearest place and reach for them, that is, with the central axis of people as the center and the length of arms as the radius, you can reach them. Among them, the chest is the most important golden position, with the clearest eyes and the most flexible manual operation, and the work should be done on the chest.

The less basic homework, the better.

The fewer basic operations, the better. Eliminate unnecessary actions. The distance of action should be the shortest, and the order of action should be determined so that it can be carried out automatically and rhythmically.

Combine more than two tools into one.

Combine more than two tools into one, or take materials from containers to reduce workload.

Use fixer

In order to maintain a good state of combination with things, that is, things and people, it is necessary to use retainers. The support behind is a kind of retainer.

The working point should be kept at an appropriate height.

In order to reduce fatigue, the operating point should be kept at an appropriate height, neither too high nor too low.

Using inertia and gravity

It is very important to make full use of inertia and gravity and use power devices to speed up the movement.

3. Action wastes songs

Manufacturing enterprises weave production actions into action waste songs, and through analysis, many redundant actions will be found:

One hand is inefficient, and two hands are idle and don't make money. Too much action takes time, too much walking reduces the effect, improper height hurts the body, turns and moves waste money, changes hands slowly, redundant actions add confusion, unknown skills should be banned, and stretching and bending should be simplified.

In Song of Waste, the reason for "stretching your arms and bending over should be simplified" is that stretching your arms for a long time is easy to twist your waist and you should do less; At the same time, bending over for too long is easy to cause sports injuries and should be streamlined.

Five, weapon five: time and space are pressing for handling.

Handling plays a very important role in the whole production process, so it is necessary to reduce the time and space for handling.

1. The importance of shortening transportation time and space

According to statistics, the freight cost of products accounts for 20% ~ 40% of the total cost of products. In the field production, the time of handling and stopping exceeds the processing time, and 85% of the safety hazards occur during handling. Poor handling will increase the defective rate of products by 65,438+00%. It can be seen that handling is very important in the production process, and it is very meaningful to shorten the time and space of handling.

2. Operating convenience coefficient

Fig. 5 is a description of the transportation convenience coefficient.

Fig. 5 Description of handling convenience coefficient

As can be seen from Figure 5, the traffic convenience coefficient is divided into five grades: 0 ~ 4:

Level 0. Level 0 is the most inconvenient. Parts, fittings and raw materials are in disorder, and when they need to be moved, they need to be boxed before they can be transported away.

1 level. It has been packed in boxes and containers, and the convenience factor is 1. Level two. Make a bracket under the box so that the forklift can be forked when it comes. The convenience coefficient is 2.

Level three. It's more convenient to put it in a forklift and push it away. The processing coefficient is 3.

Level 4. The fourth stage is the most convenient and highest stage of handling, that is, the products are taken away by slideways and slopes, slideways or conveyor belts without handling.

3. Rationalization

Reasonable handling mainly includes six requirements: reducing handling times, high-speed continuous handling, using station equipment, rationally planning factory layout, rationally planning working procedures, and civilized handling methods.

Reduce processing time

Rationalization first needs to reduce processing time. Moving around must be reduced, and secondary handling must be eliminated, so that things can be put clearly and in the right place at one time.

High speed continuous handling

High-speed continuous handling, that is, mechanized handling and high-speed continuous handling using mechanical appliances. Use station equipment

Workstation appliances refer to special tools to protect spare parts, accessories and semi-finished products from being cut and bruised during transportation, including shelves, baskets, boxes and basins. The use of station equipment can effectively ensure that the transported goods are not lost.

The role of the stent. The most ingenious workstation appliance in daily life is the bracket, which has three functions: first, protection. Protect the transported articles from harm.

Second, count. As many shelves are empty, they can only hold so many, which is simple and convenient to count. Third, it is easy to carry. Using the bracket, you can take more than one at a time, which is convenient to carry.

Selection of workstation equipment. In the factory, a lot of work needs to be done by workstation equipment. If there is no suitable workstation equipment, the processing process cannot be completed effectively.

Sixth, weapon six: man-machine efficiency.

1. Man-machine cooperation

Man and machine are a pair of contradictions in field production. Only when people and equipment cooperate closely can they cooperate with each other and continuously improve efficiency, otherwise it will cause unprovoked waste.

situation

Effect of man-machine combination

In a production enterprise, when people are preparing parts, the machine is empty, but when the machine is loaded with parts, people are idle. According to statistics, in 10 minutes of work, people only work for 6 minutes and rest for 4 minutes, and so does the machine, resulting in the starting efficiency of both people and machines being only 60%.

By improving and adjusting the time of storing and preparing parts, the man-machine can cooperate effectively.

The production process becomes: people install parts first, and machines match parts. When the machine is working, people are correcting and storing parts. This cycle does not delay people and machines, and the efficiency is improved after man-machine cooperation.

2. Ergonomics

The so-called ergonomics is the relationship between man and machine. People are in harmony with the surrounding machines, equipment, fixtures, furniture, chairs and benches. If the relationship is not handled well, it will not only hurt people, but also reduce work efficiency.

Ergonomics has specific requirements in three aspects: height, environmental indicators and color. Requirements for height

The height of the articles on the workbench and the height of the chair should be suitable for operating the working body, so that workers should try not to stand on tiptoe or bend over when operating or placing articles. Take the height of tables and chairs as an example. The American standard is 80 cm, while the best standard for a desk in China is 75 cm, and the best height for a computer desk is 70 cm.

Environmental index requirements

Environmental indicators include temperature, noise, humidity and air cleanliness.

First, the temperature. The optimum temperature is 22 ~ 25 degrees. People work most efficiently and have the clearest mind at this temperature. If it is higher than 25 degrees or lower than 22 degrees, people's efficiency will be reduced.

Second, noise. The noise of production units should generally not exceed 75 decibels, and it should not exceed 35 decibels in the dead of night. Third, besides temperature and noise, it also includes humidity and air cleanliness.

main points

Environmental indicators mainly include: ① temperature; 2 noise; ③ Humidity; (4) air cleanliness.

Requirements for color

Classification of colors. Colors are divided into two categories: warm colors and cool colors. Among them, orange is the warmest and hottest color; Followed by red, yellow, pink and light green; The bluest is the cold pole, followed by lavender, light green, dark green and deep purple.

The relationship between people and colors. When people see warm colors, their hearts beat faster and their blood pressure rises, resulting in a warm feeling; Seeing a cool color will slow your heart and lower your blood pressure, resulting in a cold feeling.

A symbol of color. Different colors symbolize different contents, such as green, yellow and purple.

First, green. It symbolizes life and safety. People's optic nerve will recover quickly in a green environment. If you are tired of reading, look at the green forest, and your eye fatigue will soon recover. In a green environment, it will make people linger and slow down the pace of action.

Second, yellow. In China, yellow symbolizes imperial power and nobility; In Jewish countries, only prostitutes and Judas wear yellow clothes. It can be seen that the meanings symbolized by different colors in different countries are completely different.

Third, purple. In China, purple symbolizes red and purple, just like a prime minister in a purple robe. Lavender is the most comfortable, and the lavender environment can improve work efficiency.

Seven, weapon seven: key route contraction.

1. The concept of critical route method

There are many processes that need to be separated and combined in the production process, which leads to many triangles in the actual production process. These triangles are the focus and core of enterprise production imbalance, and they are also the basic elements of enterprise production imbalance.

situation

Manufacturing process of parts

The working procedure of the parts in Figure 6 is as follows: firstly, make a pipe, process the pipe to make a round rib, drill holes after the round rib is made, and weld after drilling.

Figure 6 Parts Drawing

For simplicity, symbols are used instead of working procedures. If A takes 30 minutes, B takes 20 minutes, C takes 25 minutes and D takes 15 minutes, then it takes 60 minutes to complete the parts, that is, 20 plus 25 plus 15.

Do it in a down-to-earth manner on this assembly line, and you can't delay a minute. This is the so-called critical route. For every minute of delay, the whole process increases by one minute. If we advance one minute, the whole process will be shortened by one minute, but this line 30 plus 15 equals 45 minutes, and the parts have not been made yet. Therefore, there are two options. You can do it for 30 minutes, and then rest 15 minutes. You can also rest 15 minutes and work for 30 minutes. A few minutes doesn't make much difference, but if it's a huge project, you have to rest for half a month before you can start. If you don't try to balance, this phenomenon will never be eliminated. Therefore, leaders must make correct production plans.

From the case, as long as a triangle can be dissected in the production process, we can find a way to reduce mutual imbalance, that is, the critical route method, also known as CPM.

2. The role of critical route method

Using the critical path method, we can accurately calculate the project plan, project progress and total progress, and can accurately calculate the time to hours and minutes. The bigger the project is, the more obvious the effect will be if it is calculated, calculated and optimized in this way.

3. Learn the method of critical route method

To learn the critical route method, we should do three things well: be able to draw, be able to calculate and be able to optimize. Can draw.

The so-called "knowing how to draw" refers to drawing related drawings according to the known constraints between each process. Can be calculated.

Can calculate, that is, on the basis of drawing, can quickly calculate the key route, that is, the route with the longest construction period. The key route is the bottleneck, which restricts the development of all production. It should be noted that the difference in key road maps is the starting point for solving problems.

The key route is to shorten the whole production process, make each process as balanced as possible, and eliminate the imbalance between busy and idle. Optimize

After finding the bottleneck, we should find ways to optimize, shorten the date and investment, and optimize the time and cost as much as possible. There are two methods of optimization: time optimization and cost optimization.

Time optimization. Time optimization means that under the condition of ensuring manpower, equipment and funds, it is not an economic account, only considering shortening the construction period and not considering anything else.

Time optimization is usually only used when it is very large and politically significant. For example, the Olympic Games, August 8, 2008 is an auspicious day, and we must go all out. Another example is the Wenchuan earthquake, which mobilized 654.38+10,000 troops in three days to provide water, electricity, access and communication, and went all out to rescue and provide disaster relief. Time optimization is a special case. In general, not only time but also quality should be considered.

Cost optimization. The so-called cost optimization refers to shortening the construction period, shortening the cycle and saving costs. Not only political accounts, but also economic accounts.

There are two kinds of costs in engineering: direct cost and indirect cost.

First, direct costs, that is, the costs directly used in the project, such as raw materials, steel and so on. Direct costs do not change with time.

Second, management fees mainly refer to management fees. The manager should pay wages and bonuses and have office expenses. If they do a day's work, they will get a day's salary. The longer the construction period is delayed, the higher the cost.

On the premise of saving costs, we mainly reduce indirect costs.

Second, the weapon nine: visual management.

1. Overview of Visual Management

Connotation of visual management

The so-called visual management, also known as "visual management", is to show the leadership intention, technical description, user requirements, precautions and so on. Use the simplest patterns, lights and colors to play a clear reminder role.

Visual management is a management method to organize on-site production activities and improve labor productivity by using various visual perception information with intuitive images and appropriate colors.

The role of visual management

Through visual tools, such as charts, billboards, signs, objects, lights, colors, etc. , explanation, cognition, warning, judgment, action and other functions. In this way, information can become clear and questions can become transparent.

The main points of visual management There are six main points in visual management: First, you should be able to recognize it from a distance; Second, mark the place you want to manage; Third, it is easy for anyone to abide by and change;

Fourth, anyone can see it; Fifth, make the workplace bright and tidy; Sixth, transparency, visualization and standardization.

2. Three aspects of visual management

It is easy to know whether the production is normal or not through visual management, which helps to make the workplace brighter and cleaner. Generally speaking, there are three main aspects of visual management: transparency.

Transparency means turning the original opacity into transparency.

Take the boiler as an example. When you can't see how much water is in it, put a glass tube to make it transparent. At the same time, add two warning lines and alarms to the glass tube and connect them with wires. When the water level is lower than a certain level and higher than a certain level, it will give an alarm, which improves the level of visual management.

visualize

Visualization is to turn what was originally felt by other sensory organs into something that can be seen.