How to improve the utilization rate of raw materials

There are not many furniture enterprises in China that have successfully improved the utilization rate of raw materials by changing the management mode, but their experience is worth learning. Here, these successful management models are summarized into four steps to share with peers:

1. Provide unified guidance to workers (3%-5% of raw materials can be saved by optimizing the layout scheme by computer). There are many softwares that can obtain optimized layout plans, among which "round furniture design system" is widely used in furniture industry.

2. Based on the layout planning, formulate reasonable standards.

The material utilization rate of computer-optimized layout scheme is very high. Although 100% cannot guarantee that the utilization rate of single layout will be higher than that of manual layout, the overall average level will definitely save 3%-5% compared with manual layout.

Therefore, directly using the computer-optimized layout scheme as a standard to measure the utilization rate of raw materials will lead to two problems:

Too harsh, workers can only try their best to meet the standards according to the drawings, and can't exceed the standards and become excellent.

It is difficult to formulate a reasonable reward and punishment system, and there is no chance of exceeding the standard, which means that there is no reward but punishment.

Therefore, some furniture enterprises take the computer-optimized layout scheme as the calculation basis, and the final measure is to float to a certain extent on this basis. For example, the layout of a furniture factory in Dongguan, which was optimized by computer, shows that the amount of plates used in a batch of products is 2,665,438+0. After floating to a certain extent, 263 plates are taken as the standard. (Note: The traditional method may cost 273 yuan. )

3. Formulate a reasonable reward and punishment system, with benefits directly linked to income.

What is the measure of whether the reward and punishment system is reasonable? How is the income of workers linked to the utilization rate? The actual situation of each enterprise is different and cannot be generalized. Generally speaking, first of all, by establishing the relevant reward system, workers are guided to cut materials according to the computer-optimized layout scheme, rather than the punishment system. The following are two successful enterprise models for industry managers' reference:

Mode 1: A furniture factory in Dongguan

The factory mainly produces multi-variety and small-batch customized furniture products. Management usually takes the number of plates in the computer layout scheme plus 2-3 as the standard to measure the materials used by workers.

If the picking quantity of workers is less than the value specified in the material standard, 20% of the saved plate value will become an extra bonus to encourage workers;

If the quantity of goods picked by workers is equal to the standard of materials, the piece rate will remain unchanged;

If the number of materials selected by the workers exceeds the material standard, the multi-purpose board will be solved by the workers themselves, or deducted from the board saved by another batch of products, or 40% of the value of the multi-purpose board will be borne by them.

The reward system of this model is to guide workers to work hard towards the goal of saving 2-3 boards and earning 20% more 2-3 boards, thus saving more costs for enterprises.

Mode 2: A furniture factory in Guangzhou

Bamboo is used in factories, and the cost of raw materials is very high. Therefore, the number of boards in the computer layout scheme only rises to a very low level, which is used as the material standard.

If the workers cut the plates strictly according to the computer layout plan, their piece-rate wages will be calculated and paid with the coefficient of 1.2;

If the worker does not cut the plate according to the computer layout plan, but can meet the standard, the bonus will be paid according to the previous method;

If the worker fails to cut the plate according to the computer layout plan and fails to meet the standard, his bonus will be calculated and distributed according to the waste range of 0.5 to 0.8.

Because the board is not cut according to the computer-optimized layout plan, there is almost no chance to meet the standard, and workers actively support the new model in order to obtain higher income.

4. Increase the encouragement in the first year, and then adjust the salary system year by year.

No matter how the enterprise intends to change the reward and punishment system, it is always difficult to grasp the adjustment range of workers' salary at the beginning of implementation. Too high a range is not conducive to the cost control of enterprises, and too low a range is not conducive to the enthusiasm of workers.

Successful companies have encountered similar embarrassment, and their solution is:

Listen to the opinions of all parties, demonstrate repeatedly, and draw a preliminary evaluation plan;

In the first year, increase incentives to mobilize the enthusiasm of workers, so that workers can accept and adapt to new cutting methods better and faster;

Actively sum up experience and train workers to cut plates according to the optimized layout scheme;

Starting from the second year, we will gradually adjust the reward range to achieve a win-win situation for both employers and employees.

Furniture enterprises can gradually realize the above four steps according to their own actual conditions, which will surely promote the reform successfully and greatly improve the utilization rate of raw materials, thus achieving effective cost control and enhancing the core competitiveness of enterprises.

Successful enterprise cases under the new management mode

Through the above analysis, we draw the conclusion that it is not enough for furniture enterprises to strengthen the monitoring of production links in order to improve the utilization rate of raw materials. Some enterprises with advanced strategic vision have reformed the salary management system on the basis of applying high technology and achieved brilliant results. The following are the successful experiences of two Guangdong enterprises:

1. Muriel

Maria Makarenko Er is a well-known bamboo furniture enterprise in Guangdong, because the cost of raw materials is several times higher than that of ordinary boards. At the end of 2005, Maria Makarenko introduced the "Square Furniture Design System", hoping to improve the utilization rate of raw materials. After a period of exploration, it was officially implemented on June 5438+ 10, 2006.

At the beginning of introducing the software, the enterprise required Fiona Fang Company to provide corresponding management and operation experience, and made reasonable modifications according to the actual situation. Due to adequate preparation and management, the computer optimized layout scheme achieved good results immediately after implementation.

Today, Muriel can't live without optimizing the layout plan every day.

2. Mu Jing

Mu Jing is famous overseas for producing customized furniture products. In the past, the statistical error of material consumption by material control personnel directly affected the accuracy of external quotation. To solve this problem, Mu Jing cooperated with Fiona Fang Company two years ago, obtained an optimized layout plan with the help of software, and asked workers to cut materials according to the plan. The calculation error of raw materials was solved immediately.

After two years' running-in, Mu Jing is now more handy in the application of optimized layout scheme. Through the reward mode of sharing the saving results with workers, the enthusiasm of workers is mobilized, which not only greatly improves the utilization rate of raw materials, but also greatly improves the production capacity.