How to manage the garment factory

5S is the abbreviation of Seiri, Seiton, Seiso, Seikeetsu and Shitsuke. Because the initials of these five words are "S" in Japanese, they are called "5S" for short, and the activities with the contents of sorting out, rectifying, sweeping, cleaning and literacy are called "5S" activities.

1S- finishing

Definition: Distinguish between what you want and what you don't want. Nothing is put in the workplace except what you want to use.

Goal: Make "space" flexible.

2S- rectification

Definition: Important things are positioned and placed neatly according to the specified method, with clear quantity and clear labels.

Goal: Don't waste "time" looking for things.

3S- cleaning

Definition: Clean up the dirt in the workplace to prevent pollution.

Objective: To eliminate "dirt" and keep the workplace clean and bright.

4S- cleaning

Definition: Institutionalize and standardize the above 3S practices and keep its achievements.

Objective: To maintain the results through institutionalization.

5S- literacy

Definition: cultivate civilized manners, act according to regulations, and develop good work habits.

Goal: to improve "people's quality" and become a conscientious person in any work.

Visual management is also called visual management. Visual management is an effective scientific management method, which, combined with kanban, has become an important part of Toyota's production mode.

Eight key points of visual management

1, abnormal aspect

Everyone can see whether it is good or bad (abnormal)

2, accuracy.

It can judge quickly and has high accuracy.

3. results.

The judgment results will not vary from person to person.

4. Personnel (operator)

What is the morale of the operators? It can be measured by the number of proposals, the participation rate of quality circle and the number of absences. How do you know who is not on the production line today and who will take his place? These things should be "visualized" on the spot. How do you know the skills of the operators? On-site bulletin boards can post who has received what kind of job training and who needs other training. How do you know that the operator's working method is correct? "Standardization" is used to specify correct working methods, for example, operating essentials and operating standards must be displayed.

5. Machine.

How do you know that the machine is producing good quality products? Is there an automatic error-proof device? When an error occurs, the machine can stop automatically immediately. When managers see a machine that stops running, we must know why. Is this a planned shutdown? Shutdown due to mold change settings? Work stoppage due to quality problems? Shut down due to machine failure? Downtime due to preventive maintenance? The grade of lubricating oil, replacement frequency and type of lubricating oil must be indicated. The metal cover should be replaced by a transparent cover, so that the operator can see when there is a fault inside the machine.

6. Materials

How do you know whether the material flows smoothly? How do you know whether the materials are out of your control and whether you produce too much? Kanban with minimum inventory certificate is attached to this batch of products as a communication tool for production instructions between the previous and subsequent processes, so as to see the abnormal phenomena. The storage location of materials shall be indicated, and the inventory quantity level and material number shall be indicated. Can be distinguished by different colors to prevent mistakes. Signal lights or buzzers can be used to highlight abnormal phenomena, such as material shortage.

7. Method

How does the supervisor know whether the operator's work style is correct? Operating standard books are posted on each station, which can be seen at a glance. These standard manuals should explain the work sequence, cycle time, safety precautions, quality checkpoints and how to deal with changes.

8, measurement

How to check whether the process works properly? The normal working range must be clearly marked on the pressure gauge. Temperature sensitive stickers should be attached to the engine to detect overheating.

How do you know whether the improvement has been completed, whether the goal has not been achieved, and whether the improvement is still in progress? How to find out whether the accurate design has been corrected correctly? The trend chart, proposal quantity, production progress, quality improvement target, productivity improvement, mold changing time shortening and industrial accidents reducing shall be hung on the site. [2]

The purpose of editing this visual management

The purpose of visual management: with visual signals as the basic means and openness as the basic principle, the requirements and intentions of managers can be seen by everyone as much as possible, thus promoting visual management, independent management and self-control.

Edit the features of visual management in this section.

1, visualization-everyone can see it.

2. Openness-independent management and control

3. Generalization-communication among employees, leaders and colleagues.

Edit the requirements for visual management in this section.

(1) should be carried out according to the actual needs of production, stress practical results, and do not engage in ostentation and extravagance.

(2) Strictly unify the standards and do not engage in all kinds of things.

(3) It should be simple, easy to understand and easy to implement.

(4) Be eye-catching and clear, and set it where everyone can see it.

(5) Pay attention to thrift in the implementation, and don't create new waste.

(6) It shall be strictly implemented and observed. Those who violate the management regulations should be treated seriously and dealt with seriously, and must not become a mere formality. We should strengthen the authority of visual management.

Edit the visual management category 1. This red card.

Red card, suitable for finishing in 5S, is the basic starting point of improvement and is used to distinguish non-necessities in daily production activities. Hanging a red card is also called red card operation.

2. Kanban method

A display board used for basic information such as the place where articles are placed in 5S kanban operation. Where is its exact location? What to do, how much, who is in charge, and even who will manage important projects, let people know at a glance. Because of the implementation of 5S, transparency and openness are emphasized, because there is a premise of visual management, which is to put an end to black-box operation.

Kanban is a card that shows when and how much a certain material is needed in a certain process, and it is a tool to transmit signals. With the help of kanban, field personnel can realize visual management, organize, manage and improve field production activities with intuitive images and appropriate colors by using various visual perception information (tables, graphics, data and colors).

At the same time, we can find the abnormal state and management mode of the problem point at a glance-"management with eyes".

The function of kanban

1. Production plan release: release the production plan to the production site in real time;

2. Real-time output statistics: real-time collection of production site output;

3. Abnormal notification of production line: notify relevant personnel in real time in case of material shortage, equipment failure and other abnormalities;

4. Handling process tracking: track the abnormal handling process and urge relevant personnel to handle it in time;

5. Production efficiency statistics: statistics of production efficiency and statistical analysis of the efficiency of each production line;

6. Statistics of abnormal situations: count the frequency and times of various abnormal situations, and make classified analysis; [3]

Step 3: Signal light

At the production site, front-line managers must always know whether the operator or the machine is running normally. Signal lamp is a tool to inform managers when there is an abnormality in the process. Type of signal lamp:

Voice signal lamp

Notification applicable to material requirements. When the materials in the process are used up, or the kanban number light in the supply and demand letter is on, the horn will immediately inform the delivery personnel to supply them immediately and in time. Almost all factory directors must know that the signal lamp must be on at all times, and the signal lamp is also an important item in kanban management.

Abnormal signal lamp

Used in abnormal situations such as poor product quality and abnormal operation, and usually installed on the long production line of large factories.

Generally, there are two kinds of signal lights, red and yellow, which are controlled by employees. When there are abnormal situations such as spare parts running out, defective products and machine failure, it will often affect the completion of production indicators. At this point, the employee immediately presses the red light button. When the red light is on, the production manager and the factory director should stop working and immediately go to the scene for investigation and handling. After the abnormality is eliminated, managers can turn off this signal light and continue to maintain operation and production.

Running indicator lamp

Check the operation of display equipment, machine start-up, conversion or stop. When it stops, it also shows the reason why it stopped.

Progress lamp

It is more common, and it is installed on the assembly line. On the manual or semi-automatic production line, the interval between each process is about 1-2 minutes, which is used to control the assembly rhythm and ensure the output. But when the beat is separated by a few minutes, it is used to do homework. Operators should grasp the progress by themselves to prevent slow operation. The progress light is generally divided into 10. Standardized procedures have higher requirements for the steps and sequence of homework.

4. Operation flow chart

The operation flow chart itself is a concise description of the key points of the process and the operation sequence, also called the step chart, which is used to guide the production operation. In general workshops, especially workshops with complex working procedures, kanban management must have an operation flow chart. After raw materials come in, the first process may be signing, the second process may be ordering, and the third process may be conversion or transformation. This is the so-called operation flow chart.

5. Negative teaching materials

Negative teaching materials, generally combining existing things with Plato's expression, are designed to let the on-site operators know and understand his bad phenomena and consequences. Generally, it is placed in a conspicuous position with a large number of people, so that people can understand at a glance that it cannot be used normally or operates illegally.

6. Reminder board

Reminder board to prevent omission. Forgetfulness is human nature and cannot be eliminated. Only through some self-management methods can we minimize omissions or forgetfulness. For example, some workshops have a board at the entrance and exit. How many products to deliver today, when and where, or what products must be produced. Or a leader will come to inspect, there will be an inspection at 2 pm, or a leader will come to inspect. These are collectively called reminder boards. Generally speaking, the time is represented by the vertical axis and the date is represented by the horizontal axis. The time interval on the vertical axis is usually one hour, and a day is divided into eight hours. Every hour, that is, every time period, record the normal, defective or defective conditions for the operators to record themselves. The reminder board is counted once a month, summarized at the monthly meeting, compared with last month to see if there is any progress and determine the catalogue for next month. This is another function of the reminder board.

7. Regional lines

Regional lines are places or channels for placing semi-finished products, which are drawn with lines and are mainly used to sort out rectification, abnormal reasons, line failures, etc. And kanban management.

8. cordon

The warning line is a colored paint line drawn on the ground, which is used to indicate the maximum or minimum inventory in the warehouse or other places and is used for kanban operation.

9. bulletin board

The bulletin board is a prop for timely management, that is, an announcement, or a way to let everyone know. For example, there is a meeting at two o'clock this afternoon, and the bulletin board is written about these contents.

10. Production Management Committee

The production management board is a display board that reveals the production status and progress of the production line, and records the production performance, equipment operating rate, abnormal reasons (line stoppage, failure) and so on. , used for kanban management.

Content of visual management

1. Openness of rules and regulations and working standards

In order to maintain unified organization and strict discipline, maintain the continuity, proportionality and rhythm required by large-scale industrial production, improve labor productivity and realize safe and civilized production, all rules, regulations, standards and quotas closely related to on-site workers need to be made public; Directly related to post workers, such as post responsibility system, operating procedure chart, process card, etc. , should be displayed on the posting bar, and should always be complete, correct and clean.

2, production tasks and completion chart.

The website is a collaborative place, so all tasks that need to be completed by everyone should be made public. Plan indicators should be decomposed layer by layer on a regular basis, implemented in workshops, teams and individuals, and posted on the wall in the form of lists; The actual completion should also be announced on schedule, and the lottery should be used to let everyone see the problems and development trends in the completion of various planned indicators, so as to urge the collective and individuals to complete their respective tasks on time, with good quality and quantity.

3. Combined with fixed location management, realize the standardization of visual display information.

In the management of fixed location, in order to prevent the mixing and misplacing of items, it is necessary to have perfect and accurate information display, including sign lines, signs, sign colors and so on. Therefore, visualization management and fixed location management are naturally integrated. According to the requirements of fixed location management, clear and standardized information display symbols, various areas, passages and auxiliary tools (such as shelves, tool boxes, workstation appliances, living cabinets, etc.) shall be adopted. ) Standard colors should be used and should not be smeared at will.

4. The production control method is intuitive and easy to use.

In order to effectively control production operations, so that every production link and every working procedure can be produced in strict accordance with the standards of cycle and quantity, and to prevent excessive production and storage, simple and practical information transmission signals suitable for on-site working conditions should be adopted to make the next working procedure fail or stop production for other reasons, and the operator can see the signals and stop investing in time when the previous working procedure is not needed to supply WIP. For example, "billboard" is a kind of information transmission means that can play this role.

Convenient and practical information transmission signals should also be set for communication between production links and types of work, so as to minimize the loss of working hours and improve the continuity of production. For example, a red light is installed on machinery and equipment, and a fault display screen is set on the assembly line. Once the machine stops, it can send a signal, and the itinerant repairman will come and repair it in time after seeing it.

In addition to time limit and quantity control, production operation control should also include quality and cost control and visual management. For example, in quality control, every quality management point (control point) should have a quality control chart, so as to clearly show the quality fluctuation, find the abnormality in time and deal with it in time. The workshop shall publish the "Daily Statistical Report of Defective Products" to the public in the form of blackboard newspaper, and the waste products appearing on that day shall be displayed on the display platform, and relevant personnel shall conduct consultation and analysis to determine improvement measures to prevent recurrence.

5. Standardize the quantity of goods packed and transported.

The standardization of goods stacking and transportation can give full play to the advantages of visual management. For example, all kinds of articles should be packed in "five or five yards", and all kinds of station equipment, including boxes, boxes, plates, cars and so on. , should be packed according to the prescribed standard quantity, so that operators, handlers and inspectors can count conveniently and accurately.

6. dressing the of field personnel shall be listed.

The dress of field personnel not only plays the role of labor protection, but also is one of the contents of standardization and standardization under the conditions of machine production. It can reflect the excellent quality of employees and the differences between different units, types of work and posts in the enterprise, so it also has certain psychological effects, which makes people feel a sense of belonging, honor and responsibility, and also creates certain convenient conditions for organizing and directing production.

The listing system includes unit listing and individual wearing signs. According to various inspection and assessment systems within the enterprise, the results of assessment items that have an important relationship with the realization of the strategic tasks and objectives of the enterprise are visually listed in the unit, which can inspire advanced units to a higher level and spur backward units to catch up. Personal wear signs, such as badges, epaulettes, armbands, etc. , with similar functions to clothing. In addition, it can also be combined with evaluation to give people pressure and motivation, so as to achieve the purpose of urging people to make progress and promoting work.

7. Standardized management of colors

Color is a common visual signal in field management. Visual management requires scientific, reasonable and clever use of colors, unified and standardized management, and is not allowed to smear at will. This is because the use of color is limited by many factors:

(1) technical factors

Different colors have different physical indicators, such as wavelength and reflection coefficient. Equipment irradiated by strong light is painted blue-gray because its reflection coefficient is moderate and it will not cause too much irritation to eyes. Red is often used in danger signals, which is not only a traditional habit, but also because of its strong penetration and bright signal.

(2) Physiological and psychological factors

Different colors will give people different emotional effects such as weight, space, warmth, hardness and cleanliness. For example, the coloring of high-temperature workshops should be based on light blue, blue-green, white and other cool colors, which can give people a refreshing and comfortable feeling; The low-temperature workshop is suitable for warm colors such as red, orange and yellow, which makes people feel warm. Heat treatment equipment is mostly cold lead gray, which can reduce the "psychological temperature". Furniture factories see warm wood all day, and wood processing equipment should be painted light green, which can alleviate the anxiety of operators surrounded by warm colors. Physiologically, being stimulated by one or several messy colors for a long time will cause visual fatigue, so pay attention to the color of the workers' lounge. For example, textile workers' lounges should use warm colors; The smelting workers' lounge should be cool. In this way, it is beneficial to eliminate occupational fatigue.

(3) Social factors

Different countries, different regions and different nationalities have different preferences for colors. For example, our people generally like green, because it is a symbol of life and youth; Japanese people think green is unlucky.

In a word, color contains rich connotations, and all people who need to use color in the wild should have standardized requirements.