How to strengthen production site management

The following information is reproduced for reference

How to manage the site well

1. Placement management

1. Placement and placement of workpieces Areas are arranged according to categories, and work station equipment is used rationally.

2. Timely operation, frequent inspection, frequent reordering, frequent cleaning, and label changes should be reordered immediately without delay or accumulation, and should be lifted steadily and handled gently to ensure that the product appearance is intact.

3. Ensure that single items are consistent, process receipts, delivery records are consistent with the number of workpieces, and the procedures are complete.

4. Strengthen the management of non-conforming products, keep records, clearly mark them, and handle them in a timely manner.

5. No objects shall be placed or obstructed in the safe passage.

6. Fire-fighting equipment shall be placed in a designated manner and shall not be used for other purposes. It must be kept clean and sanitary, and there shall be no obstacles around it. Materials.

2. Process Management

1. Strictly implement process regulations.

2. Provide on-the-job skills training for new workers and those who have changed jobs. Only those who pass the examination and receive guidance from a master can start working. The production technology department will inspect the implementation of process disciplines from time to time.

3. Strictly implement production according to standards, processes and drawings. The process parameters and technical requirements specified in the drawings and process documents should be strictly observed and implemented conscientiously. Inspections should be carried out according to regulations and records should be kept.

4. Raw materials, semi-finished products and spare parts must be self-inspected after entering the workshop. They can only be put into production if they meet the standards or have to undergo concession acceptance procedures. Otherwise, they shall not be put into production.

5. Strictly implement standards, drawings, and process formulas. If modifications or changes are required, an application should be submitted, and after testing and identification, it can be used for production after being submitted to the Production Technology Department for approval.

6. Rational suggestions, technical improvements, and new material applications must be tested, identified, and approved before being incorporated into relevant technical and process documents before they can be used for production.

7. The newly produced tooling should be inspected and tested to ensure that there are no abnormalities and the first product is qualified before it can be put into production.

8. Work equipment in use should be kept in good condition.

9. The production department should establish an inventory account of tooling, handle the withdrawal, maintenance, and scrap procedures in accordance with regulations, and keep various records.

10. Use equipment, measuring tools, and work station equipment rationally to maintain accuracy and good technical status.

3. Quality Management

1. Each workshop should strictly implement the provisions on "Quality Responsibilities of Personnel at All Levels and Various Types" in the "Procedure Documents", perform their own responsibilities, coordinate Work.

2. Strictly control key processes in accordance with the provisions of the "Procedure Documents". For any abnormal situations, the causes must be identified and eliminated in time, so that the quality is always under stable control.

3. Earnestly implement the "three inspections" system. Operators must conduct self-inspections on the products they produce. Only after passing the inspection can they move to the next process, and the next process will inspect the products of the previous process. , have the right to refuse to accept unqualified products. If a quality accident is discovered, the person responsible will not be found out, the cause of the accident will not be eliminated, and preventive measures will not be formulated.

4. The workshop must be responsible for the quality of the products produced, so that unqualified materials are not put into production and unqualified semi-finished products are not transferred out of order.

5. Strictly divide the "three products" (qualified products, repaired products, and scrap products) into isolation areas to ensure clear markings, accurate quantities, and timely processing.

IV. Equipment Management

1. Designate a dedicated person to manage workshop equipment.

2. Earnestly implement the equipment maintenance system and strictly abide by the operating procedures.

3. Implement the "three-step method" of equipment management, adhere to daily cleaning, weekly maintenance, and monthly maintenance, and check the equipment's control system, safety devices, smooth lubricating oil lines, and linoleum after work every day Clean, make sure the oil pressure and oil level are up to standard, and add oil according to the lubrication chart. The oil quality must be qualified. Official work can only begin once there are no problems.

4. Equipment ledger cards, shift handover records, and operation records are complete and complete, the account cards are consistent, and they are filled out in a timely, accurate, and tidy manner.

5. Carry out the on-duty operation of key equipment certificates to ensure that the certificates and machines are consistent. .

6. Strict equipment accident reporting system. General accidents should be reported within 3 days, and major accidents should be reported to the equipment supervisor or supervisor within 24 hours.

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5. Tool Management

1. Various tools, measuring tools and cutting tools should be used according to regulations, and illegal use or misappropriation for other purposes is strictly prohibited.

2. Precision and valuable tools and measuring tools should be kept and used strictly in accordance with regulations.

3. It is strictly prohibited to knock, bump, scratch, rust, or deform under pressure.

4. Substandard or damaged tools, measuring tools, and cutting tools are not allowed to be used in the workshop.

6. Measurement Management

1. Users must strive to ensure that measurements are complete, accurate, clean and submitted for inspection in a timely manner.

A. Measuring tools must be kept intact, and parts and accessories must not be lost. If any of the above situations occur, they must be sent to the quality department in time for inspection, repair, and appraisal.

B. It is prohibited to use expired or unqualified measuring tools. Use them correctly, handle them with care, and strictly prohibit collisions. Wipe them clean after use. Apply oil when not in use for a long time and place them correctly.

C． All measuring instruments in use must be submitted for inspection in a timely manner according to the validity period filled in on the certificate of conformity or the notice from the Quality Department Testing Center.

2. All self-made or newly purchased measuring instruments are sent to the Quality Department Testing Center for inspection. Once qualified, the procedures for storage and collection will be completed.

3. It is strictly forbidden to use high-precision measuring tools to measure rough workpieces, and they are not allowed to be used for other purposes. Measuring tools with illegal measurement units are not allowed to be used. Documents, reports, records, etc. shall not use non-measurement units.

4． Any measuring instruments that need to be scrapped should be submitted to the Quality Department.

7. Civilized production

1. The workshop is clean and tidy, each chart is beautiful and elegant, the design is reasonable, and the filling is timely, accurate and clear. The original records, ledgers, and production receipts are complete, complete, and filled in according to regulations.

2. The handover record should be filled in accurately. The handover content includes equipment, tooling, tools, sanitation, safety, etc.

3. Keep indoors and outdoors clean at all times, and no garbage is allowed to be piled up.

4． Smoking is strictly prohibited in the production area, and cigarette butts are not allowed to be littered anywhere.

5． There should be no accumulation of water or oil on the workshop floor.

6． The pipeline routes in the workshop should be reasonably set and installed neatly, and running, dripping and leaking are strictly prohibited.

7． The pipe trenches and covers in the workshop are intact and there are no debris in the trenches. They should be cleaned up in time and blockages are strictly prohibited.

8． Work station equipment, equipment accessories, lockers, workbenches, tool boxes, product racks and various handling trolleys in the workshop should be placed in designated places to ensure clean and orderly operation.

9． The workshop should be properly lit, and it is strictly forbidden to keep lights on or running water running.

10. Adhere to on-site management of civilized production, civilized operation and civilized operation, and eradicate bumps, scratches, rust and other phenomena. Every day after work, the equipment must not be scrubbed and maintained properly, workpieces must not be moved away if they are not placed in accordance with regulations, and tools must not be placed clearly and properly. They will not leave the original records until they are properly recorded, and they will not leave the workplace until they are clean and tidy.

8. Safety production

1. Strictly implement all safety operating procedures.

2. Carry out safety activities frequently, hold pre-shift meetings, and make serious rectifications and eliminate hidden dangers from time to time.

4． Wear labor protection supplies as required and conscientiously implement safe production.

5． Those working in special types of work should hold a special operation operation certificate.

6． Apprentices, interns and other trainees should be guided by their masters in their on-the-job operations and are not allowed to operate independently.

7． Record the shift handover, check carefully after the shift, clean up the scene, close the doors and windows, and strictly manage important materials to avoid loss.

8． Personnel who are not in this category of work or who are not in this position are not allowed to operate the equipment

9. Key equipment must be managed by dedicated personnel, kept clean, and damaged.

10. Fire-fighting equipment must be sensitive and reliable, checked and replaced regularly (equipment, medicines), and the expiry date must be clearly marked.

11. Strengthen accident management and insist on not letting go of major near-misses. Original records of accidents must be kept and reports must be processed in a timely manner. Records must be accurate and reports must be timely.

12. Accidents shall be reported promptly in accordance with relevant regulations and procedures.

9. Energy Management

1. Actively perform energy conservation responsibilities and conduct serious assessments.

2. Carry out energy consumption statistics and accounting work.

3. Earnestly implement the energy consumption quota issued by the company.

4. Check the operation of energy-consuming equipment at any time to prevent running, popping, dripping and leaking, eliminate long-running water phenomena, strictly control the preheating time of equipment, and prevent empty operation.

5. No private connection of energy-consuming equipment, facilities, or appliances is allowed without permission.

10. Workshop Management

1. The workshop can formulate specific management rules according to the company's system and submit them to the supervisor for approval before implementation.

2. The workshop should ensure that rewards and punishments are clearly defined, accounts are complete, and distribution is open and fair.

3. Strict on-site management must achieve excellent production tasks, excellent technical quality, excellent management work, excellent labor discipline, and excellent ideological work.

Three major tools for on-site management

Standardization

The so-called standardization means that there are various norms in the enterprise, such as: procedures, regulations, rules, Standards, essentials, etc. These standardized things in writing are collectively called standards (or standard books). Setting standards and then putting them into action is called standardization. Those who think that standardization has been completed when standards have been compiled or revised are wrong. Standardization can only be considered implemented after guidance and training.

Innovation, improvement and standardization are the two major wheels for enterprises to improve their management level. Improvement and innovation are the driving force to continuously improve the level of enterprise management, while standardization is the braking force to prevent the decline of enterprise management level. Without standardization, it is impossible for an enterprise to maintain a high level of management.

Visual management

Visual management is a management method that uses various visual perception information with intuitive images and appropriate colors to organize on-site production activities to improve labor productivity. It is also a scientific method of using vision to manage.

So visual management is a management method characterized by openness and visual display. Comprehensive application of research results from management, physiology, psychology, sociology and other disciplines.

Kanban management

Management kanban is a very effective and intuitive means of discovering and solving problems, especially one of the indispensable tools for excellent on-site management

< p>Management dashboard is a form of management visualization, which displays the status of data, intelligence, etc. at a glance. It is mainly a transparent management activity for management projects, especially intelligence. It reveals hidden information in documents, minds or on-site through various forms such as slogans/status boards/charts/electronic screens, etc., so that anyone can grasp the management status and necessary information in a timely manner, and can quickly formulate and implement countermeasures. Therefore, the management dashboard is a very effective and intuitive means for discovering and solving problems, and is one of the indispensable tools for excellent on-site management.

Appendix Kanban Management - Exception Management Kanban

The exception management Kanban supports background data analysis reports, with exception call time points, exception processing start time points, and exception processing end time points. Statistics of exception processing time, exception occurrence rate, exception occurrence rate trend icon. Data supports the effectiveness of on-site management.

People, machines, materials, methods, environment, and measurement management

1. Operator factors (people)

Main control measures:

< p>(1) Production personnel meet the job skill requirements and have undergone relevant training and assessment.

(2) For special processes, the professional knowledge and operating skills that special process operators and inspection personnel should possess should be clearly defined, and those who pass the assessment will be able to work with certificates.

(3) Operators can strictly abide by the company's system and operate in strict accordance with process documents, and be responsible for work and quality.

(4) Inspection personnel can conduct inspections in strict accordance with the process regulations and inspection instructions, keep original inspection records, and submit them as required.

2. Machinery and equipment factors (machine)

The main control measures are:

(1) Have complete equipment management methods, including the purchase and transfer of equipment , maintenance, maintenance, calibration, etc. are all clearly stipulated.

(2) All provisions of the equipment management regulations are effectively implemented, and there are equipment ledgers, equipment skill files, maintenance verification plans, and relevant records, and the records are complete and accurate.

(3) Production equipment, inspection equipment, tooling tools, measuring instruments, etc. all comply with the requirements of process regulations and can meet process capacity requirements. If processing conditions change over time, adjustments and compensation can be made in a timely manner to ensure quality requirements. .

(4) Production equipment, inspection equipment, tooling, measuring instruments, etc. are in good condition and under control.

3. Material factors (materials)

The main control measures are:

(1) There are clear and feasible material procurement, warehousing, transportation, quality inspection, etc. management system and strictly implement it.

(2) Establish a system for incoming material inspection, warehousing, storage, labeling, and distribution, and implement it conscientiously to strictly control quality.

(3) The raw materials or semi-finished products transferred to this process must comply with the provisions of technical documents.

(4) The processed semi-finished products and finished products meet the quality requirements and are marked with batch or serial numbers.

(5) There are control methods for non-conforming products, clear responsibilities, and the ability to effectively isolate, label, record and handle non-conforming products.

(6) Production material information management is effective and quality problems can be traced.

4. Factors of the process method (method)

The main control measures are:

(1) The layout of the process flow is scientific and reasonable to ensure that the product quality meets the requirements .

(2) Be able to distinguish key processes, special processes and general processes, effectively establish process quality control points, and clearly identify processes and control points.

(3) Have formal and effective production management methods, quality control methods and process operation documents.

(4) The main processes have operating procedures or work instructions. The operating documents put forward specific technical requirements for personnel, tooling, equipment, operating methods, production environment, process parameters, etc. In addition to clarifying process parameters, the process procedures for special processes should also make specific provisions on the control methods of process parameters, sample preparation, working medium, equipment and environmental conditions.

(5) The important process parameters and characteristic values ??of the process documents must undergo process evaluation or process verification; changes in the main process parameters of special processes must be fully tested and verified or qualified by experts before the document can be changed.

(6) Specify inspection points, inspection methods and acceptance criteria for each quality control point, and provide relevant processing methods.

(7) Specify and implement the preparation, evaluation and approval procedures for process documents to ensure that the documents used at the production site are correct, complete and uniform, that the process documents are under control and that current and valid documents can be obtained on site version of the process file.

(8) All documents can be strictly implemented, and recorded information can be filled in as required in a timely manner.

5. Environmental factors (environment)

The main control measures are:

(1) There is a management system for environmental sanitation at the production site.

(2) Environmental factors such as temperature, humidity, light, etc. comply with the requirements of production technical documents.

(3) There are relevant safety and environmental protection equipment and measures in the production environment, and the health and safety of employees meet the requirements of laws and regulations.

(4) The production environment should be kept clean, neat and orderly, with no debris unrelated to production. You can learn from the relevant requirements of 5S.

(5) Materials, semi-finished products, utensils, etc. are placed and stored neatly.

(6) Relevant environmental records can be effectively reported or obtained.

6. Measurement factors (measurement)

The main control measures include:

(1) Determine the measurement tasks and required accuracy, and select the , test equipment with the required accuracy and precision capabilities.

(2) Regularly confirm, calibrate and adjust all measuring and testing equipment.

(3) Specify necessary calibration procedures. The content includes equipment type, serial number, location, calibration cycle, calibration method, acceptance method, acceptance criteria, and measures to be taken when problems occur.

(4) Save calibration records.

(5) When it is discovered that the measurement and test equipment is not in a calibrated state, immediately evaluate the validity of the previous measurement and test results and record them in relevant documents.

Process standardization puts forward clear requirements for 5M1E. We should incorporate process standardization work into the overall plan for process quality improvement. On the basis of formulating relevant standardization requirements, through the investigation and analysis of process quality, we find deviations in the implementation of specific requirements for process standardization, and then take improvement measures. Through the continuous cycle of process quality improvement, we promote the true realization and continuous improvement of process standardization, thereby achieving continuous improvement of process quality.