How to formulate a production management improvement plan

For this question, you are right to ask me. Of course, it depends on the scale of your air pressure.

How to formulate a production management improvement plan: You can refer to this tool to improve production management - 5S and TPM Practice: Introduction to 5S. Hope it helps.

The definition and characteristics of 5S

The evolution of 5S

5S originated in Japan and refers to the management of personnel, machines, materials, and methods at the production site. and other production factors for effective management. 5S is a unique management method for Japanese enterprises.

In 1955, Japan's 5S slogan was "Safety begins with rectification and ends with rectification." At that time, only the first S was implemented, and its purpose was only to ensure working space and safety. Later, due to production control and Due to the needs of quality control, the subsequent 3S, namely "sweeping", "cleaning" and "cultivation", was gradually proposed, thus further expanding its application space and scope of application.

In 1986, the first 5S book was published, which had a huge impact on the entire on-site management model and set off a 5S craze. Japanese companies regard the 5S movement as the basis of work management and implement various quality management techniques. After World War II, product quality improved rapidly, establishing Japan's status as an economic power. The most famous one in Japan is the 5S activity promoted by Toyota Motor Company. Due to the huge role of 5S in shaping corporate image, reducing costs, on-time delivery, safe production, high standardization, creating a pleasant workplace and other on-site improvements, , gradually recognized by management circles in various countries. With the development of the world economy, 5S has now become a new trend in factory management.

The definition of 5S

The so-called 5S refers to the continuous sorting, rectification, cleaning, cleaning and quality improvement of the status of various production factors (mainly material factors) on the production site activities. Since one letter of the Japanese Roman pinyin for the five words Seiri, Seiton, Seiso, Seiketsu and Shitsuke in Japanese is all "S", it is abbreviated as 5S, as shown in Figure-8 shown.

Figure - 8 The meaning of 5S

◆Organization (Seiri)

Organization is to completely separate the people, things and things that are needed from those that are not needed, and then separate them Dispose of unnecessary people, things and things. It is necessary to break through the concept of "it is useless to keep it and it is a pity to throw it away", and we must challenge the traditional concepts such as "it is difficult to make it", "it is a waste if it is thrown away", and "it may be used in the future".

Organization is a step towards improving the production site. The main point is to classify various items placed and stagnant at the production site; secondly, for items not needed on site, such as leftover materials, excess semi-finished products, cut heads, chips, garbage, waste products, excess Tools, scrapped equipment, workers’ personal necessities, etc. must be resolutely cleared from the site. The purpose of sorting is to: improve and increase the working area: there will be no debris on site, the streets will be smooth, and work efficiency will be improved; it will eliminate management errors such as mixing and mixing; it will help reduce inventory and save money.

◆Reorganization (Seiton)

Reorganization is to quantify and locate the needed people, things, and things, and to scientifically and rationally arrange and place the items that need to be left at the production site , in order to get what you want as quickly as possible and complete things under the most concise and effective rules, systems, and procedures. In short, rectification is the standardization of the way people and objects are placed. The key to rectification is to achieve positioning, quality and quantity. After grasping the above three key points, you can make a billboard and achieve visual management, thereby refining a method of placing items suitable for your enterprise and standardizing the method.

The reasonable placement of items on the production site makes the workplace clear at a glance. Creating a neat working environment is conducive to improving work efficiency, improving product quality, and ensuring production safety. There is a special study on this work, which is also called location management, or it is called the reasonable layout of the work place.

◆Cleaning (Seiso)

Cleaning is to clean the workplace and repair abnormal equipment immediately to restore it to normal. The cleaning process is based on the results of sorting and rectifying, removing unnecessary parts, or marking them and placing them in the warehouse. The focus of cleaning activities is to determine the cleaning objects, cleaning personnel, cleaning methods, prepare cleaning equipment, and implement cleaning steps according to the specific conditions of the enterprise, in order to be truly effective.

During the production process, dust, oil, iron filings, garbage, etc. will be generated at the site, making the site dirty. Dirty equipment will lose precision and cause frequent failures, thereby affecting product quality and making safety accidents difficult to prevent; a messy site will also affect people's working mood. Therefore, cleaning activities must be used to remove those debris and create a bright and comfortable working environment to ensure safe, high-quality and efficient work.

Cleaning activities should follow the following principles:

◎Items you use, such as equipment, tools, etc., must be cleaned by yourself instead of relying on others or adding special cleaners;

◎The cleaning of equipment should focus on the maintenance of the equipment. Cleaning equipment should be combined with the inspection and maintenance of the equipment;

◎The purpose of cleaning is to improve, when cleaning When abnormal conditions such as oil and water leakage are discovered during the process, the cause must be identified and measures must be taken to eliminate it. It cannot be left unchecked.

◆Cleaning (Seiketsu)

Cleaning is to carefully maintain and maintain perfection and the best condition after sorting, rectifying, and sweeping. In the production process of products, useless items will always be produced, which needs to be constantly distinguished and removed at any time. This is the purpose of cleaning.

Cleaning is not simply understood literally. It is the persistence and in-depth implementation of the first three activities, thereby eliminating the root causes of safety accidents and creating a good working environment so that employees can work happily. . This is of great help to enterprises to improve production efficiency and overall performance. When implementing cleaning activities, three concepts need to be adhered to:

◎Only in a "clean workplace can high-efficiency, high-quality products be produced";

◎Cleaning is a Act carefully and don’t just work on the surface;

◎Cleaning is a job that can be done anytime and anywhere, not before and after get off work.

The key points of cleaning activities are: adhere to the "3 don'ts" principle - that is, do not place unused things, do not mess up, and do not get dirty; not only the items need to be cleaned, but the workers on site also need to be cleaned. Not only must we be physically clean, but we must also be spiritually clean.

◆Education (Shitsuke)

Education refers to developing good working habits, observing disciplines, striving to improve the quality of personnel, developing habits and styles of strictly abiding by rules and regulations, and creating Team spirit. This is the core of 5S activities. Without the improvement of personnel quality, various activities cannot be carried out smoothly and cannot be sustained.

Therefore, when implementing 5S practices, we must always focus on improving people's quality. 5S activities begin with and end with quality. When carrying out 5S activities, the principle of self-management must be implemented. To create a good working environment, you cannot expect others to do it for you, but you should fully rely on on-site personnel to improve it.

The meaning of 5S can be summarized as table -.

Table - 5S meaning table

Typical examples in Chinese, Japanese and English

Organize SEIRI Organization Take out the trash and put items that have not been used for a long time into the warehouse

Reorganize SEITON Neatness and find the items you want to use within 30 seconds

Cleaning SEISO Cleaning Who uses it and who is responsible for cleaning (management)

Cleaning SEIKETSU Standardization Openness and transparency of management

Cultivating SHITSUKE Discipline and training Strictly abiding by standards and team spirit In the actual implementation process of 5S, many people often confuse concepts such as "organizing" and "rectifying", "cleaning" and "cleaning". 5S was rapidly promoted, and many promoters came up with various methods to help understand memory, such as comics, jingles, allegro, etc.

The following uses short sentences to describe 5S. The main purpose is to facilitate everyone's memory.

Other terms for 5S

There are many ways to say 5S. Western countries generally define 5S as classification, positioning, scrubbing, institutionalization and standardization. The first of these five English words The letter is also in S, as shown in Table -. In addition, 5S plus safety becomes 6S, adding savings becomes 7S, adding service becomes 8S, and adding customer satisfaction becomes 9S. No matter which country you are in, although there are differences in terms of 5S, the connotation is the same.

Table - 5S statement in Western countries

5S project content

Soft (classification) distinguish between necessary and unnecessary things and remove unnecessary things

Straighten (positioning) Place needed items reasonably for easy use

Scrub (scrub) Remove garbage and dirt

Systematize (institutionalization) Use Daily activities and inspection work become a system

Standardize (standardize) Standardize the above four steps to maintain and promote the activities

The effectiveness of 5S

Enterprises in production The implementation of 5S in the process is to eliminate various adverse phenomena in the factory, improve product quality, increase productivity, reduce costs, ensure on-time delivery, ensure safe production and maintain high morale of employees. Generally speaking, the implementation of 5S can produce the following effects for enterprises:

◆Enhance corporate image

The implementation of 5S activities will help improve the corporate image. A neat and clean working environment can not only improve the morale of your staff, but also enhance customer satisfaction, which will help attract more customers to cooperate with the company. Therefore, good on-site management is the best advertisement to attract customers and enhance customer confidence. In addition, when a good corporate image is generally spread, 5S companies will become the objects of learning for other companies.

◆Increase employees’ sense of belonging and organizational vitality

The implementation of 5S activities can also increase employees’ sense of belonging. Working in a clean and tidy environment can give employees a certain level of dignity and sense of accomplishment. Since 5S requires continuous improvement, it can drive employees' willingness to improve, making employees more willing to devote love and patience to the 5S work site, thereby cultivating the feeling that "the factory is home". Everyone becomes a well-educated employee with a sense of dignity and accomplishment, and will naturally do their best to complete their work. This will also help promote awareness improvement, implement rationalization proposals and improvement activities, further increasing the vitality of the organization.

◆Reduce waste

The biggest purpose of enterprises implementing 5S is actually to reduce waste in the production process. Due to the existence of various undesirable phenomena in the factory, a lot of waste has been caused in many aspects such as manpower, space, time, morale, and efficiency. 5S can significantly reduce the waste of personnel, time and space, and reduce the production cost of products. The direct result is to increase profits for the company.

◆Safety and Guaranteed

Reducing the occurrence of safety accidents is one of the important goals that many companies, especially manufacturing and processing companies, have been striving for. The implementation of 5S can make the workplace spacious and bright, avoid placing items randomly on the ground, and keep the passages clear, which naturally ensures safety. In addition, due to the long-term persistence of 5S activities, staff can develop a serious and responsible work attitude, which also reduces safety accidents.

◆Efficiency improvement

5S activities can also help companies improve their overall work efficiency. An elegant working environment, a good working atmosphere and well-educated working partners can make employees feel comfortable and help them realize their work potential. In addition, the orderly placement of items reduces material handling time, and work efficiency is naturally improved.

◆Quality Guaranteed

The basis of product quality assurance is to be serious and rigorous in everything you do, and to put an end to sloppy work attitudes. The purpose of 5S implementation is to eliminate undesirable phenomena in the factory and prevent workers from sloppy work, so that product quality can be reliably guaranteed. For example, in some manufacturers of digital cameras, the requirements for the working environment are very strict. Dust mixed in the air will cause poor quality of digital cameras. Therefore, it is particularly necessary for these companies to implement 5S.

In short, after the company implements 5S activities, the company's production efficiency has been improved, the mental outlook of employees has been improved, and the number of customers has also increased. The company has achieved overall improvement, and the negative impact has become zero, making the company Become a "70 factory" - no losses, no wastage, no waste, no breakdowns, no accidents, no complaints, no absences.

Self-inspection

It can often be found in life that good drivers tend to decorate the inside and outside of their cars beautifully to keep the car clean and comfortable; while poor drivers Generally, they don't care about the hygienic condition of the car, so they don't feel proud of the car. This is the biggest difference between a good driver and a bad driver.

After studying the knowledge points in this lecture, what do you think is the reason for this phenomenon? What are your ideas for improving undesirable phenomena in the factory?

The relationship between 5S and other activities

Many people may ask, since 5S is so important, how does it relate to TQM (Total Quality Management) and TPM (Total Production and Maintenance)? What's the relationship?

5S is the foundation of management, the prerequisite for production and maintenance of all employees, a step of TQM, and the crystallization of the implementation of ISO9000. Any company activities, if promoted by 5S, will get twice the result with half the effort.

◆Create an overall atmosphere

An enterprise, whether it is introducing comprehensive system management or promoting ISO certification and TPM management, when taking the opportunity to introduce these methods, if it does not first implement 5S activities, it will be difficult to play a good role in promoting. Promoting 5S can create an overall atmosphere, so that everyone in the organization or enterprise can develop habits and actively participate, and it is easy to obtain the support and cooperation of employees. It is also conducive to mobilizing the enthusiasm of employees to form a strong driving force.

◆Reflect results and enhance confidence

As we all know, the effects of implementing ISO, TQM or TPM activities are hidden and long-term, and difficult to see for a while; and the promotion effect of 5S It's immediate. If you introduce 5S activities before implementing ISO, TQM, and TPM activities, you can achieve significant results in the short term, thereby enhancing the confidence of corporate employees.

◆5S lays a solid foundation for related activities

5S is the foundation of on-site management. The level of 5S represents the level of on-site management, and the level of on-site management restricts ISO , TQM, TPM activities can be promoted or implemented smoothly. Therefore, only through the implementation of 5S and improving the company's system starting from on-site management can we achieve twice the result with half the effort.

It can be seen that the promotion of 5S activities in enterprises that implement ISO, TQM, and TPM provides fertile soil and strong guarantee for related activities.

Talking about preparations for the implementation of 5S

Key points of this lecture

Preparations for the implementation of 5S

Publicity and training

5S activities in the demonstration area

Stages of 5S promotion

Any enterprise must have the following understanding before implementing 5S:

() 5S activities must be carried out in a subtle way Only by operating in the right way can it be successful and last long, otherwise there will be "three minutes of heat" and it will die halfway;

() The implementation of 5S, like any management system, must conform to the "national conditions" and cannot Copying other people's models must be revised at any time according to the actual situation of the enterprise to find the method that is most suitable for the enterprise.

Preparations for the implementation of 5S

Eliminating awareness barriers

◆Main obstacles to the implementation of 5S

At present, many domestic companies have awareness After realizing the remarkable effectiveness of 5S implementation, we began to implement 5S activities at the production site. However, due to insufficient understanding or misunderstanding of 5S among employees within the enterprise, there are still many practical obstacles in the implementation of 5S. These obstacles mainly include: leaders don’t pay enough attention, and 5S activities often fend for themselves; employees are not very involved, and think that the activities have nothing to do with them, or even regard them as an extra burden.

◆The key to eliminating obstacles

Enterprises continue to improve in order to achieve the goal of a lean factory and pursue seven "zero" extreme goals, as shown in Figure -. However, the awareness barriers of business leaders and ordinary employees have seriously affected the successful implementation of 5S. Therefore, companies must carry out extensive internal awareness reforms to better implement 5S. Eliminating awareness barriers should be mainly considered from the following two aspects:

◆Eliminate leaders’ concerns

Whether the top leader of the company is determined to implement 5S activities determines whether the 5S activities can be carried out One of the key factors for success. If the leaders of the enterprise do not fully understand 5S and only implement 5S on a whim, then the 5S activities are likely to fall into a self-destructive situation and it will be difficult to promote it for a long time. Therefore, the implementation of 5S activities first requires corporate leaders to make up their minds and be fully mentally prepared for long-term advancement.

◆ Emphasize that full participation in 5S activities requires full participation. The more employees who enthusiastically participate, the more beneficial it will be to the implementation of the activities. The long-term maintenance of employees' enthusiasm for activities depends to a large extent on the willpower of top managers, which requires top managers to eliminate hesitation when deciding to launch 5S activities. In addition, companies can also make 5S activities more colorful and attract more employees to actively participate through mobilization meetings, publishing articles in internal journals, and encouraging improvement plans.

Picture - Implementing 5S awareness reform

Establishing an implementation committee

In order to effectively promote 5S activities, it is necessary to establish a promotion organization that meets the company's conditions─5S Implementation Committee. The responsible persons of the Implementation Committee include the 5S Committee, Promotion Bureau, heads of various departments, and department 5S representatives. Different responsible persons bear different responsibilities, as shown in the table. Among them, the general manager of the enterprise generally serves as the chairman of the 5S committee to promote the implementation of 5S from an overall perspective.

Table - Composition and Responsibilities of the 5S Implementation Committee

Responsibilities of the Responsible Person

5S Committee · Formulate the goals and policies for 5S promotion

· Appoint the person in charge of the Promotion Bureau

·Approval of the 5S promotion plan and the resolutions of the Promotion Bureau

·Evaluate the results of the activities

Develop the Promotion Bureau 5S promotion plan and supervise the implementation of the plan

·Organize training for employees

·Responsible for publicity of activities

·Develop promotion methods and reward and punishment measures

·Lead the development of 5S activities throughout the company

The heads of each department are responsible for the development of 5S activities in the department and formulate 5S activity specifications

·Responsible for the department’s Personnel education and publicity of activities

·Set improvement themes within the department and organize the implementation of improvement activities

·Designate 5S representatives of the department

Department 5S representative·Assist the department head to promote the 5S activities of the department

·As a liaison, communicate information between promotion affairs and the department

Case

The 5S Implementation Committee of a company’s manufacturing department consists of the chairman, committee members, officers and auditors, as shown in the figure below. Among them, the implementation responsibilities of the committee include: evaluating audit projects, arbitrating 5S audit complaints, studying and discussing feasible plans for implementing 5S, handling abnormal problems that arise during the audit process, spot-checking the implementation of 5S, formulating 5S score sheets and various rewards and punishments stipulate and supervise the fairness of 5S evaluation.

The responsibilities of the officer include: participating in 5S audits, maintaining fairness, having the right to raise objections to the scoring standards, and making suggestions for the implementation of 5S activities. The auditor's rights and responsibilities mainly include: auditing the implementation of 5S in the manufacturing department, maintaining fairness, actively raising issues and suggestions in the implementation of 5S, each audit must be approved by the squad leader, and those who resist are submitted to the committee for processing. , Audit four times a month, with an interval of at least three days between each audit.

Publicity and training

Publicity

In order to cooperate with the advancement of 5S activities, enterprises should also conduct some targeted publicity and training. Enterprises can encourage employees to put forward 5S slogans and slogans. Classic 5S slogans such as: "Everyone tidies up, the place is organized; tidying up well, the efficiency will be higher; cleaning up all the time, the quality will be high; maintain literacy, Have a good mood every day.”

In addition, companies can also use internal publications and blackboards to publicize 5S implementation techniques and key points, mobilize all employees to participate in the construction of 5S activities, and publish them frequently. Articles about some employees participating in 5S activities to ensure the long-term continuation of the 5S atmosphere.

Training

Specialized training for employees is an indispensable and important link in the implementation of 5S activities. Due to differences in employees' understanding and other aspects, when companies implement 5S within the factory, they must change the brains of all employees to eliminate backward awareness barriers and ensure the smooth promotion of 5S.

Training of key personnel

The implementation of 5S activities requires a sufficient number of employees to promote it. Therefore, when companies prepare to implement 5S, they should consciously start from managers at all levels and outstanding Key employees are selected from among the employees, and these employees organize and implement the specific implementation of 5S. Through the training of key employees, they have a better understanding of the basic knowledge and implementation of 5S. Generally speaking, the training of key employees can be carried out through outsourcing training, visiting advanced enterprises and purchasing training materials.

5S training for ordinary employees

In addition to training a group of key personnel, companies should not neglect the training of ordinary employees, that is, internal training. The usual approach is for key personnel who have received training to pass on the knowledge they have learned to ordinary employees, so that ordinary employees understand the basic knowledge of 5S, the significance of the activities and the goals of the activities.

During the training process, attention should be paid to interaction and employees should be encouraged to have full discussions and speeches, so as to deepen employees' understanding of the importance of 5S and enable employees to participate in the implementation of activities with higher enthusiasm.

Self-inspection

Training is an indispensable link for the smooth implementation of 5S activities. Enterprises must mobilize and encourage employees to actively participate in 5S knowledge training. However, we can often find that during the actual 5S training process, many employees are not very interested in the training content and do not have a strong sense of active participation. So, what kind of training method should be adopted to change employees' concepts and make them actively participate in 5S activities? If you were a promoter of 5S activities, what would you do? Please describe briefly.

5S activities in the demonstration area

The role of the 5S demonstration area

In some larger companies, or companies where internal employees have a weak understanding of 5S, We can gradually implement 5S through the 5S demonstration area. The enterprise selects representative departments with poor hardware and many problems to implement 5S as a model area for implementing 5S activities. In this way, employees from other departments can visit the 5S demonstration area, thereby promoting 5S activities to various departments of the enterprise.

For enterprises with larger scale and complex organizations, the role of 5S demonstration area is very obvious and effective. The establishment of the demonstration area can unify employees' understanding of 5S activities and better play the role of leadership; it can encourage the advanced and spur the backward; in addition, the 5S demonstration area can also change the hesitation and wait-and-see attitude of employees, enhance their confidence, and thus inspire Employees’ enthusiasm for participating in 5S activities.

The main procedures for establishing a 5S demonstration area

The main steps for establishing a 5S demonstration area include: designating the demonstration area, formulating a general plan of activities, training and mobilizing demonstration area personnel, recording and classifying Determine the problem points in the demonstration area, determine the specific plan for 5S activities, focus on countermeasures, and summarize and display the results of 5S activities. Each step has its specific work content, as shown in Table -.

Table - Main procedures for establishing 5S demonstration area

Steps and activities content

Designate demonstration area·According to the specific situation (current situation and the person in charge’s understanding of the activities) Designate a demonstration area

Develop an overall activity plan and formulate a short-term activity plan for one to three months

3. Training and mobilization of demonstration area personnel and train key promoters

·Carry out activity mobilization and relevant knowledge training for all members of the demonstration area

4. Record and classify problem points in the demonstration area·Record all 5S problem points (in the form of photos, etc.)

·Category and organize () Organize the object list; () Reorganize the object list; (3) Clean, repair, repair and paint the object list

5 Decide on the specific plan for 5S activities· Decide on the specific plan (time, location, personnel, materials, tools, etc.) for sorting, reorganizing, cleaning, repairing, restoring, and painting

6 Concentrated Countermeasures·Carry out centralized countermeasures according to the schedule

7 Summary and display of 5S results · Record the improved situation in the form of photos (photographed at fixed points), organize and compare the photos before and after the improvement;

· Conduct activities Summary and report, showing typical cases. It is worth noting that the activities in the 5S demonstration area must be fast and effective. Therefore, you should make a surprise sorting in a short period of time, make up your mind to deal with useless items, and carry out quick rectification and thorough cleaning. In addition, the results of the 5S demonstration area should be displayed to all personnel through reports, organized exhibitions and visits, so as to gain recognition and attention from senior leaders and win the support of all employees.

Phases of 5S promotion

Generally, the five activities of 5S should not be promoted at the same time. Unless it is an enterprise with a certain scale or a certain foundation, it will all start with sorting and rectification. Then do some cleaning. After cleaning to a certain extent, the inspection, inspection, maintenance and repair of equipment must meet the conditions for large-scale industrial production before cleaning, the highest form, can be introduced.

Emphasizing cleanliness is to standardize or institutionalize sorting, rectification, and cleaning, so that every employee in the enterprise can strictly abide by this standard from top to bottom and form a good atmosphere. Only in this way can the cultivation be completed. Only a company with good atmosphere and order can form an excellent corporate culture. The implementation of 5S is generally divided into the following three stages.

◆Ordering stage

The company sets standards uniformly, so that employees can develop the habit of abiding by this standard, and gradually make the company surpass the level of manual workshops.

◎The five-minute commuting time of 5S implements the foreman and cleaning equal duty system.

◎Regional planning: The region is implemented to specific departments and everyone in the department.

◎The time spent searching for items is reduced.

◎Greening and beautification of the environment, no noise.

◎Use of logo.

◎The use of safety protection equipment and the improvement of fire-fighting equipment.

◆Activation stage

By promoting various improvement activities, every employee can actively participate, making the company full of vitality and vitality, forming an improved Atmosphere.

◎Clean up dead materials and waste products.

◎General cleaning, sweeping the floor comprehensively, removing dust and dirt, and waxing.

◎All equipment is carefully inspected, maintained, and dust-proofed.

◎Management of cleaning tools (quantity management, regulations on placement methods, design and modification of cleaning tools).

◆Transparency stage

◎Rational suggestions or rational proposals.

◎Kanban management.

◎Identification management.

◎Comprehensive introduction of visual management.

◎Establish improved archives and even establish a complete museum.

◎Use of database and network. Various management methods and measures are open and transparent, forming a fair competition situation so that every employee can gain self-esteem and a sense of accomplishment through hard work