Get rid of the print shop scene chaos
Time:2024-03-14
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Field managers only for these three elements and two streams of detailed analysis and research, in order to find out the answer to the problem, today we summarized for you 9 points of the key points of field management, come to learn it.
1. Check the process flow
To find a problem in an enterprise or department, we should start from the process and analyze the whole process of existing production and work.
Which processes are unreasonable?
Where is the backflow?
Where are the pauses?
Which process routes and links can be eliminated, merged or simplified?
Analyze and judge whether each link of the flow chart is in a controlled state, test whether it can play a role as a check, whether the horizontal connection between various departments is in place, whether it is smooth, whether it is necessary to build or add new channels, and analyze whether the work functions of existing departments are in place, and whether the existing organizations should be adjusted or reorganized according to each link and transmission route of the flow chart.
2. Do the math on the assembly line
The production line and assembly line should follow the same rhythm, so that the production can be balanced. Some enterprises often appear in the production of "dry in front, look at the back, go ahead in front, and work overtime in the back" situation.
One of the reasons is that the movement is unreasonable, and the other is that the beat is unbalanced. If the sequential movement method is used, after each batch of work is completed and then moved to the next process, it will cause the next process to wait and work. If it is transmitted in a parallel moving way, that is, when one is done, one is passed to the next process, which often doubles the efficiency.
On the assembly line, the slowest worker is the one who determines the final efficiency of the assembly line.
The balance efficiency of the production line or pipeline = the sum of the net working time of each process/the working time of the longest process × the number of personnel.
The balance rate of many production lines is often less than 50%, if the long process by simplifying, speeding up, replacing, or splitting methods, the short process by cutting, increasing and so on to balance the line. The production efficiency of the entire production line will be greatly improved, and the idling and accumulation caused by the slow individual processes will be eliminated.
3. Subtract one action element
Any operation is based on manual action as the basic unit, especially labor-intensive enterprises, assembly processes, processing processes, such as these manual labor as the main process, action is a very important factor to produce benefits.
The main purpose of action analysis is to eliminate redundant actions, ineffective actions or slow actions, such as bending over, standing on a stool, squatting, the work place is not smooth, there is no suitable station equipment, and people and things are in a searching state, so as to achieve maximum work efficiency in the most labor-saving way.
This research costs almost nothing and can greatly improve production efficiency. For example, in real life, why do some people make dumplings much faster than ordinary people? Why do some people transplant rice seedlings much faster than ordinary people? That‘s because they have a knack for getting things done in the most economical way possible.
Motion analysis follows the most important principles of motion economy:
- Do not use the right hand to do what you can do with your foot or left hand. Try to work with both hands at the same time, start and finish at the same time.
- Make symmetrical movements with both hands in opposite directions.
- Materials and tools should be placed within reach of the hand as far as possible, and the appropriate position should be determined in accordance with the order of the basic working elements.
- Reduce all unnecessary actions, to know: no effective work can only be called action, and effective action is work! Keep the distance to a minimum to maximize efficiency.
- Try to use inertia, gravity, natural forces and power devices, rather than relying on manpower, of course, can reduce people‘s fatigue, thereby helping to improve work efficiency.
- In order to reduce fatigue, the working point should be maintained at an appropriate height, and this height can be measured. Through measurement and careful calculation, you can make the movement as comfortable as possible, but also reduce the fatigue of the work.
- Stand and walk around. From the perspective of lean production, in order to adjust the production rhythm, it may be necessary for a person to operate two or more equipment at the same time, which requires that the operator can not sit down to work, but should use the standing and walking mode of operation, so as to improve work efficiency.
4. The floor plan has been upgraded
Some have not carefully designed the site layout and equipment layout in the early days of the factory, or due to the continuous development of production, the continuous addition of equipment, disrupted the layout, or due to changes in product structure, resulting in unreasonable plant or equipment layout, so that products and workpieces in production transportation route is too long, which is the hidden danger of creating waste at all times. Must resolve to change.
In the process flow chart is not able to see the plane route, an arrow on the flow chart may actually walk tens of meters, so it is necessary to further find benefits in the layout.
By analyzing the operation mode and the configuration of equipment and facilities, according to the flow direction of the production process, there are no repeated routes and reverse flow, find out the unreasonable part, reasonably adjust and design a new layout to shorten the walking distance of the process route and the operator, and reduce unnecessary waste of resources.
Sometimes, the movement of a device will bring tens or even hundreds of meters of distance savings, and sometimes more space will be saved.
5. Press the transport space and time
According to statistics, 25% to 40% of the processing fee is the handling fee; 70% to 80% of the time of the process is the time of handling and stopping; 85% of the disaster in the factory occurred during the handling process.
It can be seen that the compression of the transport is very important. Improve the handling to optimize the handling, from the handling quantity, handling space, handling time to improve.
First, to reduce the number of handling and handling times.
Second, in the handling space to shorten the handling distance as much as possible, reduce the handling route and the number of times.
Third, in the handling method should pay attention to management coordination, as far as possible to use non-dynamic, such as the use of gravity on the slope or on the conveyor belt handling.
The principle of rationalization of handling is to achieve almost no loss of materials to be handled;
Handling methods should be scientific, civilized, and put an end to barbarism;
The handling environment is safe, suitable and put an end to risks; Reduce the chance of temporary placement, as far as possible once in place;
Reasonable planning of plant layout can effectively shorten the handling distance. When the plant planning has been finalized, the rationalization of the planning process can also effectively shorten the handling distance.
6. Man-machine efficiency mentioned
If people and equipment are not handled well, it will happen that either people wait for machines or machines wait for people. Human and equipment constitute the relationship between human and machine engineering. In the analysis, it is necessary to analyze the working conditions of operators and machines at the same time, whether there is idle work, waiting, and ineffective time. By adjusting the work order, man-machine cooperation is improved, and reasonable methods are sought to make human operation and machine operation coordinate, so as to reduce the waiting time to the maximum and give full play to the efficiency of human and machine. Just like squeezing water, the time waiting for each other is squeezed out, which is to benefit from human-machine joint operations.
7. Shrink key routes
Almost any product is composed of a number of parts, usually divided into several lines or several processes of production, and to the late part to assemble the parts bit by bit, in the formation of parts, parts in the process, inevitably will occur the workload of each process is different.
This will bring mutual constraints in the later production, the workload of small processes will have a lot of free time, and the workload of large processes will not have a moment to rest, in other words, the time difference is zero, which has become a bottleneck in production.
The process of zero time difference is called the key route, which restricts the production capacity and delivery time of the enterprise or workshop. After we find out the key route, we should withdraw people and property from the non-critical route, strengthen the key route, or use parallel operation, cross operation and so on, shorten the key route, constantly modify and optimize the plan, and achieve the best goal of shortening the schedule and saving costs.
The first basic skill of the production supervisor is to be able to calculate and find the key route according to the plan and production capacity. The second is to continuously compress key routes and other routes to achieve comprehensive optimization of time and cost.
8. Take a look at management visually
The human brain gets up to 80% of its information from vision. Therefore, the visual communication and command method is more direct. Using a variety of visual perception information with intuitive images and appropriate colors to organize on-site production, charts, drawings, photos, text annotations, signs, symbols as visual management tools, can easily achieve interpretation, cognition, warning, judgment, action and other functions. Therefore, visual management can also be called "visible management" and "visual management".
9. Find the root of the problem
Looking for gaps every day, in order to do better the next day - this is a very important point in Haier‘s model originality, constantly looking for problems, analyzing problems, and never stopping to improve the site, which is the common nature of quality improvement, 8D work method, CIP and other activities. It is this that drives the management operation process and keeps the enterprise in a virtuous circle.
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Anna Zhang