Pipe factory, use these 10 tips

Views : 1415
Author : Jessie
Update time : 2019-11-23 17:04:01
10 Tips for on-site management
This article summarizes the 10 rules of on-site management and shares them with you. There are only three basic elements in the field management: people, things, places; the situation on the scene is ever-changing, and it comes down to only "two streams":,logistics and information flow;

As a site manager, whether it is a production manager, production supervisor, workshop director, foreman, team leader, or improvement engineer, IE engineer, quality inspection engineer, we must carefully analyze and study these three elements and two streams and find problems. Analyze the cause and find the answer to the problem.

This paper provides an on-site manager with an idea and tools for on-site management analysis and creation and efficiency and effectiveness from scientific management.

01 Process check

The illustration of the steps and delivery routes describing a process is called a flow chart. It consists of two main categories of workflow and process flow, but the essence is the same, which can be used to represent complex processes with graphical representations.

A process or workflow is a general route of a unit process or work. It reflects the process, process, and process of connecting, determining, or checking the process, and finding a problem in a company or department. At the beginning of the process, “shun vines” analyzes the entire process of production and work, which processes are unreasonable, where are there pauses, and which process routes and links can be canceled, merged, and simplified?

Analyze and judge whether each link of the flow chart is in a controlled state? Can the inspection play a role in checking? Is the horizontal contact of each department in place?

Is it smooth? Do you need to build or add new channels? From the various links and transmission routes of the flow chart, analyze whether the work functions of the existing departments are in place and whether the existing institutions should be adjusted or reorganized?

 02 Up the floor plan

In the early days of construction, some factories did not carefully design the site layout and equipment layout, or because of the continuous development of production, the equipment has been continuously added, disrupting the layout.

Or due to changes in the structure of the product, the layout of the plant or equipment is unreasonable, so that the transportation route of the product and the workpiece during production is too long. This is a hidden danger of manufacturing waste every moment, and must be determined to change.

In the process flow chart, the plane route is not visible. An arrow on the flow chart may actually go tens of meters, so it is necessary to further find the benefits on the floor plan.

By analyzing the operation mode and equipment configuration, according to the flow direction of the production process, whether there are repeated routes and backflow conditions, find out the unreasonable parts, reasonably adjust and design a new layout to shorten the process route and the operator's walking. Distance, reducing unnecessary waste of resources.

Many times, we have to be surprised, a small change, the result is that the movement of a device will bring tens of meters or even hundreds of meters of distance savings, and even save more space.

 03 Calculate on the assembly line

Production lines and pipelines should be in accordance with consistent tempo, and production can be balanced. Some enterprises often produce "front work, rearview, ahead, and back work overtime". One of the reasons is that the way of moving is unreasonable, and the other is that the beat is not balanced.

A wooden barrel is made up of a number of different lengths of wood, the size of which is not the longest piece of wood, but the shortest one.

Similarly, on the assembly line, the slowest person is the one who determines the ultimate efficiency of the assembly line. Balance efficiency of the production line or assembly line = total of net operation time of each process/operation time of the longest process × number of personnel.

The balance rate of many production lines is often less than 50%. If the long-time process is simplified, the method of speed increase, substitution, or splitting is used to balance the assembly line by cutting, adding, etc.

The production efficiency of the entire production line will be greatly improved, and the labor and accumulation caused by the slow operation of individual processes will be eliminated.

 04 Action factor minus one minus

Any operation is based on manual movements, assembly processes, processing operations, and the like, which are manual labor-based processes. Actions are a very important factor in generating benefits.

For the purpose of motion analysis, the main purpose is to eliminate unnecessary movements, invalid movements or slow movements, such as bending work, squatting work, poor working place, no suitable tools, people and things in the search state, etc. The way to achieve maximum productivity.

This research can greatly increase production efficiency without spending a penny. For example, in real life, why do some people make dumplings much faster than the average person?

Why are some people transplanting a lot faster than the average person? That's all because they have mastered certain flaws and completed the task with the most economical action.

 05 Carrying time and pressure

According to statistics, 25% to 40% of the processing fee is the handling fee; 70% to 80% of the processing time is the time of handling and stopping; 85% of the factory disasters occur during the handling process.

It can be seen that it is very important to compress the handling. Improvement of handling is optimized for handling, and the number of handling, handling space, and transportation time are improved.

First, reduce the number of handling and the number of handling;

Second, it is necessary to shorten the handling distance and reduce the handling route and the number of times in the handling space;

Third, it is necessary to shorten the time and reduce the number of times in the handling time; in the method, pay attention to management coordination, try to use non-power, such as using gravity to slide on the slope or transport on the conveyor belt.

The principle of rationalization of transportation is to make almost no loss to the materials being transported; the handling method should be scientific, civilized, and savage and brutal; the handling environment should be safe, suitable, and prevent risks;

Reduce the chance of temporary placement, and make it as close as possible to the position; rationally plan the layout of the factory, which can effectively shorten the handling distance.

When the factory planning has been finalized, the transportation distance can be effectively shortened by rationalizing the planning process.

06 Human-machine efficiency

People and equipment are a pair of contradictions. If they are not handled well, it will happen that machines such as people are machines and others.

Human and equipment constitute the relationship of ergonomics. In the analysis, it is necessary to analyze the work situation of the operator and the machine at the same time, whether there is work, waiting, invalid time, improve the man-machine coordination by adjusting the work order, and seek reasonable The method is to coordinate the operation of the person with the operation of the machine, reduce the waiting time to the maximum, and fully utilize the efficiency of the person and the machine.

Just like squeezing water, you will squeeze out the time of waiting for each other. This is to benefit from the joint operation of human and machine.

07 Key routes shrink

Almost any product is made up of several parts, usually produced in several lines or several processes, and the parts are assembled one by one in the later stage, which will inevitably occur in the process of forming parts and components. The amount of work in each process varies.

This will bring mutual restraint in later production, there will be a lot of free time in the small workload, and there will be no rest time in the process with a large workload, in other words, the time difference is zero, and it becomes production. The bottleneck on it.

The process with zero time difference is called the key route. It restricts the production capacity and delivery time of the workshop. After finding the key route, we need to transfer people and property from non-critical routes, strengthen the key route, or adopt parallel operation and cross-operation. In the form of, etc., shorten the key routes, continually modify and optimize the plan, and achieve the best goal of reducing the cost of the schedule.

The basic skill of the production supervisor is to calculate and find the key routes based on the plan and production capacity. The second is to continuously compress key routes and other routes to achieve comprehensive optimization of time and cost. There are two ways to do this:

The first method: time optimization. It is to seek the shortest work cycle under the conditions of manpower, equipment, and capital. It can fight for time and quickly exert its investment results.

Use time difference to draw some manpower and material resources from non-critical routes to focus on key routes, or to disassemble operations, increase the degree of parallel intersection between operations, increase the input manpower and equipment, and adopt new technologies and new technologies to shorten key routes. Continuation time.

The second method: time-cost optimization. The expenditure of the project can be divided into two parts: direct cost and indirect cost.

Direct expenses refer to expenses directly related to each operation, such as fabric or auxiliary materials. Indirect expenses refer to expenses that are not directly related to various activities but vary with time. The shorter the engineering cycle, the more indirect costs. small.

Time-cost optimization is the engineering cycle when the sum of direct and indirect costs is the lowest.

08 The environment of the place has changed

Analyze whether the production and working environment meet the production, work needs and human physiological needs, analyze what items and media are still missing at the site, and propose improvement suggestions for different types of sites, and carry out “finishing, rectifying, cleaning, cleaning and literacy”. "Safety" six activities, to always maintain the A state, continuously improve the B state, clear the C state at any time, so that employees maintain strong fighting spirit and good skills, the required items are readily available, and the unwanted items are cleared at any time. The environment is smooth, clean, landscaping, safe, and civilized, so that the place and the environment can be optimized in time and space.

 09 Visual management to take a look

The human brain has up to 80% of visual information. Therefore, the method of communicating and directing with vision is more straightforward.

Organize on-site production with visually sensible and visually appropriate visual perception information, using charts, drawings, photographs, text annotations, logos, symbols, and tools for visual management.

It is easy to achieve functions such as interpretation, cognition, warning, judgment, and action. Therefore, visual management can also be called "visible management" and "visual management".

10 Find the root of the problem

Finding the gap every day to do better the next day – this is a very important point in the originality of the Haier model, constantly looking for problems, analyzing problems, and constantly improving the site, this is a quality improvement, 8D Commonality of activities such as work methods and CIP. It is this that drives the management process and keeps the company in a virtuous cycle of continuous upwards.

The ten rules of these on-site improvements, if you really use it, you will find that these weapons are extraordinary, you will be pleasantly surprised to see:

The process route is smooth, the plane layout is reasonable, the flow line disappears, the beat is more uniform, the worker operation efficiency is high, the handling is convenient, the production is balanced, the man-machine combination is close, the management is simple, a faster, A better, shorter, and smoother lean production situation has quietly arrived!

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