How to improve quality and save cost?

1: There are two ways to save costs: one is to reduce unnecessary processes in the production process or to have a better process to replace the old bad process.

Two: reduce costs from suppliers.

2. nexus 4M within the company will check and count this every month. It is best to do character and data. For example, the placement and location of tools should be clear.

3. Check the last procedure, do a good job in this procedure, check this procedure, and hand over the next procedure (which must be qualified) to reduce unnecessary internal rework.

4. Reduced failure rate (product scrapping). If it is easy to make mistakes, it should be specially handed over to the on-site sampling inspectors for sampling inspection. I don't know it's broken until the last process.

Only analyze the above points. I believe the report will be all right.

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When the manufacturing industry develops to a certain stage, it is necessary to save costs and improve efficiency as much as possible. We should strictly implement 5S and implement the Seven Quality Methods. At the same time, we should strive to implement six sigma management or lean production control, attach importance to IE projects, and strive to increase production capacity to the limit and control costs to the lowest. Then the boss will definitely promote you.

We can improve the quality and efficiency of products from the improvement of technology and methods, and we can also improve the efficiency from the improvement of equipment. Rationalization suggestions are mainly to improve quality, efficiency and save costs.

Lean production originated from Toyota production mode, which is the best production organization system and mode in manufacturing industry at present, and also the global standard production system of 2 1 century. Under the background of learning lean production mode in global manufacturing industry, how to successfully implement lean production better and more practically has become a problem that many enterprises have been thinking hard about.

Company ") is a subsidiary of China National Heavy Duty Truck Group Co., Ltd. and the first axle manufacturing enterprise in China that has passed the TS 16949 standard certification. In 2007, Daqiao Company put forward the development goal of "marching into the world's advanced assembly manufacturing enterprises", comprehensively introduced lean production methods and established a lean production management system. As a direct participant in the implementation of lean production projects, the author has made a deep exploration and summary of the practice of implementing lean production mode in Jinan Xiang Qiao Co., Ltd.

The leading idea of lean production mode is to continuously eliminate all waste in the whole production process, give full play to the intelligence of each employee, effectively allocate and rationally use various resources of the enterprise, and bring the greatest economic benefits to the enterprise. In order to completely abandon the outdated production mode, break the barriers of traditional management concepts and successfully introduce lean management concepts into the business activities of enterprises, Bridgebox Company regards lean production not only as a production mode and management mode, but also as a profound corporate culture. Therefore, Bridgebox Company starts with changing employees' way of thinking, and guides employees to establish a sense of learning, improvement and cooperation. Only when employees agree, can superiors and subordinates interact, eliminate barriers and work hard for the same goal. On the basis of * * * understanding, Bridge Box Company closely combined management technology with manufacturing technology, actively explored and innovated, and made great reforms, and achieved a series of results.

1 standardization of operation essentials

According to the requirements of lean production, Bridge Box Company adopted IE project to scientifically and reasonably adjust and transform the layout of production lines and workstations, which made the production layout more compact and reasonable, and set up a standard handheld (WIP quota) to reduce the production area and WIP, and effectively control the bumps and scratches of products. The new production line fully embodies the requirements of humanization. The production line is neat, clean, bright and comfortable, which improves the enthusiasm of employees and creates conditions for employees to produce high-quality products.

In order to standardize the operation of employees, new standard operation instructions and standard operation combination tickets have been formulated. The new operation document is very different from the previous process document, which not only marks the size of the product, but also standardizes the operation route and actions of employees and realizes the standardization of actions. Employees carry out "standard operation" in their respective work areas according to the stipulated production rhythm, standard operation instruction and standard number of hands, which realizes the production according to the rhythm, effectively improves the implementation rate of process discipline and ensures the product quality.

2 specialization of division of labor

In the past, employees in the production line were required to be all-rounders, not only to process products, but also to be proficient in equipment and tools. It takes a long time to train a qualified employee, and the quality of products has a great relationship with the quality of employees. At the same time, employees need to maintain the machine tool, change the tool, add cutting fluid, and pour iron filings, which takes up a lot of production time and seriously affects the efficiency of the equipment. After the implementation of lean production, the employees are divided scientifically and reasonably, and the operators are divided into two categories: in-line and out-of-line. The above work is based on the mountain plot map, and the work contents and standards of relevant personnel are determined (inline 15 minute maintenance, tools, self-inspection and other instructions). Through professional division of labor, we can effectively improve the quality of all work, and do a good job in tool replacement planning, equipment maintenance and self-inspection.

3 standardization of management work

With the development of lean production, according to the basic principles of lean production and the requirements of TS 16949 standard, Xiang Qiao Company established a scientific and reasonable index management system and workflow for the quality management, equipment management and tool management of the production line, and all the work and standards were implemented by the responsible person, and initially established a set of production line management system with everyone responsible and standardized management. For example, in order to strengthen quality control, "Quality Control Measures for Machining Lean Production Line" was formulated, which strengthened the control of operators' self-inspection, first and last parts, patrol inspection and special inspection.

While realizing lean production, it ensured the running quality of TS 16949 system and the ability to improve product quality, standardized the establishment and operation of product quality control in production line, and the corresponding work was effectively carried out. In order to ensure that the product quality problems are found and solved in time, SPC workstation is introduced into the production line, which truly realizes "online inspection" and improves the accuracy of product inspection in the production line.

What should I do if there are defective products in the production line? The company fully considered this point in the layout of the production line. Under the condition of not affecting the operation of production line personnel, set up a defective product discharge channel, through which employees can eliminate and isolate defective products in time, prevent the mixed use of defective products, and facilitate the timely discovery of problems. The off-line personnel transport the defective products to the defective product analysis desk, and the team leader organizes technical and inspection personnel to analyze the reasons, formulate corrective measures and implementation plans, and track the completion. After the analysis, keep it on the display platform of defective products, and post the analysis of the problems on the display platform to tell the employees what quality consequences will be caused if such quality problems occur, and make records.

4 employee improvement plan

Lean production puts forward higher skill standards and quality requirements for employees, which not only requires each employee to master the operating standards and essentials of workflow, but also requires changing the traditional production concept and accepting and understanding the concept of lean production. In this regard, the company has conducted multi-skill training and lean production practice skills training for employees to improve knowledge training. After the training, employees are tested for their operational skills and theoretical knowledge, and only those who pass the examination can go online to operate, which largely ensures the high-quality production and processing of products. At the same time, in order to enhance the vitality of the production line, improve the enthusiasm of employees to participate in quality improvement, and continuously improve work efficiency and product quality, the company has increased the scope and intensity of rewards for improvement suggestions, encouraged employees to give full play to their intelligence, actively offer suggestions and submit reasonable suggestions.

5 streamline the layout of the production line

The company made full use of lean tools and ergonomics, re-matched the capabilities of equipment and personnel, rationally adjusted the number of equipment and personnel load, made the production line flow, minimized waste, and achieved great results to a great extent. Take the lean shell processing line as an example: before lean production, the lean shell processing line had 38 operators and 18 sets of equipment, and the number of in-process products on the line was about 70 pieces, reaching 150 pieces at the most, with an average daily output of 330 pieces, and the production site operation was uncontrollable. Now, after the implementation of lean production project, the number of employees has been reduced to 30, the number of equipment has been reduced to 17, the number of online products has been reduced to 22, the per capita output has reached 378, the production area has been reduced by 80 square meters, and the operational reliability of the production site has been greatly improved.

The effective implementation of lean production has not only made Bridge Box Company achieve great economic benefits, but also changed the consciousness of employees. Great changes have taken place in employees' ideas: from initial passive acceptance to active learning, understanding and practice; From focusing only on individual efficiency to focusing on overall efficiency; From focusing only on results to focusing on processes. The work of employees is gradually standardized, and the awareness of initiative improvement, teamwork, quality control and efficiency is gradually enhanced.

There are other mountains, where stones are suitable for jade-other people's advice can help a person overcome his shortcomings.

Lean production mode is a kind of spirit, a kind of idea and a kind of method, which needs continuous improvement and perfection. Its implementation process is painful and arduous, but the result is gratifying. Just like the Tang Priest's Buddhist scriptures in the West, he went through all kinds of hardships and finally made a positive result.

The learning of lean production mode can be roughly divided into four stages, namely: initial understanding stage, compulsory implementation stage, active learning stage and self-formation stage. These four stages are closely related and inseparable. In the learning process, we should not only continue to strengthen the top-down implementation, but also step up the training of employees' conscious initiative in pursuing lean production from the bottom up. Secondly, in the specific work, we should guard against superficial articles and avoid the formalization and superficiality of lean production promotion. It is necessary to learn "shape", but it is not necessary. You can't "know what it is but don't know why" or even "draw a tiger according to a cat". We can't mechanically copy lean production methods, but should combine the company's reality, use them flexibly and take a distinctive lean road. Finally, in the process of implementation, we must achieve "two persistences", that is, persistence is both stable and fast; Stability means that lean work should be slow and steady, step by step; Fast means that on the basis of * * * knowledge, all departments should respond quickly and act quickly, and always maintain a high enthusiasm for work; Adhere to close cooperation: the implementation of lean production is not only a matter for the production department, but also a matter for all departments, and it is a matter for all leaders and employees to work together. All employees must participate and cooperate closely.

Actual management of manufacturing production site (2009-03-2517: 55: 21)

Actual management of manufacturing production site (all pictures, senior engineer-Chen Bing)

With the acceleration of the global economic crisis and tsunami, many enterprises have fallen behind in survival and competition, and the profit space of the surviving enterprises has also been greatly reduced. Those who do not have competitive advantage will be eliminated, which has become an iron law!

No matter how disastrous the global economic crisis has brought, society has entered the information age. Today, knowledge economy and modern management have become the mainstream of development. The competition between enterprises, the growing market economy and the increasingly fierce market competition. The quality, production cost and delivery date of products and services have become important conditions for the success or failure of enterprise competition. Maintaining product quality steadily has increasingly become a magic weapon for enterprises to win in market competition. The objective law of survival of the fittest determines that the survival of enterprises mainly depends on two factors: one is the market and the other is management. The products with high quality and low price are formed and realized in the field (design field, production field and sales field), and have formed the knowledge of * * *, so the market and products also depend on management to a great extent. Therefore, excellent product quality can only be achieved through scientific and meticulous website management.

Measuring the quality of enterprise production site management depends on the awareness of employees on the one hand and the mastery of site management tools on the other. Effective site management needs to master a series of tools, such as 5S management, visual management, standardized management, and quality improvement, cost improvement, delivery improvement, etc. , in order to obtain customer satisfaction. To master these tools, you need to have some basic knowledge and skills in field management.

The on-site management personnel of many enterprises are production employees, who work with previous work experience or technical ability and lack management level and skills. Therefore, management knowledge training is an important means to strengthen the production site management of manufacturing enterprises. This training course is a knowledge training tool for production site management, including site management overview, site production organization, site personnel management, site 5S management, site quota management, site standardization management, site quality management, site management improvement, site cost control, site equipment management and site safety management, covering all aspects and the whole process of enterprise production site management, hoping to play a beneficial role in site management.

The first module is an overview of field and field production management.

Site generally refers to the workplace. The production site is the place where products are produced or services are provided, that is, the place where workers use labor means to act on the labor object and complete certain production tasks. It includes not only the workplace of basic production workshop before production, but also the workplace of auxiliary production department after production, such as warehouse, laboratory, boiler room, etc. In China's industrial enterprises, it is customary to refer to the production site as workshop, workshop or production line.

If there is a site, there must be site management. On-site management is to analyze various factors of production on site by using scientific management ideas, methods and means, such as people (operators and managers), machines (equipment), materials (raw materials), methods (technology, testing methods), environment (environment), funds (funds), energy (energy) and information (information). On-site management is an important part of enterprise management. Many problems in enterprise management will inevitably be reflected on the spot. All kinds of professional management work should also be carried out on site.

On-site management is an organic part of modern enterprise management, and it is a dynamic process of rational allocation and optimal combination of various factors in production site by using scientific management ideas and methods. The management activities of enterprises are the same as human life activities, and the resources invested can be regarded as human bones, digestive system, brain and so on. , the result output. Such as facial expression, hand and foot movement ability, knowledge ability and humanistic charm. The final output result is the result made by people. In our daily life, in order to keep the body in good condition, we should take in nutrition, pay attention to rest, and carry out moderate activities and self-care. Only when all the organs of the human body are in good condition can everyone's physiological functions be realized. Any organ failure will pose a threat to the whole body and even lead to death.

Similarly, in enterprise management activities, no matter what problems appear in funds, personnel and equipment, it will bring difficulties to production. It may not be so serious at first, but with the production process, the problem will become more and more prominent until the production is stopped, thus paralyzing the production and business activities of the whole enterprise. Therefore, in order to maintain the normal operation of enterprises, it is necessary to keep the resources used in a good and balanced state, strengthen on-site management, and obtain the best economic benefits with limited resources. No matter which site we go into, we can clearly know the management level of the enterprise, so as to know the operating conditions of the enterprise. This is because the scene is the epitome of enterprise management activities, and the main activities of the enterprise are completed on the spot, which shows its importance in the following aspects:

First, websites can directly create benefits.

The site is the place where products are developed and produced. Enterprises should reduce production costs, deliver products to customers on time and meet customer expectations. All these must be realized on the spot, so that enterprises can obtain the added value of products from the spot and survive and develop in society.

Second, the scene is the source of providing a large number of information sources.

As the saying goes, seeing is believing, and indirect information is not necessarily true. If you want to get accurate first-hand information, you have to go to the scene to do in-depth and detailed investigation and understanding.

Third, the site is also the place where problems and defects occur.

Website is the front line of enterprise activities. No matter what problems and defects, they all come directly from the site. If problems and defects are not taken in time, they will be left to their own devices, and the probability of development in a good direction is much smaller than that in a bad direction.

Fourth, the scene is the first place to reflect the ideological dynamics of employees.

People are emotional and thoughtful. What a person does is not necessarily what he thinks is the most ideal and satisfactory job. If he feels dissatisfied, he may feel uncomfortable and impulsive. The instinctive primitive behavior of employing people is embodied in his work, which will directly or indirectly affect the product and production efficiency.

In short, when we arrive at the scene, we can clearly understand the actual situation on the scene. The management level of an enterprise depends on whether its on-site management has achieved the overall economic goal and set various phased and detailed specific goals, and whether it has well guided employees to carry out their work in an organized and planned way and achieved the goal economically and reasonably. Site is the starting point and end point of all activities of enterprises, and enterprises that do not pay attention to site management will eventually suffer.

Supplement:

Practical management of manufacturing production site (2) (2009-03-2518: 01:20)

Label: the action mark of an object; Work content; On-site management; random talk

The second module, on-site daily management