How to improve production quality and productivity

Productivity is an important measure to measure the efficiency of production factors (resources) of enterprises, that is, how many products can be produced at the same cost in terms of materials, labor and production facilities. For manufacturing enterprises, effectively improving production efficiency is the key to reducing production costs. First, the bottleneck production process: this is the simplest move, but it is also the most powerful one. My own "famous saying" is that "practicing simple movements to the extreme is the trick". There is a proverb: "The bottleneck process determines the maximum capacity". As we all know, balance is an important guarantee for production schedule. /kloc-as long as one link in 0/00 is inefficient, the efforts of 99 links may not be able to solve the problem of backward progress. Therefore, grasping the production rhythm of bottleneck process and continuous improvement are the most important magic weapons to improve efficiency. The old bottleneck has been solved, and a new bottleneck has emerged. Bottlenecks have been eliminated, portfolio optimization has been promoted, and production efficiency has been greatly improved. So, how to effectively remove the bottleneck process? The commonly used five-step method is to remove the bottleneck: ①. Find out the bottleneck of the system; 2. Decide how to tap the potential of the bottleneck; (3) Give the bottleneck the best resource support; 4. Loosen the bottleneck (bypass, substitution, outsourcing); ⑤ If the fourth step breaks the original bottleneck, then go back to the first step, make continuous improvement and find a new bottleneck again. 2. Implementation performance and piecework salary: I remember a management master once said: "If the fixed salary of enterprise employees exceeds 70%, the enterprise is not far from death." This sentence is easy to understand, because it is impossible for employees who "protect their crops through drought and flood" to be motivated. We often say a quip, "Time is shameless (fishing), piece count is not fatal". In fact, management is the distribution of benefits, and good distribution is a win-win situation. I have been to an enterprise with tens of thousands of people. There are 10 IE engineers in their enterprise, and they are studying how to improve efficiency every day, but the efficiency just can't be improved. My statement is simple. "The improvement of on-site efficiency is not to realize the interests of the company at the expense of the interests of employees, and such improvement will inevitably fail." IE engineers are studying how to make employees do faster and better, but it is more difficult for employees to do faster and better, and it is more difficult for employees. If his salary doesn't rise, he will definitely resign. In fact, the most precious wealth of production management is employees. The core of employees is motivation, and the focus of motivation is to meet the needs of employees. Piece-by-piece system (such as spot welding, tin welding and other processing procedures) must be adopted in the production site. In previous consulting experience, the productivity and efficiency can generally be improved by more than 10% after implementing piece-rate compensation. Piece rate is a reasonable wage method, which encourages employees to get more for more work, which can not only arouse the enthusiasm of employees, but also improve the efficiency of on-site work, ensure that the assembly line does not wait for materials, and reduce production costs. Of course, to implement piecework compensation, we should focus on solving the following six problems: 1. Repair of defective products, 2. The amount of makeup, 3. Training for new employees. Piece rate accounting, 5. Rationalization of standard production capacity. Rationality and fairness of division of labor of production line supervisors. At present, the production management form of enterprises is not suitable for piecework wage, so in some stations, if we straighten out the order of the production site and improve the working methods (reduce unnecessary working steps or let the necessary operations be completed in the fastest, safest and most comfortable way), then we must improve our work efficiency and productivity and implement the performance bonus system. At this time, the key points to pay attention to are: ① assessment items, ② calculation methods, ③ project connotation, ④ target weight, ⑤ project allocation, ⑤ scoring rules, ⑦ data sources, ⑧ assessment cycle and ⑨ prize amount allocation. 3. Encourage employees to conduct self-inspection and mutual inspection: In production management, generally speaking, as long as the quality is good, the efficiency is naturally high. Repairing defective products often affects efficiency by more than 3 times. In the previous production rationalization consultation, it was found that ordinary enterprises spent a lot of resources on the first and last parts, full inspection and special inspection, but ignored the self-inspection and mutual inspection of employees. Everyone knows that "quality is made", but many people don't understand how to implement it. Our approach is two points: 1. Employees should conduct self-inspection. In the production process, employees should: 1. "Confirm the processing quality of parts in the previous process"; ②. "Confirm the processing technology, requirements and quality of this process"; ③. "Confirm the quality of finished products delivered to the next working procedure". 2. There are generally two quality management principles for employee mutual inspection: the first principle is that when the first process provides products to the second process, if the second process detects that there are defective products, such as providing 10 products, and the second process detects that 9 products are qualified and 1 products are unqualified, then the second process has the right to file an index claim with the upstream process. The claim index here is quite amazing, growing geometrically. The second principle is that after the first process provides products to the second process, if the second process fails to detect defective products and flows to the third process, the third process will deduct the bonus of the second process ... By designing a series of systems, employees can do self-inspection and mutual inspection, which can not only greatly improve efficiency, but also greatly reduce the number of quality inspectors.

4. Establish a flexible production organization system, take the structure and operation of production organization as the main body, and carry out a series of comprehensive application activities of forms and elements. Its ultimate goal is to develop all personnel to complete production tasks on the premise of ensuring good quality. 1. The function of the production organization is to assign the overall task to each unit or individual, and establish a relationship with both division of labor and cooperation. 2. Arrange workstations according to the flow chart, determine the spacing and complexity according to the operation time, configure command workstations, input materials, identify defective products, and place fixtures and instruments and equipment. 3. Ensure that the work station is balanced and the assembly line is smooth, and arrange employees reasonably according to their proficiency. There will be no room for material accumulation and flow in the production line, no one will be busy to death, no one will be idle, and no work will be delayed. 4. Personnel stations are replaced, personal specialties are reasonably distributed, and automatic vehicles are faster and slower. 5. Pay attention to the management of new employees, designate special personnel to be responsible for guidance, clarify responsibilities and check and confirm regularly. 6. Determine effective production capacity and qualification management, which can be divided into internship period, independent period, independent period, skilled period, horizontal period and development period. 7. The power line should be clear: employees (completing tasks and reporting problems)-team leader (carrying out tasks, handling problems and reporting results)-squad leader (carrying out plans, reporting production and handling problems)-director (supervising implementation, summarizing plans and reporting results). 8. Cultivate generalists, distinguish the strengths of employees, pay attention to the training and use of employees, and consciously cultivate them in their daily work. 5. To realize the plan and increase the output, managers should pay more attention to: 1. Preparation before production should be sufficient (personnel, machinery, equipment, materials, technology, site). 2. Properly control the casting speed, keep a moderate sense of urgency when working, and don't relax. 3. Confirm the output in time and fill in the kanban. 4. Control the defective products, correct them in time, stop work if they are ineffective, and find another suitable person or find the right way to operate. 5. Incoming defective products and generated defective products shall be confirmed to be returned, replenished and replaced in time. There are many reasons that affect production efficiency, such as "acquired imbalance caused by congenital deficiency" in design and development, product line change or material production suspension caused by insufficient procurement, etc. It is not too difficult to grasp the main contradiction of the problem and improve production efficiency. Of course, in lean production, the common methods to improve efficiency are. But as a management, we must remember that production management should pursue simplification, and simplicity is efficiency; The most effective production management method is often the simplest and most direct, rather than following the trend to do the so-called six sigma and Toyota production.

There was a famous saying in the early days of the founding of the People's Republic of China: "If you understand it, you must implement it. If you don't understand, you must implement it and deepen your understanding in implementation. " We must operate in strict accordance with the process standards. In order to make operators better understand the production process and improve work efficiency, we should understand and analyze the upper and lower processes separately, adhere to the principle of continuous improvement of processes, and find the most reasonable operation mode in a feasible way. When we do our homework, should we consider the following questions: 1. Is it necessary to do an action? Is there a better way? 2. Why do you want to do it here? Is there a more suitable place? 3. Why are you doing this now? Is there a more suitable time? Then, according to my own working experience, I put forward the following views on how to improve productivity: 1. Improve our working habits 1. Keeping a good sitting posture makes the combination of the body and the workbench more reasonable, which is beneficial to work. 2. Try to use both hands in the production process. 3. Within the operating range, try to keep short-distance movement and improve time utilization. 4. The working area must be kept clean and meet the requirements of 5S specification. 2. Distribute the workplace reasonably and pay attention to the placement of raw materials (1). The movement path of hands and arms should be within the normal working area (within the reach of hands in normal sitting position). 2. Attention must be paid to working eyes, and normal vision should be ensured to see the status of the operating point. 3. Tools and materials should be placed in a fixed position so as to be accessible at one time. You can also put the most commonly used materials with high reuse rate beside them and put them in the order of material assembly. 3. Tools and equipment 1. Tools and equipment should be within your reach. 2. Design and use simple auxiliary tools or tooling to make production smoother, more reasonable and more convenient. 4. Material handling 1. In order to facilitate the visit, the design should be done in advance. 2. Whether to arrange to design some tools according to the principle of gravity to send materials to the place of use. 3. Preset and classify the materials and parts needed for the next process. 5. Save time, 1. Concentration at work can not only improve the problem of human hesitation or temporary parking. At the same time, safety accidents can be avoided. Such as iron scald, blade scratch, object scratch, etc. 2. Analyze our actions at work, which actions are necessary and can be combined, which can reduce steps and shorten time. If a person can improve himself in all aspects, the development of the company will be more stable and rapid. Employees can save one minute a day through effective methods, and employees in the workshop can save 100 minutes a day, and so on. How many batteries can this company produce a year? If we make progress and think more every day, we will not only improve ourselves in all aspects, but also the company's development will be more stable and rapid!