First, the concept of the production process and its components

The production process refers to the entire process from the preparation of the production technology until the manufacture of the product. (It is the process of converting the input of production and operation resources into output. The production operation consists of PEOPLE, PLANT, PART, PROCESS, and PLANING AND CONTRAL SYSTEM. The English words of these five words are “P”, referred to as “5P”.)

 

Modern product manufacturing processes require several steps in product and process design, process development, process equipment manufacturing, and material preparation.

 

According to the production process, the production process of the enterprise can generally be divided into four processes:

 

1 production technology preparation process

 

2 basic production process

 

3 production service process

 

Production technology preparation process

 

Product drawings, process documents, tooling mold preparation process

 

4 auxiliary production process

 

  produce

 

Process

 

Production service process

 

Material supply, transportation, warehouse, storage, etc.

 

Auxiliary production process

 

Power supply, tooling, mold manufacturing, equipment factory maintenance, etc.

 

Basic production process

 

Directly change the object of labor and turn it into a product

 

Second, the production process space organization

 

Production process space organization refers to the way in which the internal units and production stages of the enterprise and the transportation routes and the production factors such as laborers and production materials are combined with each other in space, also known as static organization. Its contents include what kind of production units are set, how to arrange these production units according to the principle of row arrangement, determine the relative position between production units and production implementation, and determine the organizational rules and interconnections of each production unit.

 

Production process space organization form:

 

(1) Process specialization principle: refers to the principle of establishing the production unit with the same process characteristics

 

(2) Object specialization principle: refers to the principle of establishing production units according to the same object

 

Third, the production capacity consulting content (factors affecting production capacity)

 

Factors affecting production capacity: such as equipment, tools, production area, number of people, technical level, process level, raw material status and supply level, production organization and labor organization.

 

The first aspect: the number of fixed assets in the enterprise

 

The second aspect: the effective working hours of the company's fixed assets during the planning period

 

The third aspect: the production efficiency of enterprise fixed assets

 

The fourth aspect: the technical process characteristics of the enterprise processing object

 

The fifth aspect: enterprise production and labor organization

 

The sixth aspect: the basic factors of organizational production capacity

 

Fourth, production efficiency analysis (capacity analysis method)

 

Production efficiency is one of the factors affecting production capacity, and the impact of production efficiency on quotas is very large. According to the standard time of the previous operation, the lower the production time quota standard of the unit product, the greater the production potential capability.

 

People are one of the most basic elements of production capacity. This refers not only to the number of workers and the technology they possess, the morale and enthusiasm of workers, but also the management level of managers is also included in the production capacity. From the perspective of the enterprise as a whole, efficiency should include the efficiency of the operator and the efficiency of the manager. In a sense, the high efficiency of business managers will directly affect the efficiency of operators.

 

In the consultation process, mold expert Luo Baihui pointed out that managers should not only pay attention to the hardware that affects the high interest rate of enterprises, such as production equipment, production conditions, etc., but pay attention to and pay attention to the software strength of enterprises, such as organizational culture, management level of management personnel. Employee morale, enthusiasm, responsibility, team cohesion, etc. If the company has advanced equipment and facilities, no advanced management level, it is difficult to propose high production efficiency.

 

V. Formulation method of production plan (predictive production plan)

 

(The production method will be different depending on the production method)

 

Production planning for predictive continuous production

 

(Predictive production is also called inventory type production. Generally, it is a large batch and medium batch production type, customers can directly pick up the goods from the finished product warehouse)

 

Therefore, determining the output of a variety is the core content of a forecasted production company's annual production plan.

 

In the predictive production mode, because the market demand for products is relatively stable and the output is also large, the equipment is generally configured according to the principle of the object, and the production is organized by the assembly line. The production plan of the predictive production method is characterized by the product's output plan based on the sales plan and product inventory.

 

Its calculation formula is as follows:

 

Monthly production plan quantity = monthly sales plan quantity + (standard stock quantity - actual stock quantity)

 

Sixth, the content management system

 

1. On-site management includes five basic elements (4M1E) including personnel management, equipment management, material management, operation method management and environmental management.

 

2. On-site management composition

 

Luo Baihui believes that to create a first-class on-site management system needs to consolidate the “foundation”, including establishing a correct on-site management awareness and strengthening “5S” activities. It is necessary to establish ten pillars: management, planning management, quality management, efficiency management, and cost. Management, equipment management, safety management, human resource management, morale management, lean management.

 

Seven, on-site improvement methods and techniques (ECRS)

 

ECRS analysis, ie, ELIMINATE, COMBINE, REARRANGE, SIMPLIFY.

 

1. Exclusion method (ELIMINATE), whether this operation can be eliminated, whether the operation can be removed; whether the link and time can be reduced; whether the number of transportation can be reduced; and whether the operator can be reduced.

 

2. Consolidation (COMBINE), whether several jobs are carried out simultaneously or merged; whether the engineering division is appropriate; whether the engineering load is balanced, and whether the inspection work can be merged.

 

3. Adjust the order (REARRANGE), whether the job sequence can be rearranged; the factory and workshop layout can be adjusted; whether the logistics route can be changed.

 

4. SIMPLIFY, can be mechanized and automated; full inspection can be changed to random inspection; can it be shortened by transportation; can we reduce inventory?

 

Eight, equipment use and maintenance management analysis

 

(equipment maintenance management analysis, TPM)

 

1. Analysis of equipment maintenance management

 

The main content of equipment maintenance and maintenance: equipment cleaning, lubrication, fastening, adjustment, anti-corrosion and safety. In the diagnosis and analysis of this work, whether the maintenance system of the main equipment is put in place: (1) routine maintenance; (2) primary maintenance; (3) secondary maintenance; (4) how to do tertiary maintenance.

 

2.TPM (TPM, TOTAL PRODUCTIVE MAINTENANCE)

 

Full production maintenance system

 

The production and maintenance system for all employees refers to the production and maintenance system for all employees to participate in the overall life cycle of the equipment with the goal of improving the overall efficiency of the equipment. The basic idea of the whole staff maintenance system is "three all", that is, full efficiency, system-wide, and full participation.

 

Its tangible effect, improving equipment efficiency, labor productivity, reducing market complaints, reducing losses

 

Its intangible effect promotes institutional reform and enhances the sense of innovation for all employees

 

IX. Supporting means of on-time production and its operational basis

 

The JIT production method regards “maximizing profits” as the ultimate goal of business operation and “cost reduction” as the basic goal.

 

The JIT production approach seeks to achieve this by “eliminating waste completely”.

 

To eliminate waste, JIT's support means:

 

(1) Moderate production

 

(2) Number of flexible configuration workers

 

(3) Quality assurance

 

JIT's operational foundation

 

(1) Production synchronization

 

(2) Production equalization

 

(3) Shorten the working time

 

(4) On time procurement

 

(5) Rationalization of resource equipment preparation: workshop re-arrangement, U-shaped production line, “all-rounder”.

 

X. Basic work of traditional enterprises to convert to lean

 

(1) Strengthen basic management and follow the path of standardized management

 

(2) Improve the production process

 

(3) Improve production activities

 

(4) “Zero-centered” organization of production

 

(5) Solve the contradiction between many varieties, small batch production and cost reduction

 

(6) Implement computer management on management tools

(The above sources are from the Internet, compiled by Junsheng Mould)