For manufacturing companies, effectively improving production efficiency is the key to reducing production costs.
- Solve the bottleneck production process
There is a motto: "The bottleneck process determines the capacity." As we all know, balance is an important guarantee for the production schedule. Among the 100 links, as long as one link is inefficient, the efforts of 99 links may not solve the problem of backward progress. Therefore, grasping the production beat of the bottleneck process and continuously improving it is a magic weapon to improve efficiency.
The commonly used five-step method for removing bottlenecks: ①. Find the bottleneck of the system; ②. Decide how to tap the potential of the bottleneck; ③. Support the bottleneck resources; ④. Untie the bottleneck (bypass, replace, outsource); ⑤. If step four breaks the original bottleneck, then go back to step one, continue to improve, and find new bottlenecks again.
- Implementation performance, piece rate
In fact, management is the distribution of benefits, and a good distribution is a win-win and multi-win. I have been to a company with tens of thousands of people. There are more than 10 IE engineers in their company. They study how to improve efficiency every day, but the efficiency just cannot be improved. My statement is very simple, "On-site efficiency improvement is not to achieve the company's interests at the expense of employees. Such improvement is doomed to fail." It means: "IE engineers are studying how to make employees do fast and well, but employees do fast and well, relatively speaking, they work harder, and employees work harder. If the salary does not increase, he will definitely not do it."
In fact, the valuable wealth of production management is employees. The core of employees is motivation, and the focus of motivation is to meet the needs of employees.
- 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 the efficiency more than 3 times. In the past consultations on rationalization of production, it was found that general enterprises spend a lot of resources to do the first and last parts, full inspection, and special inspection, but ignore the self-inspection and mutual inspection of employees.
Employee self-inspection, employees should do in the production process: ①. "Confirm the processing quality of the parts in the previous process"; ②. "Confirm the technology, process requirements and processing quality of this process"; ③. "Confirm delivery The completion quality of the next process".
There are generally two quality management principles for employees’ mutual inspections: Principle 1. When the first process provides products to the second process, if the second process detects defective products, the second process has the right to Process index claims. The claim index here is quite amazing, increasing exponentially. The second principle is that after the first process provides products to the second process, if the second process does not detect the defective products that have been stored, and it flows to the third process, the third process will be deducted Bonus for the second process...
By designing a series of systems to allow employees to do self-inspection and mutual inspection, not only can the efficiency be greatly improved, but also the inspectors can be greatly reduced.
Fourth, establish a flexible production organization system
With the production organization structure and operation as the main body, a series of comprehensive application activities of the form and elements are launched. Its final purpose is to enable all personnel to develop under the premise of ensuring that the production tasks are completed in good quality.
- Reach the plan and increase production
Managers should pay more attention to:
- The preparation work before production must be sufficient (personnel, machine, equipment, material, process, site).
- Control the pulling speed properly, keep the personnel with a moderate sense of urgency when working, and do not relax.
- Confirm the output in time and fill in the kanban.
- Control defective products, correct them in time, stop working if they are invalid, find another suitable person or find the correct way to operate.
- Incoming defective products, confirm the return, replenishment and replacement of defective products in time.
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