By taking this course, you will be able to:

● Skillfully use the ten sharp tools for production site improvement; ● Master the measures to rationalize the handling; ● Understand and recognize the handling convenience coefficient; ● Understand the impact of environmental indicators on work efficiency.

Ten sharp tools for production site improvement

I. Sharp tools 1: process flow check

The actual process exists in the various work of the enterprise, through the drawing of the flow chart, it will be easier to find the problem, so as to improve and improve.

1. Flowchart

Flowchart composition

Flowchart consists of lines or squares, the so-called decision box. The sequence of work is listed before it is checked, reviewed, audited or approved.

Through the flow chart of the check will appear two results: qualified through; failed to beat back to redo. Flowchart drawing

Drawing the flowchart, the diamond as a gatekeeper process, the square as the actual operation of the link, with a set of arrows connected to the link in which there are technical standards, process regulations, user requirements, relevant documents, etc., marked with a wavy line. That is, the simplest symbols for the most complex processes to be described.

The application of flowchart is relatively simple, just like repairing the inner tube of a bicycle, you can also draw a flowchart, so as to solve the problem faster, which is the importance of the process.

2. Process jingle

In the manufacturing enterprises, the process is adapted into a jingle:

"Box diamond plus lines, the use of a treasure, any of your process is more complex, a clear perspective do not want to escape, plus a plus, more secure strict checking, reduce a minus, in exchange for a big improvement in efficiency, through a pass, the department's functions can not be empty, a fixed must be, rules and regulations do not quarrel! The first is that there are rules and regulations not to quarrel."

Interpretation of the jingle

In the manufacturing enterprises, as mentioned in the jingle, some places flooded, lies in the place of the gatekeeper loopholes, the need for this part of the strict control; departmental shirking, lies in the failure to build bridges to solve problems through the horizontal.

Shun Jie's solution to the horizontal problem

The problem in the enterprise, can be solved horizontally should try to solve horizontally, and do not report to the leadership. Problems reported to the leadership have two disadvantages:

First, the route is too long. Originally, they can be resolved, but the detour layers of reports, and then conveyed one by one, so that the route is too long; Second, easy to cause resentment. For example, the leadership accuses an employee of always out of the problem, the employee's first thought is to whom the complaint, at this time it is particularly easy to cause resentment of employees.

3. Process case

Case

Simplification of the workshop process

A steel plant to produce sieve, sieve volume is huge, especially the flange, the need for a very thick steel into a square structure, the requirements of the material will be bending, and then welded, after the two ends of the two flanges, flanges and holes, and then welded on it.

Figure 2 shows a workshop process.

Figure 2, a workshop process flow diagram

From Figure 2, the workshop process is: under the material shop, sent to the equipment shop group, and then submerged arc welding, sent to the flange, and then check, come back to weld and then check, and finally sent to the processing workshop. During the period, because of the two units involved, in order to separate responsibilities, more inspection links.

In the lateral view, the two workshops are more than 50 meters apart, in accordance with the above provisions, back and forth to travel more than 200 meters away, and there are many internal workshops. Because of the two units involved, the unit often prevarication, one side of the urgent as a fire, the other side is slow and methodical. A simple job that used to take two people three days to do seemed unreasonable.

So, the enterprise to change the process, from start to finish by the undercutting workshop to complete, that is, by the undercutting workshop undercutting, bending, submerged arc welding, on the flange, weld flange, checking, send the workshop, which is more than 200 meters of the road do not need to go back and forth, tug-of-war shirking no longer occurs, and now 2 people as long as a day to do it all, the efficiency of the work has increased by a factor of 3.

Product production process of foreign trade enterprises

A foreign trade enterprises to produce products is divided into four major steps, as follows:

First of all, the foreign customer sample requirements. If it is a new product, by the general manager of the special review and approval, the technical department puts forward a new product development program, program review qualified to develop cross tools and samples, samples preview qualified to the marketing department, sent to the customer. If the original product, by the production department to make samples, after passing the inspection and then sent to the customer, the customer receives the product and puts forward modifications.

Secondly, sign a contract of intent, and a formal review of the contract of intent. If there is a profit, it will be implemented, no profit will be abandoned.

Once again, after making the decision to execute the contract decision, sign a formal contract order.

Finally, after review by the general manager, the production plan. Before making the production plan, inventory analysis, capacity analysis, determine the supplier, etc., and decomposed into sub-plans for each workshop, such as the plan of the stamping workshop, welding workshop. Each workshop gets the plan and then collects the material, cuts it, discharges it, and after a process, the first inspection tour of the workshop director is put into the warehouse. In addition, the products of these two workshops are prepared for pickling, and go to the pickling workshop for degreasing and pickling. At the same time, the suppliers continue to deliver, packaging, standard parts, plastic parts, raw materials, each after the inspection into the warehouse, assembly workshop one hand to receive products, one hand to receive packaging materials to start assembling, after the inspection tour qualified, and then after the sampling inspection qualified, and foreigners to determine the delivery date, and then set warehousing, customs clearance, shipment, and tax refunds.

This is a huge systematic process, well organized, not a single thing.

From the case, it can be seen that through the flow chart, you can find faults and improve the enterprise from top to bottom, left and right, front and back. Consider the problem from the overall process, do not get entangled in only one aspect, it can be seen that the process is the most effective way to solve the problem from the overall.

Two, Sharpshooter II: plan on a tune

1. Reasons for adjustment

Enterprise site layout, plant layout, equipment arrangements in the early stages of plant construction is very reasonable, but with the increase in orders, equipment, increased production, plant expansion, the original arrangement will become more and more irrational, and at this point, especially the need to once again adjust and clean up, so as not to reduce the efficiency.

Case

Process Layout Improvement

Figure 3 is an enterprise unreasonable production process layout.

Figure 3 Unreasonable Process Layout

As shown in Figure 3, raw materials from the raw material heap collar raw materials, through the lathe A lathe B, to reach the milling machine 2, and then to the lathe 3, to the grinder 4, grinder 5, grinder 6, grinder 7, grinder 8 ......, the handling takes a lot of time, and the transportation and handling does not produce efficiency and does not add value to the product.

Figure 4 Improved Process Layout

The diagram will be modified to move the material storehouse and semi-finished goods storehouse to the plant, and then reset the installation order of the machine tools, the result is that: from the raw material storehouse to receive the raw materials, through the lathe A, lathe B, to the milling machine 2, lathe 3, go around and send it to the semi-finished goods storehouse, so that the route is shorter, occupies less time, and the efficiency of taking the square on the spot is high, and a large amount of cost is saved.

2. Principles of adjustment

Manufacturing enterprises to adjust the most important principle of the floor plan is "U-shaped layout method", which is also the most advanced layout method. U-shaped arrangement method, that is, in the plant, all the equipment in accordance with the direction of the logistics of a zigzag row, in order to realize the shortest route transportation. u-shaped arrangement method in the factory plant, equipment placement occupies a very important position.

3. Cellular production

Manufacturing enterprises from the production of batches of large quantities of production, and gradually transformed into a multi-species small batch production, therefore, the small assembly line to replace the long assembly line. Among them, the small assembly line is also known as the "cell", the so-called cellular production, refers to several pieces of equipment together, a few people combined to form a small production unit.

The advantage of cellular production is that it can be adapted to the current changes in the world market, turning a long assembly line into a small combat unit.

Three, Sharpshooter III: production line counts

1. Change the way of moving

Currently, the production operation moving way is mainly a process connected to another process, resulting in inconsistencies in the front and back of the process work. The reason does not lie in the workers, but in the production plan, the usual mode of transportation.

Four, Sharpshooter IV: action elements to reduce a reduction

1. Action analysis

For labor-intensive enterprises or assembly as the main enterprise, many processes are completed by manual operation. However, the inspection of the operator's movements is measured by the labor attitude, and the results show that half of the labor movements are redundant. Therefore, companies need to analyze the movements.

The role of action analysis

As a production unit using three actions to complete the entire action is very significant. For example, Auntie Su's Food Company in Suzhou, which specializes in selling handmade wontons and dumplings, adopted the three-action dumpling wrapping method to increase the number of dumplings wrapped from 50 to 300 per worker per day, increasing efficiency by six times.

The emergence of action analysis Action analysis first appeared in the United States.

Case Study

The Origin of Motion Analysis

Peter noticed that when a worker was laying bricks, each person's motion was different. Some people needed 18 motions to lay a brick, while others needed 6 motions to lay a brick. In the 6 actions, there is a redundant action, that is, as long as 5 actions can lay a brick. Peter in the whole site to promote the five-step bricklaying method, workers under his guidance to use more and more skillful, bricklaying speed skyrocketed, from the original average of 120 blocks per person per hour to 350 blocks, nearly three times the efficiency.

Peter's friend Taylor was very encouraged, three months later, in the United States, a steel company to do shovel test. The original steel mill workers' shovels were seven long, eight short, different sizes, all brought by employees from their homes, there is no uniform standard. Taylor wondered whether the efficiency of coal mining depends on the size of the shovel. If in order to improve efficiency, the shovel will be made very large, a shovel 50 pounds, two shovels 100 pounds, three shovels 150 pounds, so the efficiency is very high, but easy to wring the waist bad; if the shovel will be made smaller, brisk is brisk, like making a frying spoon so small, dry a day to ensure that the waist will not be tired, but not out of the efficiency.

After repeated tests, to get the famous shovel answer, found that when the shovel 21 pounds when the highest efficiency, high to the original need to be done by 400 to 600 people, 140 people can be completed.

By the case can be seen, the action to study, analyze, work efficiency can get no cost straight up.

2. Basic Principles of Movement Elements

There are ten basic principles of movement elements: try to work with the feet and the left hand, work with both hands at the same time, work with both hands in the opposite direction, work with small movements as much as possible, put materials and tools in the reachable area as much as possible, work with as little as possible, combine two or more tools into a single one, utilize a holder, keep a proper height, and keep a proper height, and keep a proper height, and keep a proper height, and keep a proper height, and keep a proper height, and keep a proper height, and keep a proper height, and keep a proper height. Maintain proper height, Interpretation of the action waste song.

Try to work with your feet and left hand

The habit of working with the right hand makes the left half of the brain more developed. It should be reversed to think with the right half of the brain, freeing up the right hand and using more of the left hand and foot, such as some switches, which can be stepped on with the foot, thus freeing up both hands for work.

Working with both hands at the same time

Working with both hands at the same time, don't rest both hands at the same time, and try to find a way to do something else with your hands when you are free.

The hands move in opposite directions

The hands should move symmetrically, not in one direction, in order to avoid too much impulse force and problems.

As much as possible with small movements to complete

In manufacturing production, the human arm is divided into five grades: first, to move 25 mm, moving the fingertips is enough; second, to move 50 mm, to move the wrist; third, to move 150 mm, to move the small arm;

fourth, to move 300 mm, the middle part of the big arm to participate in the activity; fifth, to move 450 mm, then the whole arm is to be moved.

Scientific calculations show that moving 25 millimeters as long as M1, M that is, MOD, that is, the number of human movement, is the most basic, the smallest movement on the human body time spent, for 0.129 seconds. It can be seen that the smaller the movement the faster it is completed, the larger the movement, the more time is wasted, so the task should be completed with the smallest movement.

Materials and tools should be placed as far as possible within reach

Materials and tools should not be placed far away, but should be placed in the nearest place within reach, i.e., the center of a person's mid-axis, with the length of the arm as the radius, and the place where the hand reaches out and can reach. Among them, the chest part is the most important gold, the eyes to see the most clear, the hand is the most flexible, work should be done in the chest.

The smaller the number of basic operations, the better

The smaller the number of basic operations, the better, to exclude unnecessary movements, the movement distance should be the shortest, and to determine the sequence of movements, so as to rhythmically and automatically.

Combining more than two tools into one

Combining more than two tools into one, or utilizing a container for picking up materials reduces the workload.

Utilizing a keeper

To remain in good condition for a long period of time in combination with an object, i.e., an object and a person, a keeper must be utilized. Back support is one type of keeper.

Keeping the work point at a proper height

To reduce fatigue, the work point should be kept at a proper height, not too high or too low.

Utilizing inertia and gravity

It is very important to make full use of inertia and gravity, and to use the power unit to speed up the movement.

3. Waste of action song

Manufacturing companies will produce the action of the action of the action of the waste of song, through the analysis of many superfluous action will be found:

One-handed work is inefficient, the two hands idle does not earn money, too much time is spent on action, walking more efficacy is reduced, the height of the body is not appropriate to injure the turn to move the money is wasted, the two-handed exchange of action is slow, redundant action to add confusion, the unknown skills to be outlawed, stretching arms and bending to be The first thing you need to do is to get your hands dirty.

The reason for the wasteful song, "Stretching the arms and bending the waist should be streamlined" is that stretching the arms itself takes a long time and is easy to twist the waist, so it should be done less often; at the same time, bending the waist for a little too long is prone to cause injuries to the movement, so it should be streamlined as well.

Five, sharp five: handling time and space pressure

Handling in the entire production process occupies a very important position, so the handling of the compression of time and space.

1. Shorten the importance of handling time and space

According to statistics, the freight cost of products accounted for the cost of the entire product cost of 20% to 40%, in the field production, handling and stopping time exceeds the processing time, 85% of the hidden safety hazards occur in the handling process, handling is not handled well, the defective rate of the product can be made to increase by 10%. Visible, handling in the production process is very important, and shorten the handling time and space is very meaningful.

2. Handling convenience factor

Figure 5 shows the handling convenience factor description.

Figure 5 illustrates the coefficient of convenience of handling

From Figure 5, the coefficient of convenience of handling is divided into five grades from 0 to 4:

Grade 0. Grade 0 is the most inconvenient. Parts, accessories, raw materials are placed in a haphazard manner, need to be moved when you need to box before transporting.

Level 1. Has been loaded into the box, container, lift the box that is to go, the convenience factor is 1. 2 level. Under the box to do a bracket, forklift can be forked away, convenience factor is 2.

3 level. Loaded in the forklift a push away, more convenient, handling factor is 3.

4 level. 4 level is the most convenient and the highest stage of handling, that is, no handling, the use of slides and ramps, slides or conveyor belts will be taken away from the product.

3. Rationalization of handling

Rationalization of handling mainly includes six requirements: reduce the number of handling, high-speed continuous handling, the use of workstation equipment, rational planning of the factory layout, rational planning process, handling method civilization.

Reduce the number of handling

Rationalization of the first requirement to reduce the number of handling. The behavior of moving around must be reduced, eliminating the second handling, so that the placement of things in mind, and once in the right place.

High-speed continuous handling

High-speed continuous handling, that is, the use of mechanized handling, the use of mechanical equipment, high speed continuous handling. Utilization of workstation equipment

Workstation equipment refers to the protection of parts, accessories, semi-finished products in the handling of the way not to be bumped, scratched special tools, including shelves, baskets, boxes, pots and so on. The use of workstation equipment can be effectively done by the handling of goods without loss.

The role of the bracket. The most ingenious workstation equipment in daily life is the bracket, the bracket has three roles: First, protection. First, protection. Protect the objects being moved from harm.

Second, counting. How many empty brackets, can only fit how many, so counting is easy and convenient. Third, easy to carry. Using the brackets you can take more than one at a time, making it easy to carry.

Selection of workstation equipment. In the factory, there are many need to workstation apparatus to complete the work, if there is no suitable workstation apparatus, the handling process can not be effectively completed.

Six, sharp six: man-machine efficiency mentioned

1. man-machine cooperation

Man and machine is a pair of contradictory field production, only people and equipment to work closely with each other to improve efficiency, otherwise it will result in unwarranted waste.

Case

The effect of human-machine cooperation

A production company, people in the preparation of parts, the machine is empty, and when the machine is loaded with parts to run, but people are idle, after the statistics, 10 minutes of work, people only work 6 minutes, 4 minutes of rest, the machine is the same, resulting in the efficiency of the people and the machine are only 60% of the start.

Through improvement, the time for storing and preparing parts is adjusted so that man and machine can work together effectively.

The production process becomes: the person first loads the parts, the machine is loaded with parts, when the machine is working, the person is correcting and storing the parts, and so on, there is no delay between the person and the machine, and the efficiency of the human-machine cooperation is improved.

2. Ergonomics

The so-called ergonomics, that is, the relationship between man and machine. People and the surrounding machinery, equipment, equipment, furniture, seats and benches, is to promote and promote each other's relationship, the relationship if not dealt with properly, not only to the people caused by the harm, but also reduce the efficiency of the work.

Human-machine engineering mainly on three specific requirements: height, environmental indicators, color. Requirements for the height

The height of the items placed, the height of the chair of the workbench, should be suitable for the operation of the characteristics of the working body, so that the workers in the operation or placing the items as far as possible without tiptoeing and bending over. The height of the chair, desk, for example, the U.S. standard is 80 centimeters, while the best standard for Chinese desks should be 75 centimeters, the best height of the computer desk is 70 centimeters.

Requirements for environmental indicators

Environmental indicators include temperature, noise, humidity, cleanliness of the air.

First, temperature. The most suitable temperature is 22 to 25 degrees, people work most efficiently at this temperature, the most clear-headed, higher than 25 degrees or lower than 22 degrees, will make people reduce efficiency.

Second, noise. Production unit noise generally can not exceed 75 decibels, in the dead of night can not exceed 35 decibels. Third, in addition to temperature and noise, humidity and cleanliness of the air.

Tips

Environmental indicators include: ① temperature; ② noise; ③ humidity; ④ air cleanliness.

Requirements for color

Color classification. Colors are divided into two categories: warm and cool. Among them, orange-red is the warm pole, the hottest color; followed by red, yellow, pink, and light green; the bluest is the cold pole, then light purple, light green, dark green, and deep purple.

The relationship between people and colors. When a person sees a warm color, his heart beats faster and his blood pressure rises, creating a feeling of warmth; when he sees a cool color, his heart slows down, his blood pressure drops, and he creates a feeling of coldness.

Color symbols. Different colors symbolize different contents, take green color, yellow color and purple color for example.

First, the color green. Symbolizes life, safety. Human optic nerve in the green environment is quickly restored, such as reading a book tired look at the green woods, eye fatigue will soon be restored. In the green environment will make people linger, slow down the rhythm of movement.

Second, yellow color. In China, the color yellow symbolizes royalty and nobility; while in the Jewish state, only prostitutes and Judas wore yellow. It can be seen that different colors symbolize completely different meanings in different countries.

Third, the purple color. Purple color in the Chinese mind to symbolize red to purple, such as the prime minister in purple robes. Mauve color is the most comfortable, mauve environment can improve work efficiency.

Seven, sharp seven: key routes to shrink

1. The concept of the key route method

The production process has many processes that need to be divided and combined, resulting in the formation of many triangles in the actual production process. These triangles are the focal point and the core of the production imbalance that constitutes the basic elements of a company's production imbalance.

Case

Production process of parts

The process of the parts in Fig. 6 is as follows: first produce the pipe, process the pipe to produce round bars, wait for the round bars to be produced and then drill the holes, and weld the holes after they are drilled.

Figure 6 parts production diagram

For simplicity, the symbols are used to replace the process, if A with 30 minutes, B with 20 minutes, C with 25 minutes, D with 15 minutes, will be done with the parts need 60 minutes, that is, 20 plus 25 plus 15.

In this assembly line solidly do, not a minute delay, which is called the critical route, each delayed one minute, the whole process increases by one minute, if one minute in advance, the whole journey is shortened by one minute, but in this line 30 plus 15 is equal to 45, in 45 minutes when the parts have not been done, so there are two choices, you can do 30 minutes and then rest for 15 minutes; you can also rest for 15 minutes and then work for 30 minutes, a couple of minutes of the impact is not big, but if it is a huge project, to rest for half a month and then work again, this phenomenon can never be eliminated if there is no way to balance it. Therefore, it is important for leaders to develop the right production plan.

From the case, it can be seen that as long as a triangle can be dissected in the production process, ways can be found to reduce the imbalance between each other, i.e., the Critical Route Method, also known as CPM.

2. The role of the Critical Route Method

Using the Critical Route Method, the schedules of the various engineering plans and projects as well as the total schedules can be accurately calculated, and the time can be accurate to the hour and the minute. The larger the project, the more obvious the results achieved by using this method for calculation, projection, and optimization.

3. Learning the Critical Route Method

There are three things to do when learning the Critical Route Method: to draw, to calculate, and to optimize. Can draw

The so-called can draw, is based on the known constraints between the processes, draw the relevant diagram. Can calculate

Can calculate, that is, on the basis of can draw, can quickly calculate the key route, that is, the longest schedule route. Critical routes are bottlenecks, and bottlenecks constrain all production. It's important to note that the differences on the critical route map are the entry point to solving the problem.

The goal of figuring out the critical route is to shorten the entire production process so that each process is as balanced as possible, eliminating the busyness gap. Optimization

After the bottleneck is found, it is important to find a way to optimize it, to shorten the date, to shorten the investment, and to try to optimize time and cost. There are two ways to optimize: time optimization and cost optimization.

Time optimization. Time optimization, means in the case of manpower, equipment, capital guarantee, not counting the economic account, only consider the shortening of the construction period, no other.

Time optimization is usually used when encountering mega, politically significant period. Such as the Olympic Games, August 8, 2008 is a good day, you must raise the country's efforts to pay for it; and then the Wenchuan earthquake, mobilizing 100,000 troops within three days, water, electricity, roads, communications, go all out to rescue and relief efforts. Time optimization is a special case, in the usual circumstances, generally can not only consider the time, more should consider the quality.

Cost optimization. The so-called cost optimization is to shorten both the duration and cycle time, but also save money. Not only to calculate the political account, but also to calculate the economic account.

There are two types of costs in engineering: direct and indirect.

First, direct costs, that is, costs directly used on the project, such as raw materials, steel. Direct costs do not change over time.

Second, overhead, mainly refers to the management fee, management personnel pay salaries, bonuses, to have office expenses, do a day's work to receive a day's salary, the longer the delay, the higher the cost.

The main compression of overhead costs under the premise of cost savings.

Second, sharp nine: visual management to see

1. Overview of visual management

Connotation of visual management

The so-called visual management, also known as the "management of the visible", is the intention of the leadership, technical instructions, user requirements, reminders of matters, etc., with the most Simple patterns, lights, colors, to play a clear reminder of the role.

Visual management is to use the image of intuitive, colorful and appropriate visual perception of various information to organize on-site production activities, to improve labor productivity of a management approach.

The role of visual management

Through charts, signboards, labels, objects, lights, colors, and other visual tools, to explain, cognition, warning, judgment, action and other functions, so as to make the information **** there, the problem of transparency.

The main points of visual management There are six main points of visual management: First, it should be recognizable from a distance; second, marking the place where you want to manage; third, it is easy for anyone to comply with, and easy to change;

Fourth, it is visible to anyone; fifth, it makes the workplace bright and clean; sixth, it is transparent, visual, and standardized.

2. Visual management of three

Through visual management, it is easy to know whether the production is normal or not, and it helps to make the workplace brighter and cleaner. In a nutshell, there are three main visual management: Transparency

Transparency, is the original opaque into transparent.

The boiler, for example, how much water inside can not be seen when the glass tube is installed, so that it is transparent, and at the same time in the glass tube on the addition of two cordons and alarms, with wires connected to the water is lower than a certain level, higher than a certain level of water, will be issued an alarm, so that the level of visual management to raise the grade.

Visualization

Visualization, is the original use of other sense organs to feel, become able to see.