Xiamen Low Voltage Electrical Equipment Co., Ltd. is a joint venture established by the Group and Xiamen Electric Control Factory in March 2019. It mainly produces air circuit breakers imported from Italian companies and low-voltage switch cabinets imported from Germany. While introducing advanced technology, the company also introduced the production management model of European and American enterprises. Here are some of our experiences and experiences in production operation and management to communicate and share with you.
Our company has always reflected on the following questions: Has our production achieved all its potential? Is there still room for improvement? Do our employees still have potential to tap? With these questions, we have carried out many new projects Tried it and had great results.
On-site management mode
. One-flow production
The so-called one-flow production refers to the reasonable configuration of the work site, personnel, and equipment (workbench) so that there is at most one in-line production process for each process during production. From the beginning of production to the completion of finished products or finished products, there is no work in place for placing the products or packing them into boxes.
Because all parts are processed outsourced, the production workshop only performs final assembly operations. Therefore, in view of the characteristics of this assembly-type production line, we arranged it according to the process of processing the workpiece (vertical arrangement). The processes are connected with each other to form the entire production line. The advantage is that the intermediate inventory is small and the time from input to completion is short.
. Trolley production method
This method is designed according to the characteristics of the industry. First of all, most of the components of the circuit breaker are steel plate structures. The terminals use silver-plated copper bars. The overall weight is heavy. Frequent lifting operations will increase the unsafety of the operations. factors and reactive power loss. Secondly, during the production and assembly process, a variety of spare parts need to be assembled. The trolley can place the corresponding accessories and move them randomly, which is convenient and flexible. Moreover, after adopting the trolley production method, all assembly can be completed on the trolley without any need. Add another workbench. The advantage is that it not only eliminates the installation of assembly lines and large lifting equipment, but also reduces the movement and movement during the handling process.
.Ingredients production method
Since the production adopts the order-based production method, the model of each circuit breaker and the configuration requirements of each accessory are different. If the materials for each process are collected by the workers in the workshop, not only the Assembly operations are frequently interrupted and are prone to errors. In addition, the assembly of basic parts has always been a bottleneck in the production process. If more operators are required to take materials, it will directly affect the production progress. Therefore, we have specially set up a full-time batching staff to carry out the batching and accessories assembly of water spiders (very flexible small water animals). The advantage is that it not only improves production efficiency but also eliminates errors.
Self-improvement and improvement of management methods
. Pull production
The first thing to do is to change the production method from the traditional push type (that is, the entire production process is pushed from the front process to the back process) to Pull type (that is, the entire production process is pulled from the rear process to the front process). To put it simply, production starts entirely from the demand of the order. The assembly of the product is determined by the order demand information and then the processing of parts is driven. For this reason, we have set up a benchmark inventory in each link of the production system. After receiving the order, the accessory assembly process directly takes parts from the benchmark inventory to produce finished products, inspects and packages them for shipment. The assembly of basic parts in the previous process uses the kanban as quickly as possible to complete the inventory. The operating mechanism and contact pre-assembly will be replenished in a timely manner and the corresponding inventory will be replenished in a timely manner. After the implementation of pull production, the product not only achieves timely and appropriate production but also shortens the delivery time of orders. The key point of its implementation is that the inventory of each circuit breaker should be calculated based on production and in principle the order quantity should be controlled within about one day to reduce the baseline inventory.
. Kanban management
This kind of kanban is similar to the kanban between processes, except that the previous process is not an internal process but a supplier. At present, we divide parts into two categories for operation
The first type of standard parts (including screws, nuts, washers and other standard parts)
Such parts can be displayed in two boxes. The management set up two material boxes at the production site, each box containing about one month's usage (you can keep more inventory for small screws with low value). Suppliers will check with the company regularly every month and if any empty boxes are found, they will be replenished immediately.
The second type of non-standard parts
This type of parts uses the order management system for kanban management. The system can simultaneously query kanban status and operations, receive kanban, move kanban, send kanban, kanban inventory, etc. Operation
Prerequisites for implementation: The quality of such outsourced parts should be guaranteed and can basically be included in the scope of inspection-free products.
Implementation points
. First evaluate and determine the capacity and number of each kanban based on the size of the material pallet and the amount of parts used, and determine a safe ordering point
. The company's purchasing staff conducts operations through the order management system Online kanban ordering Once the information shows that the inventory has reached the order point, a new order can be placed
. Suppliers can check the kanban order status online and produce according to the kanban requirements and deliver goods on time.
Advantages: The online order management system is convenient and fast. Kanban management can be implemented to minimize inventory and achieve timely and appropriate production.
. Packaging standard management
Standardizing parts packaging and promoting the use of turnover boxes is another measure in production management. Compared with the use of original pallets, the use of turnover boxes has the following major advantages
⑴ It is conducive to fixed point, fixed volume, and quantitative promotion. We stipulate the packing capacity of turnover boxes and require suppliers to provide packaging on both sides of the box. The identification content includes order, quantity, production date, material number, supplier, weight and other contents, which facilitates the operations of sending and receiving materials, material inquiry and intermediate inventory counting in the warehouse.
⑵Implementation of visual management Different suppliers require the use of turnover boxes of different colors and code identification on the boxes so that once a problem occurs, the problem supplier can be quickly identified.
⑶Meet the requirements for identification and traceability. The labels on both sides of the outer box clearly indicate the production date, order number and other important information of the material. Once there is a problem with the parts, it is very easy to trace them back.
⑷ Improvements in industrial engineering using large pallets that cannot be placed directly on both sides of the workstation due to their large footprint. After switching to turnover boxes, we made a special trolley that can stack materials and place them next to the workstation to save money. It saves warehouse personnel and operators time when sending and picking up materials, improving work efficiency.
⑸Significant savings in the cost of packaging materials for suppliers. Suppliers in surrounding areas are required to use turnover boxes to save the waste caused by the use of disposable cartons. Some suppliers have made such calculations and reused turnover boxes more than ten times. After that, the cost of using cartons will be the same, and there will be no need to invest in new packaging, saving a lot of costs.
⑹ Keep the production line clean and beautiful. Reducing the use of cartons is equivalent to reducing waste. The workshop production line becomes cleaner.
Implementation Points In order to ensure the rapid and effective implementation of packaging requirements, we included this content as one of the important items in the assessment of supplier cooperation, and the results have been good after implementation.
.Improvements
We have made reasonable improvements ranging from the layout of the production line and the analysis of movements to the smallest screw. Because it is an assembly-type production line, a large number of screws and washers are required for assembly. We have made statistics like this. It takes about seconds to assemble a screw and a gasket. If we calculate that each circuit breaker needs to be assembled with such screws, nearly an hour of man-hours will be wasted throughout the year. For this reason, we have developed a new supplier to provide combined screw sets with gaskets that do not fall off, are convenient for transportation, and have good use effects, which greatly improves production efficiency.
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