August is the season of harvest, looking back over the past two years, we have done a series of management changes, really gain a lot, from research to production, from procurement to sales, from business to management has achieved remarkable results, but that has been past achievement, we must from now on, hard, continuous improvement, strive to be more perfect.
June 22, 2012 ~23 day, the company invited lean expert teachers are lean training for a period of two days to all levels of management, June 25, 2012 afternoon 2:00 to 5:00, Tianjiao pen industry Lean activities start meeting held in the company conference room on the third floor. Meeting was hosted by Han Zong himself, Han always emphasizes the importance of implementing lean production company, the necessity, urgency and purpose. In general, Han Dai instructions, in the production of deputy general Guan Jie's plan, Tianjiao pen industry started to lean production.
Lean production, the name of many employees had heard. In the last century seventy's, the Toyota Corporation of Japan to build up unique multiple varieties, small batch, high quality and low consumption of the Toyota production TPS (Toyota Production System), known as the "core" world class manufacturing technology, and gradually by many enterprises to adopt.
Characteristics of lean production is to eliminate all waste, the pursuit of refine on, continuous improvement.
The implementation of lean production Tianjiao purpose is the best quality, lowest cost and the shortest cycle to the demand of the market and make the most rapid response.
Quality assurance, is the lifeline of enterprise's production.
So in lean production quality is how to guarantee? In the lean production mode, the product is used in a "logistics" mode of production, thereby reducing the product placement by quality in stock; reducing repair bad and batch products in the production process of batch production caused by quality problems; to reduce the product to wait, in the process of production of semi-finished heap pressure caused by the quality problems.
Our previous quality management is "problems after check, inspection after processing", so often found when the product in question, our former process has produced large quantities of a product, and then on the products repair, there are quality problems, our management is "prevention control", using "potential failure mode analysis method" will control in the bud stage, eliminate the hidden danger in product quality.
Total quality management, automatic shutdown Poka Yoke, which is to protect the quality of the most powerful weapon of lean production methods, products through the early prevention and control, making it impossible to produce defective products. Poka-yoke means "for the first time that the things done", a direct result of the increase is the quality of the product, compared with on inspection to ensure quality, poka-yoke is starting from the perspective of prevention measures. This is the greatest degree of product quality guarantee.
Cost control, is the fundamental business survival.
With the global economic integration, the market competition is becoming increasingly fierce. For the market to provide high quality and inexpensive products, the enterprise only to reduce production cost, raise the level of management, lean production is undoubtedly the best cost control.
By analyzing the value of lean production flow, we can see the cost of the traditional mode of production waste, for example:
(1) logistics route is too long, resulting in transportation waste of time, and the connection between the existence of many waste, resulting in the operations of the production efficiency is very low;
(2) the production site has a large number of idle production equipment, occupy a lot of space, at the same time, the production site is very confused;
(3) the distance between the big production equipment, mobile operators and long distance, is not conducive to the operator in the improvement of work efficiency;
(4) multiple process section of the structure, make the logistics breakpoint, handling, stop, wait, stacking, inventory, looking for. The batch production, batch process in order to transfer, after the process is often wait;
(5) production line of large scale, production line capacity increase is not flexible, failed to keep pace with changes in the market orders, sometimes lack of capacity, sometimes in excess capacity;
(6) because of too many processes, although the difference between steps is small, however, will cause the operation cycle cumulative difference is big, the workload and the difficulty of processing distribution of different processes in different. Turns the batch on-line, each process of production is difficult to adapt to the rhythm, leading to imbalance;
(7) because of the production line in large scale, the switching line is difficult to. Logistics, information flow, process order interlocking, involves too wide, cost too much;
(8) the plant layout is the process section, so the moving material requires a lot of handling.
In view of the above conclusion, the lean thinking into the facility layout improvement, we to lean production eliminate non-value added activities as the goal, in-depth analysis and system, equipment of automation workshops were rearranged, the operators were also instill the idea of lean production, to produce according to determine the production cycle time. The improved basically realized "a stream" thought, balancing the entire production line, saving a lot of manpower, material resources and production space, improve production efficiency, reduce the cost of producing process, thereby providing a more powerful competitive products for the market.
To shorten the production cycle, market competition is a powerful weapon
In order to provide competitive new products for our customers in the most short time, we implement the APQP (advanced product development planning control program), new products from development to production, periods of less than 50 days.. Using our production system lean production "is a stream, uninterrupted production model", through the management method of flexible production, fast switching, visual Kanban management, TPM etc., products will be part of the production period is shortened to 7 days, provided a powerful weapon for competition in the market.
Through the above quality, cost, cycle and lean production. Lean production can be seen, the importance, necessity, urgency and purpose.
Sometimes will ride the wind and waves, the White Sea Ji yun-fan. We lean production work has taken a solid first step, but the future still need to constantly strive to. We must uphold the concept of lean production world without end, we found, transformation, continuous innovation, constantly good governance, sustainable development, and strive to build the company into a leader in the pens industry.