I talked about the production process of mobile phones in the early stage, and today I will talk about what management needs to be done in the production process to ensure the yield of the product?
Have you ever heard of the term "man-machine-material method environmental testing"? The Human Machine Material Method is a total quality management tool derived from the Toyota Production System (TPS), also known as the "Five Management Principles" or "Five Elements". It represents people, machines, materials, methods and environment, which are the key factors that affect product quality in the manufacturing process.
Case Study: Suppose that in an electronic product manufacturing enterprise, the practice of man-machine-material law can be reflected in the following way:
People: The company regularly conducts professional skills training for employees, including operation skills, safety knowledge, quality control, etc., to ensure that each operator can master the assembly process before product production, and can find and solve problems in a timely manner, implement continuous career development plans, and cultivate employees' multi-skill and innovation capabilities; Encourage front-line employees to put forward suggestions for improvement and improve product quality.
Machine:
1.Equipment procurement and selection: According to the production process requirements and long-term development planning, scientifically and reasonably select the appropriate production equipment, consider the performance, efficiency, energy consumption and maintenance cost and other factors, ensure that the equipment is correctly installed in accordance with the technical requirements provided by the manufacturer, and carry out strict and meticulous debugging to ensure that the equipment meets the design standards and technical parameter requirements. (Train operators in equipment operating procedures, safety specifications, etc., to ensure that employees can use equipment correctly and proficiently for production operations).
2.Equipment inspection and maintenance: formulate and implement a strict daily equipment inspection system, timely discover potential equipment failures and hidden dangers, and regularly carry out preventive maintenance of equipment, including lubrication, cleaning, fastening, etc., to prolong the service life of equipment;
3.The use of modern information technology means to monitor the operation status of equipment in real time, to achieve equipment failure and health management (PHM), the establishment of a rapid response mechanism, once the equipment failure can be quickly diagnosed and repaired, reduce unplanned downtime.
4.Spare parts management and inventory control: Reasonable planning of spare parts inventory of key parts and wearing parts to ensure that they can be quickly replaced in case of emergency, and reduce the risk of production stagnation caused by insufficient spare parts, 5By developing "machine" management measures, companies can effectively reduce costs, improve product quality and production safety while maintaining efficient operation of equipment.
Material:
1.Material Requirements Planning (MRP): According to the production plan and product structure, formulate an accurate material requirements plan to ensure that the material ** matches the production demand.
2.Procurement management: select qualified suppliers, sign long-term and stable supply contracts, ensure stable and reliable material quality, strictly control the procurement cycle, and reduce the risk of inventory backlog or shortage.
3.Material warehousing management: Implement strict acceptance procedures for the received materials, including quantity counting, quality inspection, etc., to ensure that the warehousing materials meet the requirements; The information system is used to code and register the material to realize the transparency and accuracy of the material information.
4.Inventory management: Implement reasonable inventory strategies, such as ABC taxonomy, adopt different inventory control means for materials with different values and turnover rates, use advanced storage facilities and technologies, optimize storage layout, and ensure the safety, cleanliness and traceability of material storage.
5.Material outbound management: according to the production order or picking list for material issuance, follow the first-in, first-out (FIFO) principle to avoid material expiration and invalidation, regular inventory, check the consistency of physical and book data, find and deal with discrepancies in a timely manner.
6.Material handling and distribution: design efficient logistics paths and handling processes, reduce unnecessary material handling losses and waiting time, monitor the use of materials in the production line in real time, implement kanban management or JIT (just in time) just-in-time production mode, and ensure that materials are delivered to the work site on time.
7.Waste and utilization: Establish a waste system, reasonably classify and collect the leftovers and non-conforming products generated, and reuse or dispose of them in compliance as much as possible.
Method: including work instructions, operating procedures, inspection standards, process flow, work flow, management regulations, etc. It covers the technical requirements and management specifications of the whole process of design, processing, assembly, inspection, etc., to ensure that the products can be produced in accordance with the established best methods and standards in each link, so as to ensure the consistency and stability of product quality, eliminate waste in the production process through value stream analysis, and shorten the product manufacturing cycle.
Environment: Keep the production site clean and orderly, reasonably lay out the production line to reduce handling and waiting time, and control the temperature, humidity, cleanliness and other conditions of the production environment to meet the production needs of precision electronic products. For example, a constant temperature and humidity system is set up in the electronics workshop to avoid dampness or failure of components due to environmental changes.
Through the above cases, we can see that the man-machine-material method not only focuses on the quality of a single link, but also emphasizes systematic comprehensive management and continuous improvement, so as to achieve the efficient and stable operation of the entire production system and the steady improvement of product quality.