From a lean point of view, manufacturing is the only link that directly creates value for customers (other departments are support), which can also explain why many Japanese companies emphasize manufacturing-centric, and their core purpose is to highlight the rapid response around manufacturing.
But as a manufacturing department, dominate more than 70% of the entire factory of people, machines, material resources, it will indeed face a lot of pressure and challenges, today I want to talk to you from the pain points faced by the manufacturing department, I think the manufacturing department at least faces the "eight pain points", and it is very common.
1.Planning disorders.
As mentioned earlier, the manufacturing department controls most of the manpower, machine, and material resources, but how can these resources be really allocated? The answer is planning, which is to keep the entire manufacturing department running in an orderly manner and delivering efficiently. However, the fact is that the manufacturing departments of most enterprises are not working in a disorderly manner and delivery is difficult.
For example, the factory only has a sales plan, and there is no special production plan and procurement plan. For example, there is only a monthly plan, no weekly plan and daily plan, you say that you want to produce in an orderly manner every day, okay? For example, planning in the morning and adjusting in the afternoon, how do you say manufacturing?
It can be said that if you don't plan well, it will be extremely harmful to manufacturing.
2.There are more insertions.
Frequent insertion is a common problem for many enterprises, such as the change of the customer's plan; For example, the sales have an inaccurate grasp of the delivery cycle; There are also other abnormal adjustments and so on.
As a manufacturing department, it is actually very disgusting and a headache. Every order insertion seems to be well-reasoned and evidence-sufficient, but it does reflect the problem of the entire order management of our factory, which needs to be solved from the source with the coordination and cooperation of sales, planning, material control, manufacturing and other departments.
The more orders are inserted, the more waste the factory has, and the weaker the factory's order management will be.
3.The materials are not matched.
For assembly enterprises, 10 enterprises are at least 9This problem exists in 5 enterprises, and it is a typical pain point problem.
What are the problems? For example, delivery problems caused by lack of materials; For example, due to the shortage of materials, the problem of waiting for people and machines and the problem of switching; There are also other material inventory and capital occupation problems caused by lack of materials.
It can be said that the incomplete set of materials will make the site feel great, because it will greatly affect the efficiency of the manufacturing team.
4.Quality planning is insufficient.
Quality is manufactured, quality is planned, this is the source.
For the manufacturing department, on the one hand, it is necessary to do a good job in the corresponding implementation, and at the same time, it is also necessary to promote the improvement of quality planning. For example, because some items are not included in the inspection, resulting in undesirable outflow; For example, because the inspection method and frequency are unreasonable, it is difficult to find the defects; For example, because the source manufacturing conditions are not monitored, resulting in defects.
Quality planning is to avoid non-manufacturing and non-outflow from the source and fundamentally.
5.Insufficient verification of new products.
This is an aspect that everyone pays less attention to, but in fact, it hides a very big problem and has a very big impact on manufacturing.
For example, due to the lack of verification of new products, there are a bunch of mass production quality problems; For example, due to the insufficient verification of new products, the production of products is unstable and the delivery of products is difficult; For example, because of the insufficient verification of new products, the processing cost of products remains high, and factories do not make money or even lose money.
In my opinion, many companies have not gone through the standardized product validation process (the automotive industry is relatively better), but in fact, this is a waste of the basics.
6.Equipment failures are frequent.
For equipment-intensive enterprises, equipment is the core resource of manufacturing, and frequent equipment failures are bound to have a great negative impact on the quality, delivery and cost of manufacturing.
For example, delivery problems caused by equipment failure; For example, the problem of waste of people, machines and materials caused by equipment failure; There are also batch defective rework and even scrap problems caused by equipment failure.
For such enterprises, TPM must be on the list, and OEE must be improved.
7.There is a large turnover of people.
As mentioned earlier, the problem of machine and material, and people are another major resource of the manufacturing department. If there is too much turnover, the consequences can be imagined.
For example, the loss of backbone and experience due to the large turnover of personnel; For example, because the training caused by the excessive turnover of personnel cannot keep up, the cost of trial and error for newcomers is high; For example, because of the large loss of personnel, it is difficult to recruit people, which leads to great pressure on delivery.
Appropriate turnover is acceptable, but larger turnover must be avoided as much as possible.
8.The ability of the team to improve is weak.
For manufacturing sites, there are plenty of opportunities for improvement. At the same time, for the manufacturing department, it is also burdened with a large number of QCD indicators to improve the pressure, so if the team lacks the ability to improve, what will be the consequences?
For example, the on-site inventory is very high and there is a lot of handling, but everyone thinks it is normal; For example, the process of rework and scrapping is serious, but everyone is helpless; For example, the delivery has been tight, but everyone will only work overtime all day to put out the fire.
Without the ability to improve, the manufacturing department will be very tired and very passive, because most of the planning is finally implemented on the spot, and most of the indicators are also reflected on the spot.
The "eight pain points" commonly faced by the manufacturing department can only be treated at the source, and it will not be "painful".