Reduce waste and enhance the core competitiveness of enterprises
Talked about the waste of manufacturing enterprises in the past to give the impression that corporate managers may have been thrown into the garbage in a lot of materials, parts or only a small part, but will do the rest thrown away.This part of the course is a waste, but this is only a small part of a waste or is very easy to find waste, and waste of large manufacturing enterprises, it includes a lot of content, roughly summed up in six categories: more waste, waiting for the waste, waste handling, processing, waste, inventory waste and defective products, repair of the waste.The following detailed description of each of the elements contained in waste and the resulting problems.
1, the more waste
Waste, including doing more and more as early as two parts, there may be some managers can not understand how this is a waste?This is not done out of something can also use it?In actual fact, more out of the product or part is likely to become sluggish after less than expected, and the need to occupy more and more product out of the container and warehouse space, the need to increase staff handling and managing inventory, etc. Thesewill lead to increased costs.More importantly, the more the stock will hide a lot of unknown issues.If there is no inventory, there are problems will soon be found.For example: If the machine shop unstable operating conditions, when there is no inventory, because of the need to do a certain number of outputs, once the machine stops running, she would affect other sectors of the supply of materials or components, so the machine where thedepartments must find ways to ensure that the machine has been in a runnable state.If a stock is not the case in the past have excess inventory, even if the machine is broken and will not affect the normal operation of the production, so there is no such awareness of the relevant departments to routine maintenance machines.Like to do more harm done early, but the other point is: Now that most companies are by order, if made in advance out of the product or part, once the customer order cancellation or change, What is done can not be undone, waste is notirreversible.
2, the waste of waiting
Waiting for the arrival of materials, waiting and waiting for parts transfer machines running all over the waste.Enterprises will not wait because employees did not work to pay, and wait longer, you need to hire more workers to complete tasks as scheduled delivery of orders, in a certain period of time, if forall kinds of wasted time waiting, we need more people in a shorter time to complete task orders.
3, the waste handling
Handling itself is a waste material should ideally enter the shop from the first stage of a finished, the next direct the flow of processes, in the middle do not need human or equipment (such as forklifts, etc.) of the transportation, handling.Processes such as direct use of tilt between the pipeline that does not require human or mechanical equipment does not need electricity.If you need transportation, you must have the human and mechanical equipment, materials or components must also be a temporary placement area, these are wasted.So in the design of the relationship between the warehouse and workshop, as well as the relationship between the workshop and the workshop, when one must take into account the distance from transport or transfer to a minimum distance of priority.There is also a consideration is that now many of our factory floor is designed by function, such as press shop, machine shop, etc., but the concept of process point of view, the situation should be based on the actual placement of equipment to the designposition, to ensure that the minimum distance of transport, not to management functions need to be the same machine into a single region.For example, if a first stamping parts, polishing, etc. and then after several steps, and then go through the stamping process, if the design of the workshop by function, then the part to come twice a stamping plant, than by technologyprocess machinery and equipment to set the distance to a lot more moving, because the process set up by the words, there will be placed in the press to do after polishing processes, such as the nearest place.So basically do not need to carry out.Between the warehouse and the warehouse, storage warehouse and workshop within and between, temporary storage of less than warehouses, temporary storage sites and transportation between the workshop are all wasted.Therefore, storage and warehouse in the design of various types of materials should be placed in the warehouse, what position should consider handling quickly and easily.
4, processing of waste
Many factories of product design there is no clear or precise criteria, different people on the same product or part of the requirements are not the same, this way, the processing of the product will waste a lot of work.We all must meet minimum standards to qualify, and then additional work on this basis, the additional number of working hours is the amount of waste.For example, a hardware, a product used in the internal, according to process requirements only need to flash after casting workshop will deal with the corners a little bit on it, and some designers in the design process when the product isjoined the polishing process, this very beautiful part grinding, polishing process is the increase in waste, because it does not impart any added value, only increased cost of the product.Product design department in the design of the product must first be a cost when the concept of thinking in the design of this product on the basis of how the plant to mass production (such as: multi-piece design Universal), how to design staff processing the action at least, how to design toto reduce the complexity of processing (in order to improve the passing rate).The design and production engineering department in the list of materials (BOM) of the time, which may consider the use of more economical materials, including the complexity of finding suppliers and transportation costs and so on.In addition the production sector must develop in strict accordance with the standards set to produce, not self-assertion, not raise their production requirements, of course, can not be less than the production of standard rework.Human waste is not only a waste of processing time-cost, but also a waste of water, electric, management costs will increase.
5, the waste inventory
Mentioned earlier in front of more or do, these will have excess inventory, while often also because of more procurement, procurement, and other errors cause a lot of inventory.More production or procurement of these stocks, it is possible for a long time, or less than they could ever use, more alarming is that a lot of material because of the durability or demanding on the environment and the last to be scrapped.