One, organizational implementation, publicity and education
1, the establishment of a lean production project team and organizational structure.
2, open lean production knowledge lectures, organize staff to learn about lean production knowledge, focusing on the training of middle-level cadres.
3, carry out lean production knowledge questionnaire examination.
4, the establishment of batteries, components professional group or according to the line set up activity groups.
Second, the implementation of the system
1, the development of lean production management
2, the development of lean production line acceptance
3, the development of the working group responsibilities
Third, the implementation
1, against the lean production standards, to identify problems.
1) Production management
a) Production plan is made from sales plan. The daily production plan of the section is decomposed into parts and processes.
b)There is a want plan for the latter process to the former process between sections.
c)The production plan and process transfer are managed by Kanban.
d)Work in progress to set the maximum reserve quota, the site of the work in progress does not exceed the reserve quota, the work in progress fixed, quantitative placement, over the eye to know the number of clearly marked.
e)Production arrangements to meet the just-in-time production, concealment of the balance of inter-process convergence, no stoppages in the phenomenon of waiting for materials.
f)Work section to establish parts and components, in-process input and output accounts
g)Workstation equipment is fully equipped to achieve the refinement of the number of over-knowing
h)Production site has no idle equipment, tooling, in use equipment and tooling has a daily maintenance plan, the use of the state of good.
i)Equipment one or two maintenance plan, wearing parts have spare parts, equipment failure prevention-oriented, timely maintenance.
j) equipment, equipment, tools, safety regulations, producers operate in accordance with the provisions.
k)Equipment, tooling, fixtures, tools, and work sites comply with safety evaluation regulations, and workplace accidents are 0.
2) Process and labor management
a)Equipment and tooling are arranged according to the process flow, and the combination of man and machine is reasonable with no obvious and ineffective walking distances and waiting times.
b) dynamic flow of products in the section on the upper and lower processing, no static storage.
c)The same workstation can arrange the production of multiple varieties
d)In the cycle time can be completed in a number of processes
e)On the next process, the product transfer distance is short, to reduce the ineffective distance.
f)Reasonable and standardized product placement, easy to reach.
g)Production line personnel should be adapted to a multi-competent, section head, line head for the whole line through
h)Operating instructions, inspection instructions, equipment point inspection card, safety regulations complete, placed in the work site.
3) quality management
a) production staff to master product quality control standards, inspection methods and can seriously carry out self-inspection, self-inspection records.
b)Production personnel operate according to process specifications, no unauthorized operation and do not accept, do not manufacture, do not pass non-conforming products.
c)The product quality status is clear, non-conforming products are strictly isolated.
d)Means of testing is complete, can hide enough product quality control needs.
e)Weekly inspection of tooling, equipment and inspection tools with records
f)Stable product quality, defective products are less than the control targets, quality problems are solved in a timely and effective manner, and there is traceability.
g) TS16949 program documents are effectively implemented.
h)Product quality to implement the assessment of rewards and penalties
4) Logistics management
a) Raw and auxiliary materials, outsourcing parts purchasing program volume does not exceed the maximum reserve quota.
b) Raw and auxiliary materials, outsourced parts, finished products, spare parts, tools have the highest and lowest reserve quota.
c)Raw and auxiliary materials, outsourced parts, spare parts, tools, low-value consumables have consumption quota indicators, and decomposed into sections, individuals.
d)Carry out cost accounting.
e)Strictly according to the production plan limit supporting timely feeding.
f)Inventory of finished products, outsourcing parts, raw and auxiliary materials, fixed, fixed area neatly arranged, standardized packaging, open the box to know the number of accounts, cards, things in line.
g)Reasonable logistics flow, no ineffective labor and waste in handling
h)Material input and output accounts, and input and output balance.
5) equipment, tooling management
a) equipment, tooling in perfect condition, the status of the correct identification, no idle equipment
b) equipment has a pre-maintenance, pre-inspection plan, daily maintenance plan and normal implementation. Operators participate in equipment maintenance.
c) Equipment and tooling are repaired in a timely manner without affecting production.
d) There are equipment, workpiece repair and maintenance accounts.
6) Site management (7S)
a) the work site to implement the management of positioning, product and material positioning neatly arranged, clearly marked, correct.
b)The work site is free of clutter.
c)The working environment is clean
d)The production personnel are uniformly dressed, the operation is standardized, and the safety protection measures are in line with the standard.
e)Equipment, work clothes and tools are clean.
f)Products and materials are reasonably arranged and occupy little space.
2, develop improvement programs
1) create a general assembly lean production line program
2) warehouse lean management program
3) sections, individual costing program
3, the lean line, warehouse lean management program for review, modification, confirmation.
4, according to the program to organize the implementation
5, in accordance with the lean production standards, inspection, rectification, acceptance
Four, review the organization of the four lean production line operation effect review
Five, lean PDCA sequential improvement