in the production process, the daily production plan can't be implemented in place. Many times, it's not the plan itself that has a problem, but in the process of implementing the plan, all kinds of abnormalities will occur in the production process. Abnormal production mainly includes abnormal quality of incoming materials, abnormal personnel, abnormal process quality, abnormal equipment, abnormal environment and abnormal technical structure.
in the production process, there will be bottlenecks because of these anomalies. In the production process of small and medium-sized enterprises, these anomalies and bottlenecks will occur from time to time. If the production plan can be completed on time, there must be a set of mechanisms to deal with and deal with anomalies quickly.
Any anomaly is gradually or temporarily deviated from the standard. If the small anomaly is not handled in time or improperly, it may evolve into a large anomaly according to geometric progression due to the domino effect. Therefore, the analysis and prevention of abnormal production, timely response and standardized treatment are the focus issues that every enterprise urgently needs to pay attention to, and this is also the focus of production management in small and medium-sized enterprises.
1
What is an exception?
1. Violation of normal conditions
2. Not clearly defined in specifications and regulations
3. Phenomenon and conditions that have never been seen before
2
Necessity of making exception handling procedures
Timely handling of abnormal conditions can stabilize production and ensure the production of products under controlled conditions; Reduce the cost of quality failure through appropriate prevention costs.
let's share several exception handling processes.
material exception handling flow
the exception specifications of each material loss are obtained through negotiation between PSE and SQE; The loss-making specifications are determined by PSE.
Handling process of abnormal material breakage
Suitable for engineers and foremen
Handling process of abnormal yield
Generally, there are 3 abnormal single lines in a row, and a total of 5 pieces need to be repaired;
special anomalies, such as bad Bonding and Mura, need to stop and call for repair if one piece is found;
equipment exception handling flow
for the low OEE of single line caused by long-term downtime and high maintenance frequency, it is necessary for equipment and process to put forward improvement countermeasures for this equipment exception.
generally, it is only necessary to notify the ministerial supervisor of any abnormality; if the important model affects the delivery plan, it needs to be reported to the factory director;
environmental exception handling process
environmental safety exception notification process
dust-free environmental exception notification process
The above cases are for reference only
The accurate classification of abnormal events in the workshop is the premise of early warning and management of abnormal events, and only by refining them into various production links and different specific types and forming standards can they be operational. The classification will be different and the emphasis will be different depending on the nature or production type of the enterprise. The scientific nature of the judgment standard determines the accuracy and effectiveness of the abnormal cause analysis. Below, according to the causes of abnormal production in small and medium-sized manufacturing enterprises, the abnormal production is divided into the following seven types and seven treatment methods, which are shared with colleagues and welcome to leave a message.
1. handling of anomalies caused by human factors
on-the-job operation training is one of the most basic solutions to prevent production anomalies caused by human factors. Especially for new employees, those who fail the training are strictly forbidden to take up their posts. Employees are required to master and strictly abide by the operation essentials or production operation procedures of this position and strengthen the control of production process.
establishing an effective communication mechanism is one of the key measures to quickly find out the causes of abnormal production. No matter whether abnormal production occurs or not, enterprise managers should establish a "people-oriented" attitude and establish a long-term communication mechanism. If there is, it will be corrected, if there is no, it will be encouraged and actively responded.
Operators are managed by authority classification and post classification. People with different authority operate different contents, and people with different posts operate different post contents, so as to reduce the overlapping and overlapping of work tasks. Personnel management is standardized by "fixing posts, personnel, and responsibilities" to reduce abnormal problems caused by human factors.
2. Abnormal handling of production equipment
Establish daily inspection system of production equipment and strengthen preventive maintenance management of production equipment. That is, to prevent the problems before the equipment breaks down, and to detect key equipment regularly.
Carry out routine equipment inspection before shift, adhere to the first product inspection system, and verify the reliability, stability and accuracy of production equipment performance.
In the production process, positioning devices such as tooling and fixtures should be used as much as possible to reduce or eliminate operation errors and mistakes caused by manual random operation.
3. Abnormal handling of production raw materials
Strengthen the incoming inspection of raw materials and check before use to ensure the correctness of materials used in each process.
after the production plan is issued, relevant personnel need to immediately confirm the material status, check whether there is a shortage of materials, that is, whether the inventory quantity of materials meets the production, and conduct dynamic tracking and feedback to avoid the occurrence of anomalies.
if the material is cut off, operators can be arranged to do pre-processing preparation work, station 5S, equipment maintenance or other sporadic work, education and training, holidays, etc., or coordinate with the production management department to make plan changes and arrange the production of other products.
4. abnormal handling of production process methods
to avoid abnormal operation methods, the most important task is to formulate and implement standard operation instructions, continuously optimize production process technical parameters and ensure product processing quality.
Maintain the accuracy of tooling and fixtures, and conduct regular inspection and maintenance.
strengthen the process control of key processes and special processes.
Strictly observe the process discipline, check and supervise whether employees really carry out the production operation procedures, and prevent unauthorized changes to the process and drawings.
when the process is abnormal, immediately notify the quality control, biotechnology or R&D departments and take immediate measures.
5. Handling of abnormal product quality
For products that are difficult to produce, have many defective products and have special requirements, we should make key plans before production, and promptly notify the Quality Control Department and relevant departments with warning lights, telephone calls or other effective ways to reduce and eliminate the occurrence of abnormalities.
strengthen the first inspection, self-inspection, sampling inspection and mutual inspection of products, and appropriately increase the frequency of special inspection according to the quality requirements and complexity of products. Strengthen the quality veto power of quality inspectors, and the management personnel shall inspect at any time, and strictly inspect the products when they are sold out of the warehouse, so as to prevent unqualified products from entering the warehouse and leaving the factory.
the production department assists the quality control department and the responsible department to study countermeasures together and cooperate with the implementation of temporary countermeasures to ensure the completion of production tasks. Make follow-up records, use QC tools (such as Plato, causal analysis chart, histogram, etc.) for statistical analysis, and actively find ways to cure the abnormality.
6. Abnormal handling of production plan
According to the trend of market development, we should be flexible in making production plan, so that we can adjust the plan quickly and reasonably according to the actual situation in case of abnormality;
arrange the inventory, warehousing and return of products, semi-finished products and raw materials left behind due to plan adjustment;
arrange personnel to prepare materials and equipment to be replaced as quickly as possible.
7. Handling of other anomalies
For production anomalies caused by factors such as finance, market, policy, immature technology and imperfect technology in the initial stage of new product research and development, in addition to taking quick response measures, we should improve dangerous operations, difficult operations and important processes according to specific process requirements, and create a good operating environment in terms of sound, vibration, temperature and lighting. By changing the operating environment, employees feel safer and can work with peace of mind, thus effectively improving their enthusiasm and enthusiasm for work; By promoting 5S and strengthening visualization and kanban management, the workshop site is more clear at a glance; By rationalizing the proposal, we will strengthen the awareness of frontline staff, so that abnormal situations can be exposed in advance, prevented in time, and nip in the bud.
in a word, the most important method to deal with abnormal problems is the formulation, implementation and effectiveness verification of "preventive measures" and "corrective measures". When an abnormality occurs, the "5W2H" analysis method must be adopted for analysis and confirmation. After the abnormality occurs and is handled, it is necessary to make inferences to find the root of the problem and cure it. After the production abnormality is eliminated, in order to avoid the recurrence of similar problems, we must adhere to the principle of "three don't let go", that is, "don't let go until the cause of the problem is found, don't let go until the solution is found, and don't let go until the responsible person is found".
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