The reform of lean production mode is of great significance to enterprises. The idea of lean production management is a kind of modern production management thought which focuses on reducing waste and improving efficiency. Non standard automation equipment is to combine the non-standard characteristics of different products in different industries to analyze and formulate practical methods.
In most cases, although the structure and size of a company's products are changeable, the operation process is relatively standard. In fact, single piece flow process is the flow process of operation, which is still in line with the basic flow process idea. Therefore, most products can realize single piece flow processing through the standardization of non-standard products.
How to realize single piece flow processing production is the primary purpose of non-standard automation equipment.
Non standard characteristic analysis
Before implementation, the company's products should be classified according to the product properties and scope of use. In fact, it is a standardized design of a class of products (it is impossible to make refrigerators and cars in one production line).
When designers design non-standard products, most of them use the standardized products as prototypes to improve the design. Therefore, the standard product as a design prototype is the basis for the analysis of non-standard characteristics of non-standard products.
Technical personnel must seriously study and analyze the process of products, pay special attention to the process design of non-standard parts, and must consider the existing production line equipment, tooling, tools, and even the working space, and complete the process design of non-standard products as far as possible under the existing process level.
At the same time, if it is found that the design structure is not conducive to the production under the existing conditions in the process analysis, it is necessary to communicate with the designer on the existing production and manufacturing platform without changing the customer requirements.
Finally, the process personnel must clearly explain the special process treatment on the process analysis card.
Standard chemical process design of non-standard products
In order to have a clear production main line, the new process route must be established on the basis of the original standard product production process route.
In the process design, the method of trunk line plus branch line is adopted. The standard operation process is taken as the main line, and the non-standard part is overlapped with the main line in the way of branch line. So long as we design the process rhythm of non-standard part, we can organize the production in the original standard operation way, make the whole production planning and production control simple, and reduce the production of non-standard customized products Uncertainty in the process.
Planning non-standard operation in advance
Including the logistics planning in the operation process to ensure the standardization of non-standard operation. Site planning is carried out to place the materials required by each process nearby, so that the production personnel can obtain materials nearby without off-line, so as to ensure continuous production and reduce the waste of picking time.
Set up movable tooling in process transfer room to reduce handling waste, etc.
Standardize all kinds of standard operation actions, formulate the standard table and form the operation standard.
Using scientific method to measure and analyze the working hours of standard operation
On the basis of standard operation, in order to avoid the inefficiency caused by non-standard products, it is still necessary to monitor the actual work and correct some unnecessary waste activities through process monitoring.
At the same time, referring to the original standard operation process, the "non-standard coefficient" is used to adjust, so as to ensure that the upper limit of working hours of non-standard operation products is limited, and it is also conducive to the arrangement of production plan and multi variety operation scheduling.
Balance the production line capacity and the range of mixed model products through scientific man hour measurement (to ensure the best economy).
In the actual production management, it is necessary to use camera monitoring to observe the whole operation process of employees. Through the analysis of the camera process, it is necessary to find out the places worthy of improvement (including the improvement of tooling, the storage position of materials, etc.).
Use statistical tools to make standard tooling with wide application range (80%) to improve speed and quality
Combined with the different characteristics of the products, based on the previous process analysis, process layout and action research, we can research and manufacture the operation tooling suitable for most products.
In this way, some seemingly non-standard products can be produced in a standardized way (for example, only the size changes compared with the standard products), which naturally improves the quality assurance ability, reduces the production preparation time and improves the operation efficiency.
Setting of quality monitoring points
In order to achieve a flow of production, quality inspection must be included in the production line planning as a production process, and inspection procedures should be set to ensure product quality. At the same time, we should strengthen the awareness of "quality is produced by manufacturing, not by inspection", and strengthen self inspection and mutual inspection of working procedures.
In order to meet the mixed model production of products as wide as possible and implement Kanban management practically, various products are identified by Kanban, and each process is organized according to Kanban requirements.
Construction of soft environment
All kinds of soft systems must be set up. Production line material supply system, stop line system, on behalf of the post system and so on, and effectively implement.