The hottest new trend of lean production flexible

2022-08-16
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New trend of lean production: flexible manufacturing

in the process of pursuing flexible manufacturing, a world top 500 r company has achieved the coexistence of various production methods and achieved great economic results. Under the same plant and equipment conditions, the production capacity of the copier has been increased to more than 3.5 times of the original design capacity with capital operation as the link. Based on the analysis of a demonstration production line, company X, another high-tech multinational company, found that 60% of the original production line was redundant. By removing these redundant parts and recombining the production line, the site utilization rate of the following small method of maintenance was increased by 80% in just four months. At the same time, the production capacity was doubled by using the dismantled equipment, Save a lot of investment in expanding reproduction

today, enterprises are facing the challenge of changing business environment. The globalization of market competition, the diversification and uncertainty of customers and market demand, the shortening of product life, the intensification of price competition and so on all put forward new and higher requirements for the existing production methods of enterprises. In order to survive and develop in the cruel competition, enterprises must study some low-cost and rapid response manufacturing methods. Flexible manufacturing (or flexible production) is the general name of these methods. Therefore, flexible manufacturing is not so much a production method as a new manufacturing concept

in the process of contacting customers, we often hear such complaints:

"now there are more and more product varieties produced, and the time for changing lines is longer and longer, so the production efficiency is low, and the inventory is also large."

"nowadays, customers send instructions two days in advance and ship the goods on the third day. They can't produce products in two days at all, so they can only increase the product inventory to meet the needs of customers?"

"the minimum production batch of each machine is 200 kg, but the customer's order is getting smaller and smaller, sometimes even 1 or 2 kg. Each time such an order is made, the remaining inventory will be increased, and it will accumulate more and more, so we can only increase the warehouse to deal with it."

in short, in the face of changes in customer demand, it seems that enterprises have little choice, and many times they can only passively accept it to increase inventory to solve the problem. Is there really no way to deal with it better? This is a problem that needs us to think seriously. Otherwise, if we meet the needs of customers at the cost of increasing inventory and costs, the survival of the enterprise will eventually be challenged

in the past two years, as a management consultant, we have tutored and are tutoring many large enterprises, such as Fuji Xerox, Alps and meihua, to carry out production reform, and specifically practiced the reform process of flexible manufacturing. Facts have proved that as long as we start from the concept of flexible manufacturing and specifically study ways to solve problems, our experimental machines can be more accurate after year-round research and testing, improve the rapid response ability without paying cost, and meet the needs of customers

we can use several specific cases to illustrate the concept and implementation method of flexible manufacturing

in order to enable readers to better understand the significance of flexible manufacturing and understand the new ideas of realizing flexible manufacturing, some representative flexible manufacturing methods are briefly described below

1. Cell production mode: compared with the traditional mass production mode, cell production mode has two characteristics: one is small scale (short production line and few operators), and the other is that small production cells after standardization can be simply copied. Because of these two characteristics, the cell production mode can realize (1) simply cope with the change of yield, and by replicating one or more cells, it can meet the production demand of integral multiples of cell production capacity; (2) Reduce the occupation of the site, and the cells can be simply copied (the cell production line can be built in one day), so it can be simply removed when it is not needed, so as to save the site; (3) The number of workers per cell is small, which reduces the difficulty of balancing the working time between stations. The difference of working time between stations is small, and the production efficiency is high; (4) Through the reasonable combination of employees, that is, by the combination of employees with the same ability into cells, the highest level of operational ability of employees can be brought into play. If we can give corresponding rewards according to the production capacity of each cell, it is also conducive to promoting benign competition between cells. There are various forms of cell production lines, including O-shape, U-shape, dining table shape, cart shape and so on

2. One person production mode: we have seen such a situation that the assembly time of a product in the CMA national quality inspection center directory is less than 10 minutes in total, but it is still arranged on a tens of meters long assembly line, and the assembly work is completed by dozens of people on the line, and each person's operation time is only 10 or 20 seconds. For such products with relatively short operation time and small output, if we can break the routine (assembly line production) and change each employee to complete the whole product assembly task alone, we will achieve unexpected results. At the same time, because job performance (quality, efficiency, cost) is directly related to employees, one-man production mode can not only have the advantages of cell production, but also greatly improve employees' quality awareness, cost awareness and competitiveness, and promote employees' growth

3. One flow production mode: one flow production mode is realized by canceling the trolley in the machine room and allowing the products to flow individually in the machine room through reasonable process arrangement and the setting of sliding plates in the machine room. Its advantages are: (1) greatly reducing the inventory of intermediate products and reducing the occupation of funds and sites; (2) Eliminate unnecessary handling between machines and reduce the dependence on handling tools; (3) When the product has quality problems, the information can be fed back to the front in time to avoid scrapping a large number of intermediate products. One flow production method is not only applicable to machining, but also to the process of product assembly

4. Utilization of flexible equipment: a product called flexible pipe (plastic and metal) began to be favored. In the past, many enterprises would purchase standard assembly lines for production, but now they are gradually replaced by simple flexible production lines assembled by themselves. In comparison, the flexible production line can first reduce the equipment investment by more than%. Secondly, the equipment installation does not need professionals, and the general staff can quickly complete the installation in one weekend. Thirdly, it can be removed at any time when it is not needed, so as to improve the site utilization efficiency

5. Trolley production mode: we often see that a product is transferred from one line to another in the manufacturing process, and the transfer tool is trolley. Focusing on the losses in the process of moving and transferring, someone proposed a trolley production line, that is, to complete all assembly tasks on the trolley

6. Fixed line and variable line methods: according to the change of the output of a product, two types of production lines are set, one is to meet a relatively fixed fixed production line, and the other is to meet the changing part of the variable production line. Usually, traditional production equipment is used as a fixed line, while flexible equipment or cell production methods are used as variable production lines. In order to completely reduce costs, the change line in Japan often employs part-time workers dispatched by labor companies to deal with it, and can be returned at any time when it is not needed

the general trend of flexible manufacturing is that the production line is shorter and simpler, and the equipment investment is less and less; The intermediate inventory is less and less, the site utilization is higher and higher, and the cost is lower and lower; The production cycle is shorter and shorter, and the delivery speed is faster and faster; All kinds of losses are less and less, and the efficiency is higher and higher. It can be seen that the realization of flexible manufacturing can greatly reduce production costs and strengthen the competitiveness of enterprises. Since flexible manufacturing is a new and high-level manufacturing concept, it is worth thinking and creating in the spirit of continuous improvement. (end)

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