Shulou(Shulou.com)06/02 Report--

If you are a customer, how should you consider a manufacturing plant?

Productivity? Product quality? Reputation?.

It's much more than that. Thousands of considerations may suffocate you.

The following ten direct pain point questions can help you choose a reliable manufacturer quickly and efficiently!

Q1: do you know the "5S criterion" for judging the order of manufacturing plants?

One of the easiest ways to assess the effectiveness of a factory is to see if it is in order. Even the most orderly manufacturing plants may have chaos, but dirt is not allowed, which will make it worse. The "5S" criterion in lean production can be used as an excellent factor in judging the order of manufacturing plants:

cleanup (Sort)

Only items necessary for work are stored in the work area. All other items are removed. The cleaner the factory, the more efficient it is, the less time is wasted, and the workers can focus on the task at hand without being distracted.

rectification (Set in order)

Rectification can be regarded as "everything in the right place and in its own place". If you know where the item should be, you will try to make sure it belongs to it, which avoids wasting time looking for the items you need while doing your work, such as sorting items into categories.

(photo: your desktop and other people's desktop gif)

cleaning (Shine)

Except for all items in their own place, workstations as well as floors, walls and equipment should be kept clean. A clean working environment not only helps to cultivate pride in work, but also helps to motivate workers to produce quality products that customers are satisfied with.

Standardization (Standardize)

Factory operation of standard equipment and processes can effectively avoid accidents, which can slow down production and may lead to quality problems.

hold (Sustain)

Every efficient factory has a process to ensure uniform quality and set a special time for cleaning and finishing. This kind of working condition needs to be maintained continuously, if not, it will be very difficult for the factory to realize its full potential and operate efficiently.

Q2: is the new production target and operation target transparent?

We are familiar with the principle of "there are many people and great strength". The same is true for manufacturing factories, where all factory owners need to work together towards the same goal, and the resultant force will be much greater than the superposition of individual forces. Therefore, the factory's production targets and operating indicators should naturally be transparent, but for the manufacturing industry, these goals need to be measured or modified from time to time. Manufacturing factories can advertise it by posting bulletin boards, but smarter factories will skillfully use the built-in operational indicators of the manufacturing ERP system to automatically update measurement results online, saving a lot of labor time such as collecting, collating and publishing data.

Q3: should the production process be more like a straight line or a curve?

Suppose the production facility is spaghetti. So is your production process like unboiled dry noodles or more like boiled noodles entangled together? Highlight: it is important to simplify the production process as much as possible, so that the production process is as simple as a straight line, so that the movement between workstations is minimal and there is no need to track backwards (if possible). After eliminating unnecessary handling and moving work, the throughput will be increased, inventory will be reduced, production will be increased, and operational efficiency will be improved immediately.

Q4: is it necessary for each workstation to be equipped with operating instructions and product specifications?

The common feature of efficient manufacturing enterprises is to attach importance to quality, which means that workers must be able to use process instructions, assembly drawings, technical specifications and worksheets at any time when carrying out their work. Each workstation must have a place to store the necessary written materials for workers to obtain. Of course, more and more manufacturing plants have been equipped with mobile devices to display data (if this is the case with your manufacturer's checks and balances, please turn on the lights for him). Integrating quality into work is far more cost-effective and efficient than rework in the future. Please make sure that everyone in the factory keeps in mind that quality is a priority. It is not difficult for everyone to have an operating instruction and product specification.

Q5: how to deal with the waste in the production process?

It is difficult for any manufacturing plant to avoid producing some waste products in the production process, but some enterprises may hide these waste products, as if the whole workshop produces high-quality products and is very efficient. But in fact, the right thing to do is to put these wastes where everyone can see them, so as to make people realize that this is the price paid for mistakes. In fact, some companies even put waste value next to the scrap heap to make people remember that quality is money, and quality will affect follow-up orders and customer satisfaction.

Q6: is every workstation equipped with error prevention measures?

All manufacturing plants want to ensure that each process avoids errors as much as possible and ensures product quality. Therefore, fixtures and fixtures that only allow the product to come from one direction are essential, which helps to avoid assembly errors. The fixtures on the workstation seem inconspicuous, but they are actually very important to improve the safety and quality of the factory, and also help to protect the safety of the staff.

Q7: does the workstation need more than one shift in inventory?

Inventory should be located near the location that needs to be used, but this does not mean that all inventory is placed in the workshop. Excessive inventory in the work center can lead to unnecessary material handling and blur priorities. Too many materials means that staff have to spend time looking for the parts they need in a pile of inventory, which does not speed up the search for the materials they need. Please keep the inventory as long as possible for one day or one shift in order to achieve maximum efficiency.

Q8: are all stocks labeled and clearly marked?

Many parts look similar, but in fact, the specifications are different, and the factory needs to make sure that each item is labeled and clearly marked. However, when labeling, lockers and containers also need to be standardized to facilitate search. Most manufacturing ERP solutions have built-in label printing capabilities, which greatly reduces the time cost of manually managing labels. If you have this feature in your manufacturer's solution, congratulations to the right manufacturer. If not, it's time for you to consider a different manufacturer with a new ERP system.

Q9: is the equipment maintenance schedule developed and posted?

Among the incidents that disrupt production and shipping plans, nothing is worse than accidental equipment downtime. The factory should make a comprehensive maintenance and calibration plan for each equipment. Post the schedule and indicate the date of a preventive maintenance (PM). Knowing the planned preventive maintenance time can help improve manufacturing efficiency, and workers and regulators can plan production more effectively and ensure that preventive maintenance is not ignored.

Q10: do you clearly attach importance to quality?

One of the most effective ways to ensure efficient manufacturing activities is to attach importance to quality. High-quality products help the factory to produce according to plan, ensure timely delivery and make customers more satisfied. Good product quality helps to control cost and reduce scrap rate and rework rate. Each step you take to improve quality further strengthens security, and the two complement each other. How to manage production quality efficiently, many manufacturing industries have used quality management system (QMS), which can be integrated into the manufacturing ERP system. The applicable QMS facilitates recording and process control, as well as training, corrective action management, and change control.

After reading the above problems, you may find that many manufacturers are on the verge of reaching the standards. it may be because the ERP system of the manufacturing plant is not updated, the labor cost is high and the efficiency is low, or because of ignoring quality management, the production process is confused, the product quality is low, and customer satisfaction decreases. If these questions are at your heart, you may need to consider a different manufacturer, or you may want to consider changing your manufacturer to another ERP partner (QAD knows about it).

Of course, if you are reading this article, you are the manufacturer, and all the above ten questions are up to standard, then please raise your hands (retweet, leave a message and like this article), a large wave of customers are coming to you!

Read the original: https://www.qad.com/zh_CN/blog.cn/-/blogs/--9-18

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