Source|Network
The full text totals 3247 words and needs 8 minutes to read. The following is the main text: Production phenomenon:
1. The semi-finished products or materials of the front and rear processes are not connected. You can't come for what I want, but I don't want to come.
2. In the factory, the production departments, semi-finished products pile up like warehouses, and production cannot flow smoothly like flowing water.
3. The production schedule is a mere formality. You make your plan and I make my product. The production plan has a low rate of compliance, and the production plan is not prestigious.
4. The production schedule is changed frequently, either adding or canceling.
5. There are many urgent orders,The production plan cannot be carried out, so the so-called affects the whole body.
6. When the production is disordered, the quality will be out of control. The out-of-control quality will be reworked and the original production plan will be disrupted.
7. Excessive backlog of materials, parts or finished products makes it difficult for enterprises to allocate funds.
8. Endless overtime, working overtime every day, people become production machines.
9. Delivery is often delayed, which affects the company's reputation.
One of the reasons for the above chaos is that the production work lacks the necessary institutional support, and there is no certain standard to regulate product sales, sales planning and production planning, production planning and material planning, production Planning and production dispatch work.
At a deeper level, the problem lies in the production operation process itself. The production management department has deviated from the work functions of the command center and operation hub, and has become a subsidiary unit of the production department. This is The root cause of the above chaos.
Therefore,Establishing a production management system that is both scientific and suitable for the actual situation of the enterprise, standardizing work responsibilities and specific work procedures has become the key to solving the above chaos. So how can we make a good production plan?
01
standardize the production management system
many factories producing widespread disorder, produce unstable The problem is mainly due to the fact that the factory failed to establish an operational production management system, the production command center has insufficient control and randomness. As the scale of the enterprise grows, it will become more chaotic, and even form a dilemma of bad habits. Therefore, it is necessary Strengthen system construction.
From the sales department to the production department, establish a sound management system, standardize and restrict everyone’s behavior, and finally establish a good production order and eliminate chaos. These are to do a good job in production management and standardize production planning. The basics.
02
capacity load analysis
for productivity analysis, lack of understanding,The "Production Schedule" drawn up based on experience is often inconsistent with the actual implementation. The "Production Schedule" is difficult to implement, and production management cannot perform its due function.
These require enterprise production managers to comprehensively consider capacity in terms of product types, manufacturing processes, and the equipment used in each process.
Compare the load of existing machinery and equipment and production tasks, and when the capacity is over or under, the capacity can be adjusted for a long time or for a short time.
1. Short-term capacity adjustment
is not prepared, or the product and the amount of manpower generated in advance are not fully prepared, or the amount and manpower generated in advance Or when the machine load and demand are unbalanced, the possible methods are:
2. Long-term capacity adjustment is available 0 span1 span _p7br _span0 span1 span _span4p _span1 Consider extending the working hours of the types of work or adding new equipment to increase production. For production factors, comprehensively considering factors such as cost and production efficiency, the final decision can be made whether to extend the working hours of the types of work or add new equipment.
03
balanced sales plan and production plan
1, production-oriented enterprises according to relationship marketing The difference can be divided into inventory production and build-to-order enterprises.The former emphasizes production in accordance with the established plan, and the sales department makes sales estimates based on products, market conditions and sales methods, and sets the minimum finished product inventory accordingly to carry out serial production; while the latter is to start arrangements after receiving customer orders Production.
2, plans to develop
(1) sales plan
reality, very much in the factory, There is no annual sales plan in advance, or there is an annual plan. The monthly orders received by the sales department either exceed the original plan amount or are too different from the original plan, resulting in the entire factory including production management, quality control, materials, and production. And the personnel department was in a hurry and was struggling to deal with it, which eventually led to a lengthened delivery period, an inability to increase production, and a major impact on production efficiency and product quality.
At this time, business executives often blame the production department. In fact, when various production factors are relatively stable, most of the chaos comes from the lack of a reliable sales plan, which leads to failure Make a perfect production plan, schedule control will naturally be challenged.
Therefore, regardless of the inventory production type or the order production type, the sales department should conduct market research every year and make estimates, and fully consider the customer category, product category, number of orders, and delivery Time and other factors, the formulation of monthly sales plans for the year, is the basis for the normal development of production work.
(2) Monthly plan
The sales department proposes to sell about span4 on the 20th of each month. The shipment plan should consider the order status and the actual load status of the production department.
Before the end of the month, the sales department, technical department, supply department, and production department will review the next month's sales (shipping) (shipping) plan, and the sales department will finally determine a relatively detailed plan , The technology department determines the technology research and development (adjustment) plan, the supply department determines the purchase plan, the production management department proposes the next month's production plan, and also considers the order status and the production capacity of the production department.
The sales department, production management department, and technical department conduct "production and sales coordination" to determine production tasks. In addition, the production department is required to set aside a certain amount of time (usually around 5%) Additional urgent orders are prepared.
In addition to annual and monthly plans, sales and production departments should make weekly and daily plans to ensure that the execution cycle of the plan is as short as possible, so as to have a more detailed control of the overall situation and timely problems remedy.
3. Assignment of work tasks
After the production plan is determined,The production department should use the team as the unit to schedule the team production plan.
For the same product, the production process schedule must be able to connect, so that the flow of semi-finished products will be smooth. A certain amount of buffer is reserved between shifts and groups to avoid failure to connect or accumulate too much.
4. Preparations before preparing the production plan
_p 1, know whether the materials are available or not _p Product processing procedures;
(3) Material usage channels;
(4) Understand the market demand;
5 Full set of conditions;(6) Effective tracking and control of production progress;
(7) The production instructions must be carefully and accurately issued, and must not be missed.Missing;
(8) Information needs timely feedback and follow-up;
(9) Appropriate consideration of abnormal conditions; (11) Manage independent demand; (12) Quality situation and quality control; (13) If the order is too tight, it is impossible to consider the insertion period. Situation; (14) Understand the product, related process, bottleneck process: purchase the first process first; (15) understand the material performance; _span4 (1) (17) reasonably deploy personnel; (18) contact the supply warehousing department and personnel to ensure the supply of materials; (19) Contact the engineering and technical departments for technical support; (20) Develop and view the corresponding series of plans: such as product development plan, production job sequencing plan, personnel plan, capacity plan and load plan, inventory count Planning, shipping plan, material plan, outsourcing plan, etc. 04 schedule 1, calendar (Order Production) Planning a schedule for the entire process from the sales department receiving the order to the production department completing the production and shipment, from which you can get: (1) How to connect the whole process. (2) How to simplify the whole process and how to do it to shorten the time and win orders. (3) Establish a standard time for each stage of the process, which can be done as:
B Production management is the basis for production planning.
C each team progress control pointer of .
The order-to-production schedule usually uses the reverse scheduling method, that is, after the shipping date is determined, the production plan, material plan, and purchase plan are carefully arranged.
2. People tend to focus on the production department for the speed of delivery. In fact, the production time is only a part of the total time, and the production time is the most difficult to compress.
We should try to shorten the time in terms of product design time, procurement time, delivery time, etc., and the interaction between designing products, purchasing materials, and producing products complements each other.
Which products have high market demand and a long life cycle can be produced from inventory. For products with low demand and short life cycle, make-to-order production can be adopted.
05
production schedule management
1, production schedule management content
From the schedule benchmark process, we can see thatThe output of a product needs to experience many departments and personnel, and each department and personnel should have their own progress, and they should be mastered and controlled.
Unlike some companies who regard the production schedule as the responsibility of the manufacturing department and ignore the schedule management, the schedule management can be summarized into the following aspects:
strong
(1) Transactional progress
Time control for material analysis and ordering after receiving customer orders.
(2) Procurement schedule
should be ordered with standard materials and spare parts.
(3) Inspection progress
should be controlled after the material is accepted by 1span .
(4) Outsourcing progress
, the control of 1span out of the production time span.
(5) Production progress
is dually controlled by the and production management department.
2, schedule management method
progress more commonly used control laws have
(1) Batch Control Act
The production plan is compiled in a certain batch and used as a benchmark for schedule management. This method is suitable for inventory-based products.
(2) Order control method
4 This method is sometimes suitable for the production of 1spanspanspan 4 orders. It is delivered in batches and in installments, and the order can also be split to issue a manufacturing order), is the most common practice in general enterprises.
3. The basic process of production schedule management
(1) The sales department signs the load of production capacity combined with the production management staff.
(2) The sales department negotiates with the production management department to schedule a sales plan (total and detailed order number, product, quantity, delivery date).
(3) The production management department schedules quarterly, monthly, and weekly production plans in accordance with factory capacity and sales plans.
(4) Purchasing department according to the production plan and material inventory,Determine the purchase plan and negotiate with the supplier in time to determine the plan.
(5) The purchaser shall verify and follow up the progress of the material supply.
(6) The warehousing staff prepares the required materials in advance, and feedbacks to the purchasing staff in advance if they encounter shortcomings.
(7) The production department controls the production capacity and controls the production schedule in accordance with the production plan, and promptly feedbacks the production management personnel to the production management personnel and controls and adjusts the problems in time.
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