Experience sharing of production planning management 1 1. Production management
Production management refers to the management of the establishment and operation of enterprise production system. Also known as production control. Its contents include: ① production organization. That is, site selection, factory arrangement, production line organization, implementation of labor quota and labor organization, and establishment of production management system. (2) production plan. That is, making production plans, production technology preparation plans and production operation plans. ③ Production control. That is, control production schedule, production inventory, production quality and production cost.
Second, the task of production management
The task of production management is: through production organization, according to the requirements of enterprise objectives, to establish a technically feasible, economically economical, material and technical conditions and environmental conditions permit production system; Through the production plan, the optimal operation scheme of the production system is formulated, and through the production control, various relationships inside and outside the production process of the enterprise are adjusted in time and effectively, so that the operation of the production system meets the requirements of the established production plan and achieves the expected production variety, quality, output, production cycle and production cost. The purpose of production management is to achieve less input, more output, and obtain the best economic benefits. Using production management software, such as the well-known 800 customer production management software in China, aims to improve the efficiency of enterprise production management, effectively manage the information of production process, and thus improve the overall competitiveness of enterprises.
Main modules of production management:
The main modules of production management: planning management, purchasing management, production management, quality management, efficiency management, equipment management, inventory management, morale management and lean production management. The goal of production management:
Efficient, low-consumption, flexible and punctual production of qualified products, providing satisfactory services.
Efficient: quickly meet the needs of users, shorten the delivery time of orders, and strive for users.
Low consumption: the lowest consumption of manpower, material resources and financial resources. Realize low cost and low price.
Flexibility: can quickly adapt to market changes and produce different varieties and new varieties.
Punctuality: providing the required products and services, qualified products and satisfactory services within the time and quantity required by users: it means that the quality of products and services has reached the level of customer satisfaction.
Third, the production management methods
1, centralized factory network
Many factories designed according to a unified goal can be better organized and operated more economically. Generally speaking, small-scale specialized chemical plants should be established instead of large-scale vertically integrated manufacturing plants.
2. Group technology
Unlike transferring work from one department to another and handing it over to professional employees, group technology considers all the operations of manufacturing parts and puts the machines that complete these operations together. The technical department of the group reduced the movement, waiting time and WIP inventory between different operations, and also reduced the number of employees required. However, employees must be flexible enough to operate centralized equipment at work and complete the processing process of workpieces. Because the supplier has advanced technical level, the safety of the work has also been guaranteed and improved.
3, the source of quality control
Controlling the quality of source code means doing it well at the beginning of the work. When an error occurs, stop the process or assembly line immediately. Workers become inspectors of their own work and take full responsibility for the quality of their products. Because workers only pay attention to one part of their work at a time, it is easy to find quality problems in their work. Source quality includes automation or automatic detection. It is faster, easier and more repeatable for automatic equipment or robots to carry out quality inspection, which is suitable for too large and complicated work that can not be completed manually.
4.JIT production
JIT means producing necessary products when necessary, not overproducing. Anything that exceeds the minimum requirement will be considered as a waste, because the energy and raw materials invested in things that are no longer needed are not used now. JIT has been applied to repetitive production enterprises. Although there may be great differences between workstations, it is still possible to minimize the transition time and keep the delivery volume to a minimum-usually110 of the daily production volume is taken as the unit delivery batch. Suppliers sometimes even have to supply materials several times a day to keep small quantities and low inventory. When all the waiting quantity becomes zero, the inventory investment is minimized, the lead time is greatly shortened, the enterprise responds to the demand change quickly, and the quality problems are exposed quickly.
5, balanced production load
Balanced production process can reduce the reaction usually caused by unbalanced planning and become a balanced workshop production load. When the assembly line changes, this change is amplified in the whole production line and supply chain. The only way to eliminate this problem is to establish a fixed monthly production plan, so that the productivity is fixed, thus minimizing changes and adjustments. For small-scale production, we can solve the problem of unbalanced production load in the workshop by establishing the same product mix every day.
6. Kanban production control system
Kanban control system uses symbolic devices to manage JIT logistics. In the material control system, containers can be used instead of cards. The card or container forms a semi-pulling system. The power to produce or supply parts comes from the demand of downstream business. The following figure shows an assembly line that supplies parts to an existing machining center. The machining center produces two kinds of parts, A and B, which are stored in containers between the assembly line and the machining center. Every container near the assembly line has a transport kanban, and every container entering the processing center has a production kanban. This is the so-called two kanban system. When the assembly line takes out parts from a container full of a part A, a worker calmly takes away the carrying kanban, puts it into the production kanban and sends it to the storage area of the mechanic center. Workers in the machining center find the container of part A, take out the production kanban, load the parts and put them into the carrying kanban. This allows containers to be sent to the assembly line. The production kanban taken out is put on the tool rack in the machining center, so that another batch of raw materials can be put into production. The kanban on the tool rack becomes the distribution table of the machining center. Kanban cards are not the only way to issue production requests; Other visual methods can also be used when publishing production requests.
7. Minimize mold changing time.
Because JIT production is based on small batch production, the end-changing work in the estimation period must be completed quickly, and now mixed production is consciously carried out on the production line. In order to reduce the mold changing time, the mold changing work in JIT system is divided into internal mold changing and external mold changing. Internal die changing can only be carried out after the machine stops, while external die changing can be realized during the operation of the machine. Other devices that can be used to save mold changing time, such as duplicated tool racks, can also achieve this goal.
Experience sharing of production planning management II. Formulate a reasonable system.
"People tell people to do things, and policies drive tens of millions." This shows the importance of the system. The system is to regulate people's behavior, restrain those who are irresponsible and operate casually, and avoid economic losses to enterprises and people who cooperate with them because of the deviation or mistakes of a few people's behavior. The system only decides how to deal with certain things in the process of work. More importantly, it is necessary to supervise everyone's strict implementation through inspection. Reward and punishment is to ensure the implementation of the system, and it is a means to implement management by economic means, which fully embodies the difference between doing good things and doing bad things. Only by formulating rules and regulations that conform to the actual situation of enterprises, finding problems through inspection and ensuring implementation through rewards and punishments can the best results be achieved. Scientific and reasonable rules and regulations (regulations) are the basis of doing well production management.
Second, the implementation of rules and regulations.
When implementing the system (regulation), we should follow three principles: process, clarity and operability.
Process is to turn decision into process. Everything can be divided into three stages: before, during and after, and the corresponding work content can be determined according to different stages. The biggest advantage of the process is to emphasize execution in the whole process of things happening. The purpose of process management is for the overall work result, rather than emphasizing something itself.
Clarity is to make the key elements in the process into quantitative indicators. If you want to emphasize something, just quantify it. Not quantifying is tantamount to telling others that you don't care and don't value it. If it can't be quantified, it can't be assessed, and it can't be really implemented.
Operability is to make what has been quantified operational. If a plan has only indicators and no specific action measures, it will not be implemented. Only through specific measures, it will not be implemented. Only through concrete measures can the plans and arrangements considered by managers be put in place and the management objectives can be achieved. Thinking of not saying is equal to daydreaming, talking about not doing is equal to saying in vain, saying well is not as good as doing well, and only when it is done well can it be effective.
Third, grasp the overall situation and fine management.
Grasping the overall situation is to ensure the continuity, balance and coordination of the production process; Fine management is the detailed management of the whole process of things, paying attention to both the process and the result.
The so-called continuity means that all factors in production are not allowed to be cut off, so that the whole production chain is closely connected and runs continuously. Personnel shortage, material interruption, equipment failure, safety accidents, etc. , it will waste time and affect the continuity of production.
The so-called balance means that the ratio of supply and demand in production capacity and quality (quantity and quality) of each section and post is roughly equal. If there is an imbalance between supply and demand and a surplus of defective products, it will cause an imbalance in the whole production.
The so-called coordination mainly refers to the coordination between people. That is, between cadres, between cadres and employees, and between employees, they live in harmony and cooperate properly. As long as we cooperate with each other, cooperate closely, pay attention to service, communicate actively, be responsible and work hard, our team will have a harmonious situation, a harmonious environment will promote the coordination of production process, and production will be in a sustained and stable state.
The continuity, balance and coordination of production are the basis of improving work efficiency and the premise of improving product quality and reducing production cost. As a production management cadre, we must first stand at a certain height, focus on the overall situation and grasp the overall situation; Secondly, do a good job in the production site management, concentrate on the process details, formulate standardized operation standards, assess the work effect, cultivate employees' good work style and habits, prevent a "short board" or "worm board" from appearing in the "wooden barrel" in the production process, and ensure that all the boards are roughly the same in height, relatively uniform in quality and moderately matched with each other, thus continuously ensuring the maximum water capacity of the "wooden barrel". Attention should be paid to the "short board" and "insect board" formed by human factors, so as to ensure that all "boards" are roughly the same in height, relatively uniform in quality and moderately matched with each other, thus continuously ensuring the maximum water holding capacity of "wooden barrels". What needs to be focused on is the "short board" and "worm board" formed by human factors. In addition to giving guidance on the work concept, we should also enhance their work confidence, praise and affirm their achievements, find problems with everyone, analyze problems, and propose solutions and measures to prevent problems from happening again. There is an idiom called "let nature take its course", which means that when conditions are ripe, things will naturally succeed. In production management, we can't have the idea of waiting for the conditions to mature. We must take the lead, win a battle and make some preparations.
Fourth, staff concept and skills training.
The management of production process, in addition to equipment and technology, is mainly the management of personnel. People are right, and so is the world. Through the guidance of ideas, the enhancement of consciousness and the training of skills, all employees are encouraged to be willing, capable and capable, and the ability of all cadres and employees to observe problems, find problems in time, actively analyze problems and solve problems correctly is continuously cultivated. The renewal of ideas will make employees have the idea of being willing to work and fighting for it, and have the attitude of taking the initiative to work; The improvement of technical and operational skills will enable employees to be competent for their jobs. The organic combination of the two will produce satisfactory working results. Only in this way can we achieve real implementation, not by quality, quantity and time, but by high quality and high standard, ahead of schedule, beyond the expectations of leaders, and achieve work results beyond the expectations of leaders.
Production planning management experience sharing 3 (1) production planning (PC) The production planner of a company is a very important link. From the perspective of qualification, the existence of order delivery must be considered in combination with customer requirements and the comprehensive operation of the company. First of all, we should communicate and cooperate with sales, material planning and other departments, do a good job in market sales analysis, control workshop production capacity, actively find problems and solve them. According to the strict production scheduling plan of the sales plan, the production tasks of the current month are assigned to each workshop in the form of standard production plan, so as to ensure that all departments in the workshop coordinate with each other and complete the workload on time, so that the produced goods can be delivered to our customers in time with good quality and quantity. Specifically, improvements can be made in the following two aspects:
1. 1 The relevant system, process preparation and assessment mechanism of production plan need to be improved. As far as the current situation is concerned, our company's plan is still in a passive position, and the production plan is basically based on the capacity of the current month, lacking the sales plan provided by the market from the source as a reference; Teacher Wang Jiayao said that the evil source of unfinished plans is sales and inventory. Without a good sales plan and a large enough inventory, the enterprise can't survive, which gives me the feeling that it is talking about our company. Therefore, our next step is to improve the current production planning process, increase the formulation of supply sales plan, and then decompose the production plan to make it more accurate; Secondly, improve the corresponding system and KPI index of production planning post, and then gradually improve the accuracy of production planning forecast;
1.2 communication between departments involved in production planning is not timely and active. At present, due to the fact that kitchen waste and other factors are considered in the production plan, the access factor is not considered, so adjustments will occur in the implementation process. Then, because the communication between departments is not timely, the initiative is not active, and the sales are not timely, the production departments often do not completely follow the production plan, which is mainly manifested in the phenomenon of privately adjusting the production plan; In the future business, we should strengthen the coordination between the sales department and the production department to ensure the smooth implementation of the process, and do not reduce the accuracy of the production plan because of poor communication; Require the sales plan to collect the relevant data of the market sales situation on that day in time, so as to communicate and feedback in time and provide effective basis for adjusting the production plan;
(2) Material Control (PMC)
2. 1 Strictly control the inbound and outbound documents, strengthen control and prevent delivery errors.
2.2 Effective communication, cost reduction and reasonable material demand planning.
2.3 Track and communicate the production schedule and material plan in time, cooperate with the production plan, realize good material loss control, improve the accuracy of material preparation, avoid material shortage and ensure the smooth production.
2.4 Introduce new planning and material control methods, and make every effort to promote the operation in ERP system to ensure the systematicness and integrity of data.
2.5 Strengthen the analysis and tracking of kitchen raw material collection, and formulate emergency plans for the factory;
2.6 Monitoring of material warehousing: the change of demand forecast and the adjustment and control of corresponding inventory, long-term purchase batch and forecast inventory, and demand forecast system.
2.7 Develop the pre-purchase inventory system, and quantitatively calculate the purchase safety inventory, maximum inventory, minimum inventory, inventory turnover rate, sales plan and inventory plan.
2.8 Classification of procurement supply chain: establish the procurement time and report maintenance of each material, and incorporate supplier classification management into company assessment to enjoy resources and prevent abnormal change management of procurement plan.