Overcome difficulties, reduce costs and increase efficiency

April was originally the start of our company's new fiscal year, but the sudden epidemic disrupted the established work rhythm, and it was not until May that a small number of work and production resumed, which was aggravating for a manufacturing enterprise that was already under great pressure. Our company's operating data last year showed that labor costs have risen sharply, raw material prices have risen sharply, the company's profits have fallen sharply, the current operating pressure has doubled, and there are many difficulties. As a mature company for more than 20 years, we chose to face the difficulties. The first and foremost is that production needs to reduce costs and increase efficiency, which is also imminent. During the epidemic, everyone worked from home, brainstormed online meetings, and negotiated a series of improvement plans. After the gradual resumption of work, we implemented them.

A production plan lock

In a manufacturing enterprise, the rationality of the production plan directly affects the production cost. The production scheduling unit is the baton of production, and the production plan is locked and unchanged, and strict implementation is the lowest production cost. Originally, the company had a lock-in requirement, but due to various reasons, it was not fully implemented. There are also cases where we stepped too far and failed to meet the standard, but the impact was even greater. Based on this, we have learned from experience and combined with the current situation, and locked the production plan of the three processes of rubber mixing, molding and post-processing for one week. After resuming work, we strictly implemented it and made certain progress.

2. Personnel demand forecast

In order to achieve the lock-in of the weekly production plan, stable attendance of personnel is a necessary condition. In addition to adopting an excellent retention mechanism, it is also very important to replenish personnel in a timely manner. For this reason, the production scheduling unit proposes personnel requirements 10 days in advance according to the production plan. These 10 days include All the time of recruitment, induction training and induction training, so as to establish the "General Worker Scheduling - Induction - Recruitment Day Transition Table", providing enough recruitment time for the personnel department to achieve stable attendance of personnel.

3.equipment comprehensive physical examination

Equipment is one of the important factors to ensure production capacity. The stable performance of equipment is based on daily rational use and maintenance. Good maintenance will not break. Last year, our company did not do enough equipment management, resulting in unsatisfactory equipment status and sometimes even affecting production. This year, the company put forward a goal to restore the equipment in use to the factory state, that is, to be in good condition. After discussion, some improvement plans were determined. First of all, our equipment supervisor took the lead in inspecting each part of each equipment one by one, conducted a comprehensive physical examination of the equipment, listed a list of problems, and formulated a spare parts procurement plan and equipment maintenance plan for this. Daily standardized management of equipment, inspection, special warranty, fixed warranty and complete warranty are all implemented, and finally the equipment is in good condition.

4. mold physical examination

The mold and the product are in direct contact, which directly affects the production cost of the product. Good mold products have low defects, convenient and labor-saving mold ejection, fast trimming and even no flash. For this reason, we learn from the method of equipment improvement to conduct a comprehensive investigation of the mold status. , a complete overhaul. Conduct physical examination and satisfaction survey on all molds in process. The satisfaction survey is mainly based on the impact of the auxiliary mold on operation safety, production efficiency and production environment. , The mold management department and the user department jointly scored. At present, the satisfaction survey has been completed, the mold physical examination has been completed 30%, and the mold maintenance work has been fully carried out, which is a very challenging job.

5. product TOP7 improvement

Product quality and efficiency are also a large part of the cost. The company has recently established a product improvement team consisting of 7 people from the quality control and manufacturing departments. According to the ranking of product defects, each person selects the most familiar product for improvement, combined with the production plan to ensure There is always an improved product on hand every day, and the product is made for life. The improvement is based on the improvement of production quality and production efficiency. First, data statistics of products are carried out to determine the main defects, use 5why to find out the real cause, formulate effective measures, and then effectively implement and standardize. We take the form of regular meetings to review the phased improvements, and brainstorm for key problems. At present, the TOP7 improvement work is carried out in an orderly manner, and we look forward to the release of the results.

All the above improvements revolve around cost reduction and efficiency increase, and some even require a very long period, but it is indeed the road we must take. Only by continuously cultivating internal strength and improving management can we remain invincible in the ever-changing moment and ensure the competitiveness of our products. We will uphold the company philosophy and continue to improve to the end!