Recently, the Sinopec Jinan Engine Division held a mid-term summary of lean production. So far, lean production has been operating in the Jinan Engine Department for more than 5 months. The lean production is from standardized operations, personnel optimization, streamlined production, assembly line balancing, movable rate monitoring, work in process quantity control, quality control, TPM, logistics improvement The work was carried out from different perspectives such as the construction of the grass-roots team and the visualisation, and the work was pushed forward in depth.
The number of systems is greatly reduced
In order to reduce the waste of inventory, the cylinder head workshop strictly controls the number of WIPs between processes. First of all, the optimization of the process layout, so that the process time is equalized to avoid the accumulation of the transfer of the workpiece; secondly, re-layout of the production line equipment, erected roller, to ensure that the workpiece along the line to achieve streamlined production. Formulated inter-session period quantity standards and strictly managed turnover tool boxes.
Through a series of measures, the number of B-line systems in the cylinder head shop decreased significantly. From January to March, an average of 2,860 pieces decreased to 1,124, a decrease of 60.7%.
Implement equipment TPM management
For machine shops, the stability of the equipment is the key to streamline production and inventory, and ultimately affect the production efficiency. Under the guidance of lean thinking, pilot unit cylinder head workshops actively explored new methods for equipment management and maintenance, introduced implementation equipment TPM management, ie full production and maintenance, and committed to maximizing the overall efficiency of equipment. The specific approach is to optimize the maintenance of the equipment, to combine the maintenance of the operators and the professional preservation of equipment personnel, and to supervise and supervise the process managers at all levels from the supervisor to the manager in charge.
Improve assembly shop logistics
For the assembly shop, the advantages and disadvantages of logistics and distribution methods have a major impact on productivity and product quality. To this end, the assembly shop took a series of measures to optimize the distribution of parts and components, and successively carried out the following work: 1. The management of product layers and classification was divided into A, B, and C categories. The large items delivered by using special equipment are Class A parts, such as: supercharger, water pump, supercharger exhaust pipe; moderate volume is Class B, such as: main bearing bush, rear oil seal, filter assembly, fuel pipe Small size does not occupy the site space as Class C, such as various standard parts and small parts. 2. Visualized kanban delivery delivery information; 3. According to production beats, strictly match the number, or set the delivery cycle or implementation of space full replacement. 4. People-oriented, positioning parts and components, especially heavy parts located in easy to obtain place.
Improve the quality management system
Quality is a permanent topic. There is no best and only better. Under the guidance of the lean concept, from the first-level and second-level quality management departments to the production line, the quality control process is re-arranged, and the quality control node is added to the processing line. Daily non-performing product registration analysis, set the responsible person to correct deadlines, visualize quality information. These tasks have resulted in a significant improvement in the qualification rate for the integrated end-of-line PPM of the cylinder head and the assembly line.
Visualized management at a glance
Since the implementation of lean production, it has a deeper sense of visualisation. Visualization is visualization and the presentation of information. Presented on the establishment of a public platform, the person who does the work is a record of the work, is a timely summary of the work, and the manager can see the progress of the work, can guide, supervision. Personnel information, production information, quality information, equipment information, knowledge learning, reward and punishment information, etc. can all be presented in a flexible format.