Abstract: This management method focuses on analyzing and explaining the process management of die-casting production, identifying and eliminating waste, establishing a long-term management mechanism, and triggering the organic combination of various teams. From the control of conditions during the production process, such as optimizing process technical parameters and forming standardized operation documents, periodic maintenance of equipment, creating standard inspection manuals and supervising their implementation, etc; Moving on to the problem exposure mechanism in the production process, managing the efficiency of responding to abnormal handling and problem-solving capabilities; Finally, each service team provides material preparation and technical support during the production process, cultivates versatile workers, such as mold maintenance, on-site technical support from process technicians, and quality control.
Keywords: safety lighting system; Exception handling; Process technology; Quick switching; Multi skilled workers; Equipment maintenance and inspection; Mold management
1. Overview
With the continuous maturity of the die-casting industry and the advancement of die-casting technology, industrial robots have gradually replaced the work content of workers and formed a standardized production mode. In the context of continuously rising raw material prices, increasing internal production and manufacturing costs, and fierce market competition, enterprises are forced to shift from extensive management to refined management, seeking benefits from management, achieving efficiency improvement and cost reduction, and promoting the maintenance of competitive vitality in order to achieve long-term and stable development. Therefore, consider the management methods for the efficiency of single die casting machines from the following dimensions.
2. Management of production conditions
(1) 5S management: 5S refers to organizing (SEIRI), rectifying (SEITON), cleaning (SEISO), cleaning (SEIKETSU), and literacy (SHITSUKE), also known as the "Five Rules".
Sorting: Distinguish between items that need to be and those that don't, keep only necessary items on site, and manage the on-site space;
Rectification: Essential items are placed neatly and orderly according to regulations and methods, clearly labeled, and time efficiency is managed;
Cleaning: Remove dirt and debris from the site, remove material waste from the work area, and manage the working environment;
Cleaning: Institutionalize and standardize the methods of organizing, rectifying, and cleaning to maintain their results;
Literacy: Everyone operates according to rules and regulations, develops good habits, and makes everyone a cultured person.
Through the continuous deepening of 5S management, we will use 5S to help us analyze, judge, and handle various problems that exist. Implementing 5S can improve the quality of enterprises, increase productivity, reduce costs, ensure on-time delivery, and also ensure safe production while maintaining and continuously enhancing the high morale of employees. A company must implement a 5S plan in order to improve and continuously enhance its corporate image. Implementing 5S ultimately achieves:
Improving and enhancing corporate image: A neat and tidy work environment that easily attracts customers and makes them feel comfortable; Meanwhile, due to the spread of word-of-mouth, companies can become role models for other companies, greatly enhancing their reputation.
Promoting efficiency improvement: With a good working environment and atmosphere, coupled with highly cultured partners, employees can concentrate and conscientiously do their job well, which will inevitably greatly improve efficiency.
Reduce until faults are eliminated, ensuring quality: Excellent quality comes from a good working environment. The working environment can only be effectively avoided from contaminating or damaging machinery, maintaining equipment efficiency, and improving production quality through regular cleaning, inspection, and inspection.
Ensuring enterprise safety production: Sorting, rectification, and cleaning must be done with clear storage, and things should be placed in their original positions. The workplace should be kept spacious and bright, and the passages should be unobstructed at all times. Items that should not be placed on the ground should not be placed. The factory is orderly, and the occurrence of accidents will naturally be greatly reduced. Of course, safety will be guaranteed.
Improving the mental state of employees and revitalizing the organization: It can significantly improve the mental state of employees and revitalize the organization. Employees have dignity and a sense of achievement, are dedicated to their work, and drive ideological improvement.
So 5S is the fundamental management of enterprises and an essential management to promote their development.
(2) F=(X) Condition management: Many enterprises only focus on results and neglect process control in their production management process. Often, adverse results are repeatedly generated, problem points recur, and the root cause cannot be cut off. At the same time, when the process conditions are not properly controlled, it brings many unstable factors to the results. It is very likely that a deviation from a certain condition in the process will result in poor results, and the problem points that cause poor results cannot be quickly identified. Therefore, the management of production process conditions is very important in the production process. Once the conditions are well managed, the results naturally occur. Therefore, all conditions (X) that affect the results (F) must be identified and managed ().
People: Use a skill matrix to evaluate the skills of on-site operators, and adopt a four level training mechanism to train the skills of operators, achieving job responsibilities and job duties. Prepare homework instructions and guide operators to operate according to standards. It is strictly prohibited for operators to not comply with on-site standards to ensure effective management of manufacturing requirements on the production site. It can be managed through the following management methods:
1) Production personnel meet the job skill requirements and have undergone relevant training and assessment.
2) For special processes, it is necessary to clearly define the professional knowledge and skills that special process operators and inspectors should possess. Those who pass the assessment must hold a certificate to work.
3) For key positions with special requirements, personnel who have passed professional assessments, possess on-site quality control knowledge, and are experienced must be selected and appointed.
4) Operators are able to strictly abide by company regulations and operate strictly according to process documents, and are responsible for their work and quality.
5) Inspectors can strictly follow the process specifications and inspection instructions for inspection, keep original inspection records, and submit them according to regulations.
Machine: Develop daily, weekly, and monthly maintenance manuals and equipment inspection forms for equipment, guide personnel at all levels to implement equipment self preservation activities in accordance with standards, establish frequency of replacement of vulnerable parts, and ensure equipment mobility and productivity. By implementing OEE management for equipment, the efficiency of production line management can be improved through the following management methods:
1) There are complete equipment management measures, including clear regulations for equipment procurement, circulation, maintenance, upkeep, calibration, etc.
2) All provisions of the Equipment Management Measures have been effectively implemented, with equipment ledgers, equipment skill files, maintenance and calibration plans, and relevant records. The recorded content is complete and accurate.
3) Production equipment, inspection equipment, tooling tools, measuring instruments, etc. all meet the requirements of the process specifications and can meet the process capacity requirements. If the processing conditions change over time, timely adjustments and compensation can be taken to ensure quality requirements.
4) Production equipment, inspection equipment, tooling tools, measuring instruments, etc. are in good condition and under control.
Material: The quality of materials is directly related to the stability of production efficiency, and the basic concept is that all products launched are qualified. Establish material judgment standards based on process technology management standards, and effectively guide operators to implement the principle of "three no combat" to control material defects at the forefront. It can be managed through the following methods:
1) There are clear and feasible management systems for material procurement, warehousing, transportation, quality inspection, and strict implementation.
2) Establish a system for incoming material verification, storage, labeling, and distribution, and strictly implement it to control quality.
3) The raw materials or semi-finished products transferred to this process must comply with the provisions of the technical documents.
4) The semi-finished and finished products processed meet the quality requirements and are labeled with batch or serial numbers.
5) There are control measures for non-conforming products, clear responsibilities, and the ability to effectively isolate, label, record, and handle non-conforming products.
6) Effective management of production material information and traceability of quality issues.
Method: By sorting out the technical requirements, establishing management parameters for the technical requirements, forming standardized operation documents, and providing training, execution, inspection, and processing for these operation documents, the production process can be controlled. It can be managed through the following management methods:
1) The layout of the process flow is scientific and reasonable, which can ensure that the product quality meets the requirements. This can be combined with the achievements of lean production.
2) Can distinguish key processes, special processes, and general processes, effectively establish process quality control points, and clearly identify processes and control points.
3) There are formal and effective production management methods, quality control methods, and process operation documents.
4) The main processes have process specifications or operation manuals, and the process documents provide specific technical requirements for personnel, tooling, equipment, operating methods, production environment, process parameters, etc.
5) The process regulations for special processes should not only specify the process parameters, but also make specific provisions for the control methods of process parameters, sample preparation, working medium, equipment, and environmental conditions.
6) The important process parameters and characteristic values in the process documents have been evaluated or validated by the process; The changes in the main process parameters of special processes must be thoroughly tested and verified or approved by experts before the documents can be changed.
7) Specify inspection points, inspection methods, and acceptance criteria for each quality control point, and specify relevant handling methods.
8) Establish and implement procedures for the preparation, evaluation, and approval of process documents to ensure the accuracy, completeness, and uniformity of the documents used on the production site. The process documents are in a controlled state, and the current effective version of the process documents can be obtained on site.
9) All documents can be strictly executed, and recorded information can be filled out in a timely manner according to requirements.
10) Most important production processes use control charts or other control methods.
After standardizing the above management conditions, using a fishbone diagram to analyze the impact of each factor on the management results can quickly identify the reasons that affect the results and achieve a fast correction mechanism. When all factors are executed according to standardization, but the results still show abnormalities, root cause analysis should be conducted to identify the root cause, in order to implement improvement activities. By improving the results to be good, standardization should be formed for the improved results. Continuously promoting the standardization of management conditions can avoid the occurrence of poor results and maximize the stability of production efficiency.
3. Problem exposure mechanism and response efficiency management in production
1) Andeng System: Andeng System refers to an information management tool used by enterprises to collect information about equipment and quality on the production line through lighting and sound alarm systems distributed throughout the workshop. In a lighting system, each device or workstation is equipped with a call light. If a problem is found during the production process, the operator (or the equipment itself) will turn on the light to draw attention, so that problems in the production process can be dealt with in a timely manner, avoiding interruptions in the production process or reducing the possibility of their recurrence. Through the management of the lighting system, the problem points of the machine can be quickly exposed, promoting the rapid handling of abnormal shutdown of the machine, minimizing the downtime of the machine, and at the same time, driving the service awareness and efficiency of each service team towards the production line.
2) Management Dashboard: By recording and summarizing the problem points of each machine through the management dashboard, the problem points are exposed, allowing managers at all levels to effectively identify and understand the abnormal situation of the machine. At the same time, through monthly and annual summary and analysis of the abnormal problem points, the experience of managing and solving the problem points of the machine can be effectively summarized, which can achieve the inheritance of experience and improve the efficiency of handling exceptions, achieve rapid response and handling of exceptions, and ensure the effective duration of machine production.
3) Establish a response mechanism: When an abnormality is detected in the production machine, the safety light system is triggered, and the service response efficiency of the service team is crucial, directly related to the production efficiency of the machine. Therefore, when setting up the safety light system, a management mechanism should be introduced. Each service team must arrive at the site within one minute when the safety light is triggered, bring corresponding tools, and implement the response according to the exception handling process. Responsibility areas can be divided according to the production line machine, so that the efficiency of the production machine is directly linked to the response and processing ability of the service team, and use the mechanism to drive the enthusiasm of the service team.
4. Service management of the service team
1) Process technology: Process technology not only needs to complete the sorting of technical requirements, but also needs to establish standards for biotechnology requirements, standardize the management conditions in the process, and output these standardized documents to provide training and guidance for machine operators, so that they can master various control conditions in the production process. During the production process, process technicians should regularly inspect the performance of machine operators, supervise them to follow standard documents, and strictly prohibit arbitrary changes to equipment parameters and conditions to ensure the effective implementation of biotechnology requirements. If problems are found, they should be promptly corrected or a team should be organized to carry out technical breakthroughs. Distribute corresponding responsibilities and rights to process and technical personnel, making the standardized documents of on-site biotechnology elements authoritative.
2) Equipment Maintenance: Establish and improve daily, weekly, and monthly maintenance and inspection standards for equipment, output equipment inspection operation manuals, and train and guide operators to implement equipment maintenance according to standard documents. During the production process, periodically supervise the execution, and at the same time, establish planned equipment maintenance to elevate post maintenance to preventive maintenance and then to the improvement maintenance stage. While guiding machine operators to carry out independent maintenance, they should also exercise the skills of maintenance personnel, improve their ability to solve abnormal problems, and be able to quickly handle equipment abnormalities in the production process.
3) Mold management: Establish hierarchical maintenance management standards for molds, form a standardized management process from mold acceptance to mold scrapping, establish mold archives, effectively record and analyze various data of molds. The maintenance and upkeep of molds are classified according to their urgency and importance, and the handling of mold problems during the production process is prioritized to achieve rapid response and ensure the efficiency of machine production. Fully prepare the molds that need to be changed on the production line again, effectively manage external SMED operations, and cooperate with production to complete rapid mold changes.
4) Team cooperation and supervision: Each service team and production team establish a management mechanism for mutual service supervision. The process technology inspects and supervises whether the on-site machine operators comply with the standard documents, and the on-site machine operators operate according to the standard operation documents. If there are problems, the process technology should be organized to reflect on whether there are problems with the standard settings, and take corresponding responsibilities; Equipment maintenance personnel shall inspect and supervise whether the on-site maintenance and inspection by the machine operators are in place, and have the right to assess those who fail to follow the standard documents. However, if the equipment stops production beyond the specified time period due to abnormal equipment, the equipment maintenance personnel shall bear the corresponding shutdown losses; The same mechanism is applied to service teams such as mold management, forming a virtuous cycle of mutual supervision and management.
5. Summary
（1） When all conditions in the production process have been standardized, the operating time of each institution is also fixed, and the production cycle time of a single product on the machine is fixed. The shift output can be stably achieved, and the production efficiency of the machine can be stable.
（2） Continuously identifying waste in the production process, effectively exposing and improving problem points in the production process, and through the management of the service
team, continuously shortening the downtime of the machine to ensure maximum efficiency in production, the production efficiency of the die-casting machine will definitely be improved.
Authors of this article: Zhao Ping, Jiang Xiaoyong, Tang Guoqing, Zhang Yangang, Zhu Yongxing, and Huang Zhongqiang from Chongqing Huantai Machinery Manufacturing Co., Ltd
