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China's cutting equipment network news: Guide: After entering the 21st century, the business environment has undergone fundamental changes. Due to the globalization of market competition, diversification of customer and market demands, personalization, and relative surplus of production, the life span of products has been shortened and the price competition has become increasingly fiercer. In order to survive and develop in brutal competition, companies must study low-cost and rapid-response manufacturing methods. The general term for these methods is flexible manufacturing. Flexible manufacturing is not only a production method, but also a new manufacturing concept.
After entering the 21st century, the business environment of the company has undergone fundamental changes. Due to the globalization of market competition, diversification of customer and market demands, personalization, and relative surplus of production, the life span of products has been shortened and the price competition has become increasingly fiercer. In order to survive and develop in brutal competition, companies must study low-cost and rapid-response manufacturing methods. The general term for these methods is flexible manufacturing. Flexible manufacturing is not only a production method, but also a new manufacturing concept.
FX Hi-Tech found that 70% of a production line is redundant. By removing these redundant parts and reorganizing the production process, the utilization rate of the site is more than doubled in just four months, and the equipment removed can be Duplicate a production capacity that is twice as high as the current situation, so that the company's nearly ten million US dollars in investment for the expansion of production is not needed.
Ricoh (Shenzhen) Co., Ltd. uses a flexible manufacturing concept to realize a variety of production methods coexisting. Under the same production plant and equipment conditions, the overall production capacity has increased to 3.5 times the original design capacity.
This shows that flexible manufacturing is setting off a cross-century productivity revolution.
Flexible Manufacturing in a Variety of Ways The following representative flexible manufacturing methods can help us to better understand how flexible manufacturing solves problems in traditional production:
Cell production methods: Compared with traditional mass production methods, cell production methods have two characteristics: one is a small scale (short production line, few operators), and the other is a small production cell after standardization can be simply copied. Because of these two characteristics, cell production methods can be realized: (1) simply respond to changes in production, by replicating one or more cells, it can meet the production requirement of an integer multiple of cell productivity; (2) reduce site occupancy, and cells are It can be simply copied (the cell line can be set up in one day), so when it is not needed, it can be easily dismantled and saves space; (3) The number of operations per cell is small, which makes it difficult to balance the working time between workstations. The difference in working time between workstations is small and the production efficiency is high. (4) By combining employees reasonably, that is, by composing employees with comparable competencies into cells, the highest level of operational capability of employees can be fully exerted. If we can give corresponding incentives to employees according to the productivity of each cell, it will also help promote good competition among cells.
One-man production method: We have seen this situation where the assembly time of a product is less than 10 minutes in total, but it is still arranged on a tens of meters long assembly line, and the assembly work is done by several individuals on the line. , Everyone's working time is only 10 to 20 seconds. For such products with relatively short working hours, if we can break the routine (line production) and instead complete the entire product assembly task for each employee, we will be able to obtain unexpected results.
A stream production method: a stream production method is achieved by: cancel the trolley between machines, and through a reasonable process arrangement and inter-machine slip board settings to allow products to flow between the machines. Its advantages are: (1) greatly reducing the inventory of intermediate products and reducing the occupation of funds and sites; (2) eliminating the needless handling between machines and reducing dependence on transport tools; (3) when quality problems occur in products, The information can be fed back to the front in time to avoid causing the retirement of a large number of intermediate products. A flow production method is not only suitable for machining, but also for the process of product assembly.
Trolley production methods: We often see a product in the manufacturing process, from one line to another line, the transfer tool is a trolley. Focusing on the loss during handling and transfer, someone invented the trolley production line, that is, complete all assembly tasks on the trolley. This will not only save the production line, but also greatly increase the efficiency of handling and transfer.
Fixed production line and changing production line method: According to the change of output of a certain product, two types of production lines are set, one is a fixed production line that meets the minimum batch size, and the other is used to meet the changing production line. Traditionally, traditional production equipment is used to fix production lines, and flexible equipment or cell production methods are used to change production lines.
The use of flexible equipment: A product called a flexible pipe (both plastic and metal) has become popular. In the past, many companies used outsourcing standard production lines for production, but now they are gradually being replaced by simple flexible production lines that they assembled. In comparison, the flexible production line can save more than 70-90% of equipment investment. Second, equipment installation does not require professional staff. General employees can quickly complete the installation on a weekend. Third, they can be removed at any time when they are not needed. Site utilization efficiency.
The general trend of flexible manufacturing is: the production line is getting shorter and shorter, more and more simple; equipment investment is getting less and less; intermediate stock is getting less and less, site utilization is getting higher; production cycle is getting shorter and shorter, and delivery speed is faster The faster the time comes, the less and less all kinds of losses and the higher and higher efficiency. It can be seen that achieving flexible manufacturing can greatly reduce production costs and strengthen the competitiveness of enterprises.
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