In carrying out quality work, I found that many companies have some misunderstandings in the implementation of fixed management. Now combined with some practical and personal feelings encountered in my actual work, I propose and analyze it with my colleagues. The purpose is to clear the source and introduce the fixed management of our country into the right way, so as to achieve better management results, which is beneficial to Promote the improvement of product quality.
1. One of the misunderstandings, it is not clear what "5S" is
It should be said that the starting point and intention of many companies to promote "5S" is good, that is, they want to sort out the production site. Once, when I promoted “5S†in a newly established company, I first gave the staff a fixed management training, and then fixed the design. When working on a fixed design of a workshop, I encountered difficulties. The fixed design plan has been changed several times and cannot be fixed. The layout inside the workshop could not be fixed for the time being, and we had to temporarily put the fixed design on it. In order to institutionalize the company's fixed management, I prepared the company's "fixed management system" (draft) and gave it to the company's CEO. Unexpectedly, after the company CEO looked at it, couldn't understand what was called fixed management? Later, I remembered that when I was training, the company’s CEO was on a business trip, not in the company, so he didn’t know that “5S†was fixed management. When I told him that the management was "5S", he still had some doubts. So, I will show him a "Introduction to Fixed Management" written by Mr. Shimizu, who was 20 years ago, until then, he realized that "5S" is the fixed management.
2. The second part of the misunderstanding, the meaning of "5S" is not clear.
The first two Ss of "5S" are sorted and reorganized. Regarding the meaning of collation, many of the explanations about 5S articles are mostly correct, that is, "differentiate the items that are needed and not needed, and clean up the items that are not needed on the spot." But what is rectification? Many companies fail to explain them correctly and even give a wrong definition.
Some companies define the rectification as: "The products must be positioned according to the regulations, the method is fixed, the placement is neat, and the labeling is clear." Some companies understand the reorganization and rectification as placing items neatly.
We know that the relationship between people and things is divided into three types of states, namely, A (closely combined state), B (state in which certain activities need to be done), and C (states that have nothing to do with work). When Mr. Shimizu Shiri talks about the combination of people and things, the purpose of reorganizing and reorganizing is as follows:
(1) For Class A items, their status must be maintained;
(2) For Class B items, the state must be analyzed, and through improvement, gradually approaching Class A to improve its existence value;
(3) For Class C items, transfer them to other workshops by adjustment to re-establish their existence value. If there is no such possibility, discard them.
In the article "Introduction to Fixed Management", Mr. Shimizu Shiri describes the definition of fixed position: "The so-called fixed-position is to deeply discuss management purposes, constraints and methods of use, and stipulate standards for the state and method of the place and object. "The constraints here refer to conditions and requirements such as safety, efficiency and quality.
In the "Mechanical Industry Quality Management Textbook", "fixed" is defined as: "Scientifically determine the placement area or the solid position of various items on the production site."
From the above, I think that the meaning of rectification should be summarized as "scientifically stipulate the place where the articles are stored, the state of the objects and the method of representation, so as to make it convenient to use."
The third S in 5S is “literacyâ€, and some units interpret their meanings as employees dressing, wearing caps, grooming, behaving in a speech, and having a time concept. There is no doubt that these codes of conduct are needed for a formal company. However, the literacy in fixed management has its specific meaning. In the article "Introduction to Fixed Management", Mr. Shimizu Shimizu once pointed out: "The Code (original code, now most articles have translated it into literacy) can be understood as a method of thinking. Any activity of the company depends on people to do it. Therefore, it is very important to ask the basic code of conduct for people." Many companies rely on the “Code†to try to use it as an important means of preventing the collapse of fixed management. He also said that many enterprises have not done a good job in managing their own management. They often have a situation of "one tight, two loose, and three collapses." One of the reasons is that the standard and structure are fixed, that is, the system itself. unreasonable. Overemphasizing the “Code†also makes it easy to shift the focus on improving the system's hazards.
From the above, in the fixed management, the so-called literacy is to require employees to consciously and conscientiously implement the management system related to their positions and fixed management. If the fixed management of the company is not implemented well or there is a problem, it should be checked to see if there is a problem with the relevant standards or structure. If there are system problems, companies must seriously improve them.
The original intention of literacy can be summarized by the three words “rule of the rules†for employees. But for the enterprise, it is by no means just a summary of the three words of the rules. For example, to do a good job in the fixed management of the mold, it is necessary to carefully implement the mold management system including mold acceptance, numbering, registration, warehousing, requisition, maintenance, appraisal, and re-stocking. However, if the numbering method of our mold is not scientific or even problematic, then the fixed management of the mold is inevitably not good.
3. The third misunderstanding, the promotion of "5S" is the following workshop and workers.
A few years ago, I worked in a Wenzhou company. The company boss hopes that the new engineers can change the appearance of the production site in a short period of time. After considering and agreeing with the company's CEO, the engineer decided to promote "5S" throughout the company. Therefore, he first issued a notice about the "5S" requirements of the workshop, then conducted training and developed a checklist for the workshop "5S". Then organize the office and other departments to go through the inspection every day. What to check? I took a look at it, mainly to check if the workers are doing well. For example, the drawings on the machine are not placed? Did you clean the work place before work? and many more. For the time being, the contents of the "5S" inspection standard are correct. Because the company organizes the work of reorganizing and reorganizing various workshops and departments, there is no organization to carry out scientific design, and there is no corresponding station equipment and facilities. After checking for a while, the workshop site was still the same, and it could not be checked, and it eventually became a cut-off.
Why is this situation in the fixed management of this enterprise? Very simple, the company's management is missing. What the management should do is not done. You can ask the workers and naturally you can't do it. For example, we know that the promotion of “5S†requires that no items can be placed in the workshop channel. This company is because the workshop is too small, the workpiece has to be placed on the safe passage for a long time, and the passage of the workshop can not be vacated. Obviously this The company does not have the basic conditions for promoting "5S". For example, the work, quantity, cutting tools and other items used by workers at work are not placed, and some work stations do not even have a toolbox. We ask workers to do so, how can we do it? Got it.
Carrying out "5S" is actually more of management's business. What should be done first in management?
First of all, whether the workshop layout is reasonable, if it is not reasonable, it needs to be adjusted. Secondly, is the facility and equipment required for the site set up fully equipped? Again, have the rules and requirements for the placement of various items been specified? Has the relevant system been developed? and many more. These issues are all considered and carefully managed.
When I was working in Quanzhou, I went to a company that produces brake pads. The company's factory building is transformed from the old house, there is a small workshop in the warehouse, and the main workshop has both metalworking and heat treatment. The company CEO wants to promote "5S". I have seen him in his workshop and said to him: "The conditions for your 5S are not mature." He does not understand, saying that "5S" is not just putting things in order? I told him that we must first rationalize the production process of the product, re-do the production layout, and then put the items in place.
When I was working in a company specializing in the production of road construction machinery in Quanzhou, the chairman asked me to give them a management class. I was invited to talk about the basics of fixed management. When he learned that the process route of the workshop was not smooth, he immediately instructed the technical department to come up with a new process layout plan and make process adjustments. When I went to the company a week later, I found that the workshop was adjusting the equipment according to the new process layout. I know that this company has a lot of production equipment, many of which are still large equipment. This company is very touched by the spirit of respecting knowledge and working hard. Later, the chairman of the company told me that after the workshop was re-set, the production process was smoother than before, and the work efficiency was improved. I am happy for him in my heart.
It can be seen that it is not just the workers' affairs to do a good job of setting up management. More things are things on the management side.
Generally speaking, the following work is mainly done during the design phase:
(1) Make a fixed diagnosis of the area, object or site to be fixed, determine the required items (Class A, Class B) and unneeded items (Category C) and the identification method, and determine the items to be removed and their Disposal method;
(2) Thoroughly clean and rectify the area to be set; mark the required and unneeded items, and remove unnecessary items; clean up or leave dead ends.
(3) drawing a fixed map;
(4) Determine the placement method for the items to be used, determine the required containers and number them;
(5) Determine the required information;
(6) Clearly responsible for management.
The main tasks to be done in the preparation stage are:
(1) making or repairing the required containers;
(2) making information media;
(3) Prepare the site where the items need to be removed;
(4) Dividing a fixed area or site;
(5) Prepare the necessary standards and rules and regulations.
All of these management should be carefully organized and solidly done. Otherwise, if these tasks are not done well and they are not done, they will require workshops and workers to implement fixed-positions, and how to set up management is also not good.
4. The fourth part of the misunderstanding, promote "5S", the more S, the better.
Nowadays, many companies in the society have increased their security requirements and turned "5S" into "6S". This shows that everyone attaches importance to safe production. Mr. Qing Shui, the inventor of the fixed management, once said: The most critical of the "5S" is the first two S. When we are doing the finishing work, we must consider the safety of our employees and consider them comprehensively from the relationship between the proper handling of things and places, people and things, and people and places. Organizing and reorganizing is not simply cleaning the workplace, putting things in order and finishing. Because each item is fixed, it is scientific and reasonable. The so-called science, of course, includes security. For example, the height of the items stored on the shop floor should be appropriate, otherwise it will endanger the safety of employees. For another example, the lathe operator should strictly prohibit the placement of the chuck wrench on the headboard, otherwise it will bring danger to himself and the surrounding employees.
Cleaning, for the equipment, it is necessary to maintain according to the regulations to ensure that the equipment is in good condition. If we can't do our best to maintain the equipment, what is the use of adding an S?
Furthermore, from a management point of view, safety production is a comprehensive management task that involves not only equipment management, personnel management and fire management, but also security. Enterprises must establish and improve safe production organizations, and formulate a set of scientific and effective safety production management systems in combination with the actual situation, and often check and summarize them in order to continuously improve and improve them. It is by no means an additional S in the fixed management can solve the problem.
As Mr. Shimizu said, the key to the core of fixed management is the first two S. He just reminded us to insist on working hard to organize and rectify. Under the premise of optimizing the process route, the overall layout and management of the site should be continuously optimized; in the enterprise where the process layout is determined, a process and a process must be completed to improve and improve the level of on-site fixed management.
5. Misunderstanding 5, some hope to replace the site management with "5S".
Some company CEOs saw "5S" and thought that "5S" was very useful and should be promoted throughout the company. He invited people to give lectures, put video, and developed a responsibility area. The work cannot be said to be done less. However, the entire production site management remains the same. Why is this the result? Because the company has been busy with a few people from the beginning of training to the fixed design, the production department has never been involved, they have not only turned their minds, and the enthusiasm of on-site management has not been mobilized. What do they usually do, or how to do it. The company's "5S" seems destined to fail. The reason for this, I don’t want to say that everyone is already clear. In the minds of the bosses, his real idea is to solve all or major management problems on the spot through "5S", and even want to replace the site management. The author believes that fixed management is an effective way and means to do a good job in on-site civilized production, but it is impossible and impossible to solve all problems in on-site management. Those who attempt to replace the on-site management ideas and plans with "5S" are unrealistic and undesirable.
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