As a discrete manufacturing enterprise that produces according to orders, the multi-variety and small-batch manufacturing mode, coupled with customers' strict requirements on product quality, technology and delivery, not only makes the management difficulty greatly increased, but also the operating cost of the enterprise is extremely high. In this context, how can discrete manufacturing enterprises effectively control, reduce costs and increase efficiency in order to reshape their core competitiveness?
In the face of complex production process and scattered paper/localized production factor failures, the production process is often opaque, production is extremely difficult to warn, defective products can not be intercepted in time, and even quality problems can not be traced back, which makes it difficult to trace products after production.
With the rapid growth of business scale, orders are increasing. In order to conform to the trend of digital transformation, meet more and more detailed customization needs, and realize multiple internal drives such as cost reduction and efficiency increase, business growth and competitive advantage, customers are constantly accelerating the pace of management innovation, actively seeking coastline technology based on the present and focusing on the future, and actively seeking to meet customers' needs of "quick response", "full traceability" and "high quality"
In view of the management pain points and core business needs of enterprises, Coastline Technology reorganized the production process from the actual business perspective of discrete manufacturing industry, controlled the core links of the production process, and integrated digital quality management and bar code technology to re-engineer the production process.
0 1. Mobile input of inspection data
In the production process management, starting with the quality management of the whole production process, the quality inspection data of the whole production line from incoming inspection (IQC), process inspection (IPQC), process final inspection (FQC) to delivery guarantee (OQA) are efficiently entered into the system by using PQM (Digital Quality Management) developed by the enterprise cloud platform of the coastline science and technology chain.
On the one hand, instead of the traditional manual recording of inspection data, it is inefficient, error-prone and costly to manually enter the spreadsheet; On the other hand, PQM integrates 6-sigma and lean theory, including SPC, CPK and other practical tools, which can automatically generate multi-dimensional visual reports, improve data utilization, make workshop information more transparent and real-time by using visual kanban, improve the control and response speed of production process, and provide effective basis for quality improvement.
02. Barcode traceability of quality information
In terms of quality tracking and traceability management, we will continue to upgrade, link PQM with coding application, record the whole life course of products based on barcode technology, and use the scheme design logic of "combining software and hardware with data transformation" to complete the deployment and landing of the solution in only 1 week.
By customizing the PAD+ code gun, the serial barcodes of key elements such as people, machines, materials, methods, environment and measurement in the workshop can be realized, and the digital upgrade of the production line can be realized, so as to effectively collect the relevant information and data of each product from materials, production, finished product delivery, logistics and transportation, track the whole process of its life cycle, establish a comprehensive and efficient quality traceability system, and enable enterprises to realize early warning and monitoring of production anomalies and after-sales quality tracking.
As a lightweight and highly adaptable total quality management system, coastline PQM+ code application truly integrates the concept of "quality management" into the manufacturing process, and its implementation effect is far more than electronic data and bar code management.
By introducing the total quality management system of coastline science and technology (PQM+ coding application), the first-time qualification rate of customer-related production line products increased by 10% for the first time, reaching a higher level in the industry and maintaining continuous improvement;
With the help of the intelligent fool-proof mechanism of the system, the customer automation machine has realized the function of automatic interception and early warning of anomalies, the interception rate of anomalies has reached 100%, and the single-line staffing has been reduced by12, greatly reducing the personnel cost;
In the past, once abnormal production or after-sales customer complaints were found, it was necessary to manually look through a large number of documents to find and locate the problem point, which was inefficient and even difficult to find the problem most of the day. With the us5ming PQM+ code, the production records and quality data of all defective products can be queried or exported in 5 minutes by directly inputting the bar code on the WEB, and the abnormal response can be completed quickly, and the traceability efficiency of quality problems can be improved by nearly 50 times.
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China is currently implementing the "Made in China 2025" strategy, aiming at building a manufacturing industry with international competitiveness, and its ultimate goal is the quality of manufacturing products.
"Made in China, quality first" has become the common sense of the government and manufacturing enterprises. By promoting the application of quality management software in enterprises, improving the quality management level of manufacturing industry and enhancing product competitiveness, "Made in China" is no longer synonymous with low-quality products.
Factors affecting the quality of enterprises
To do a good job in the quality management of enterprises, it is necessary to find out how the product quality is formed, find the source from the complicated quality problems, prescribe the right medicine, and fundamentally reduce the quality problems.
From the formation mechanism of product quality, product quality is planned by market research, determined by design, guaranteed and realized by manufacturing, confirmed by inspection and displayed in use. Therefore, product quality is the product of the process, and its formation process includes five links: market research, product development, design, equipment and raw material procurement, manufacturing and inspection, sales and service. The activities of each link are undertaken by all departments of the enterprise and all its members, which are all important links in the process of product quality generation and formation.
Manufacturing is an important part of product quality formation. Its main quality objectives are: making production plans in an economical way, organizing balanced production according to the specified requirements, strictly implementing the requirements of product technology and process documents, implementing quality control, and producing products with the quality meeting the drawings and standards according to the required quantity and date.
For the production process, there are six main factors that affect the quality of products, namely: people, machines (machinery and equipment), materials (materials), methods (methods), measurement (measurement) and environment (environment). Therefore, quality management software came into being. In view of the factors that affect product quality, quality management software can control the process of these six factors and fundamentally help enterprises to do a good job in quality management.
Problems existing in quality management of manufacturing enterprises
In recent years, with the continuous development of social economy, consumers have higher and higher expectations for product quality, and enterprises pay more and more attention to the control of product quality. But in terms of the final effect, there are still many problems.
How to improve the quality level of manufacturing enterprises?
Quality is the life of an enterprise and the display of its overall quality. Enterprises can take measures from three levels: target management level, actual operation level and information technology level to enhance and improve the quality management level of manufacturing enterprises. What is quality management software?
Generally speaking, as long as it is an information system, it is called IS (Information System). The design of information system generally has no strict guiding ideology, and the purpose is to realize the informationization of management.
Quality management software is a simple and efficient management automation system by employees through computer technology and internet technology, which is used for manufacturing enterprises to carry out quality management and standardize all aspects of business activities. Quality software information system can be called QIS (Quality Information System). Quality management software can help the quality operation of enterprises meet certain certification requirements and help the products or services of enterprises meet certain quality requirements.
What are the functional modules of quality management software?
At present, there are many kinds of quality management software on the market. According to the products of various software manufacturers, quality management software can be divided into product information management, inventory management, procurement management, production management, equipment management, laboratory management, quality management, sales management, after-sales management and other modules according to functional modules. A large-scale system covering product design, manufacturing, inspection, quality analysis and after-sales can meet the data analysis needs of enterprises for a series of operations such as product design, product manufacturing, product inspection, product experiment and product traceability.
Quality management software should manage all the links that affect product quality, such as temperature, humidity, cleanliness and pressure in the workshop, warranty and efficacy of production equipment, inspection equipment and experimental equipment, storage of products during transportation and maintenance, quality assurance of materials, laboratory conclusions, etc.
Classification of quality management software
In order to meet the needs of enterprise quality management, there are many kinds of quality management software in the market, mainly based on total quality management, without clear classification standards. Enterprises can choose suitable software according to their actual needs, strengthen quality management, and make their products or services meet quality requirements.
Ji Meng Intelligent has created a management software-Digital DreamWorks, which belongs to manufacturing intelligent manufacturing. The quality management system of Ji Meng Intelligent Digital DreamWorks starts with quality, and analyzes the whole process quality data in combination with massive product quality data, so that enterprises can realize intelligent quality management from data information.
At present, many manufacturing industries in China have gradually realized production automation and management informationization. With the concept of "Industry 4.0" put forward, most domestic manufacturing industries are gradually moving towards manufacturing intelligence. With the help of big data technology, DD-Factory helps enterprises to build a "internet plus" quality management platform and improve product quality control ability, which is the only way for enterprises to lead to intelligent manufacturing.
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