Su HY takes the ERP system as the platform, combines the personalized characteristics of internal production, and comprehensively realizes the information interconnection of the production process of the group aiming at the one piece flow system of the Shuttle Division, the hanging system of the Knitting Division and the IE-box system of the Special Arts Division, forming a brand-new lean production mode with the group as the core, integrating the personalized production operation modules of each division through information technology, reengineering the traditional production process, controlling the production cost, and improving the management level, thus improving the real-time rapid response and market-oriented rapid response of the enterprise.
1, the main methods of Jiangsu HY supporting lean production with information technology
HY Art dyeing and finishing market positioning in Jiangsu determines the diversity and richness of products in various business units within the group. Conventional production processes and processes are not completely compatible, so it is impossible to adopt a unified production system to meet its personalized production needs. Instead, it is necessary to set up a case to effectively integrate and integrate lean production according to its individual characteristics and different needs.
2. Establish a variable project team, realize the mobile management of the project implementation process (1), and form a matrix project team. Each division shall set up a project team composed of production and technical related personnel and external experts, so as to achieve the goal of overall control and phased implementation by formulating the project plan and project implementation time. The team made it clear that the Information Technology Section would take the lead in monitoring the implementation progress. During the on-line period of the project, summarize the implementation progress and existing problems of last month, and put forward the improvement measures and implementation plan for next month to ensure the orderly implementation of the project.
(2) change organization and flexible management
In the process of project promotion, once it is found that the original project team is difficult to complete the project schedule or faces new technical problems, it will integrate human resources across departments within the group to support each project to advance as planned.
(3) Using OA platform to assist communication
As a communication and cooperation platform between the group's major projects and sub-projects of various business divisions, the OA office automation system of the group plays a very important role. The overall planning progress of the project and the progress of sub-projects are released in OA at the first time and form a database; The experience and knowledge accumulated during the project implementation went online in time, making OA platform the second classroom to promote all employees of the group to learn the integration of industrialization and informatization and understand lean production training.
3. Production and implementation of the project.
According to the concept of lean production management (www.chinatpm.net), the project is implemented by scientifically designing and optimizing the logistics route, walking distance of personnel, plant utilization efficiency, rational equipment layout, energy saving and environmental protection processes. Before the equipment installation, the project team visited and investigated excellent enterprises around the goal of lean production, and combined with the suggestions of industry experts and external experts, re-planned the original unreasonable layout of the workshop, effectively shortened the logistics route by optimizing the layout, and improved the management level and labor production efficiency of the enterprise while improving the scientific design of the production process. Equipment installation and trial use need space and time, while workshop production needs to be carried out as planned to ensure customer delivery. Each project team should make careful plans in advance, and large projects should be implemented step by step. Small projects should use holidays to organize surprise inspections to ensure that the rectification and production are correct. During the implementation of the thread hanging project in the knitting division, the project team moved the two groups to the temporary site after repeated research, and after the first thread hanging was suddenly installed in the vacant site, the sewing team could be stationed in the line, and then the equipment was installed and debugged after being stationed in the vacant site of the team, which achieved good results.
4. Replace traditional mass production with digital equipment and one-piece assembly line.
How can garment production enterprises improve production efficiency and reduce production costs through management promotion? This is not only an industry problem, but also a bottleneck problem that has long plagued all business departments. As a business department that implements the Group's information-based lean production project, although the online projects are different and the software or hardware used are different, the management idea of the project design is highly consistent: that is, to comply with the demand trend of multi-variety, small batch, personalization, fashion and rapid response in the mainstream textile and garment market in the future, the original large packaging process (ranging from 10-20 clothes per package) is changed into a single-piece process (1). As an industry positioning of "China Art Dyeing and Finishing Innovation Expert", the Group aims to realize interactive innovation between digital technology and handmade folk art and enhance the competitiveness of traditional tie-dyeing market. The specific approach is:
(1) Shorten the production cycle with one piece flow production.
HY Shuttle Division mainly produces high-end brand women's wear at home and abroad, with many styles, few quantities, rapid changes and high requirements. The original large-scale production mode based on European and American orders can no longer adapt to the changes of the group's target customers. In order to adapt to the changes of the market, improve the flexible production capacity and efficiency of enterprises and shorten the production cycle, it is imperative to introduce one piece flow operation.
(2) Introduce advanced numerical control equipment to improve production efficiency.
The suspension system production line introduced by HY Knitting Division represents the advanced equipment level of domestic garment industry, and its intelligence is higher than that of one piece flow system. Each production line is controlled by computer, and the production line automatically generates one-piece assembly line, which can reduce the accumulation of semi-finished products by more than 75%, and can be adjusted and improved in time once accumulation points appear. On the production line, a T-shirt can produce the first finished product within 30 minutes from input to output, and the subsequent production will continue to output according to the rhythm of each process to avoid the accumulation of semi-finished products. The production line of suspension system can arrange cross-production at any time according to the operating rhythm of employees and the balanced progress of production. The production efficiency has been greatly improved, and it has become one of the business divisions with the best implementation effect of information lean production in a single project of the Group.
(3) Establish quantitative operation of production process oriented by IE analysis.
The Group introduced the concept of industrial engineering (IE), and based on objective and quantitative data, approved the production capacity and personnel of each position, which brought brand-new management concepts and experiences to traditional garment enterprises. All production departments have established IE teams. Before each product goes online, IE team carries out process analysis and scientific division, and then sets takt time and reasonable target output, so as to realize flow production under scientific quantification, shorten production cycle and improve labor productivity.
5. Realize the information resources of the Group based on information technology.
The introduction of information technology has laid a solid foundation for Jiangsu HY to improve the comprehensive competitiveness of enterprises by comprehensively promoting lean production management under the background that China textile and garment industry has entered the era of low profit. Based on the ERP software platform, Jiangsu HY carries out system integration or secondary development of projects of various business divisions, and truly realizes the sharing of production resources and information resources within the group. After the computers of four production lines are connected to the network through knitting thread, remote viewing software is installed for managers and workshop directors, which basically realizes remote real-time online viewing of production progress, production trends and indicators, and the production data of the day is immediately imported into ERP system, and salesmen can query the production situation and interact with each other at any time through ERP; Special Arts IE-box system inserts employee cards and process cards into the card inserting machine, and production information can be imported into the software in real time. After managers and salespeople install the corresponding software, they can know the production progress in time by entering the order number.