There are two ways to improve the efficiency of multi-variety and small batch production: reducing the replacement of parts and improving the flexibility of production system.
(1) Reduce part differences
There are three ways to reduce the change of parts: implementing three methods (product serialization, parts standardization and generalization), implementing group technology and implementing change reduction methods.
The implementation of product serialization can reduce the types of products, and the various needs of users can be met through product series.
The standardization and generalization of parts can directly reduce the changes of parts.
When combining similar parts into a part family by group technology, the same or similar methods can be used to deal with them, thus reducing repetitive work, saving time, improving efficiency and improving work quality and product quality.
(2) Improve the flexibility of the production system
System flexibility refers to the ability of the system to deal with external changes. The flexibility of the production system includes two aspects: First, it can adapt to the processing requirements of different products or parts. In this sense, the more types of products (parts) that can be processed, the better the flexibility; The second refers to the conversion time. The shorter the conversion time between different parts, the better the flexibility.
There are two ways to improve the flexibility of production system: hard method and soft method. The hard method is to improve the flexibility of machine tools, and the soft method is to adopt group technology.
Homework 4: What is Agile Manufacturing and what is its function?
Agile manufacturing, in order to meet the needs of market competition, strengthens the adaptability and competitiveness of enterprises by emphasizing flexibility. Its functions are:
1. With the help of information technology, the internal and external suppliers and customers of the enterprise are organically integrated into a whole, responding to market demand quickly and designing and manufacturing brand-new products quickly;
2. Constantly improve old products to meet customer needs and extend product life;
3. Adopt advanced manufacturing technology and highly flexible design to realize complete production according to orders;
4. The "virtual enterprise" adopts a dynamic organizational structure to effectively use external resources;
5. Fully mobilize people's enthusiasm and creativity.
Chapter VI Quality Management
Homework 1: What is the basic method of total quality management?
The basic working method of total quality management is PDCA cycle, in which
P (planning), D (execution), C (inspection), A (handling)
The characteristics of PDCA cycle are:
1.PDCA cycle must form a big circle in sequence, and then rotate continuously in four stages.
2. Big rings and small rings promote each other.
3. Cycle up. PDCA cycle doesn't end until the end of phase A, but it has to go back to phase P to start a new cycle, so it keeps spinning.
Homework 2: How to Analyze Histogram
(1) symmetric type, also known as normal type, has a straight square with a peak in the middle in the histogram, which is symmetrically arranged left and right. This is a typical normal distribution pattern.
(2) Deviation is usually caused by some processing habit and other reasons.
(3) Double peaks. This is often caused by the mixing of two different distributions, such as the products produced by two machine tools or the mixing of two raw materials with certain differences.
(4) sawtooth. This is usually caused by too many groups or incorrect measurement readings in the process of histogram making.
(5) flat top shape. This is often caused by some slow and changeable factors in the production process, such as tool wear and operator fatigue.
(6) Island indicates abnormal process quality, which is often caused by changes in raw materials, short-term operation of unskilled workers or measurement errors.
Chapter VII Equipment Management
Operation 1: How many stages has the development of equipment management gone through? What are the main characteristics of each stage?
1. After-the-fact maintenance refers to the maintenance after equipment failure.
2. Preventive Maintenance This system requires that equipment maintenance should focus on prevention, do a good job in the process of equipment use, strengthen daily inspection and regular inspection, and carry out planned maintenance of equipment according to the wear law of parts and inspection results before equipment failure.
3. Production and maintenance choose maintenance methods according to the importance of equipment; Preventive maintenance is adopted for key equipment, and after-the-fact maintenance is adopted for general equipment that has little impact on production.
4 Maintenance and prevention This means that the maintenance problem is considered in the design and manufacturing stage of the equipment, so as to improve the reliability and maintainability of the equipment, so as to minimize or prevent the failure of the equipment in future use, and once the failure occurs, the maintenance work can be carried out smoothly.
.5 On the basis of equipment maintenance and prevention, from the viewpoint of behavioral science and system theory, the concept of integrated equipment management was formed in the early 1970s. Terotechnology, or integrated equipment management, formerly known as terotechnology in English, is an important way to implement total equipment management, mainly including TERO Technology and total production maintenance.
Chapter VIII Material Management
Job1; How to use ABC classification to manage materials
Generally speaking, for low-value C materials, we can control it loosely, keep a high inventory and avoid shortage; For high-value Class A materials, strict control should be implemented to reduce inventory.
Class A materials should be strictly controlled as far as possible, including the most complete and accurate records, the highest operational priority, frequent inspection by senior management, careful and accurate determination of order quantity and order point, and close follow-up measures to minimize inventory time.
Normal control of class B materials, including recording and regular inspection; Only in case of emergency will higher priority be given; Orders can be placed in economic batches.
Simple control of class c materials.
Homework 2: What is value analysis and how to apply it in material procurement?
Value analysis helps to reduce the cost of purchasing materials. Value analysis should answer the following questions:
(1) What is the function of outsourced parts?
(2) Are these functions necessary?
(3) Can we find the standard parts that can realize these functions?
(4) What is the cost of spare parts?
(5) What substitutes can achieve equivalent functions?
(6) What is the cost of the substitute? Value analysis is usually completed by a team including engineers, technicians, production managers and buyers.
Chapter IX Human Resource Management
Homework 1: What is the quality of work and life, and its relationship with human resource management in enterprises?
The quality of working life refers to the satisfaction of employees in the organization in many aspects related to work, such as participation in decision-making, information sharing, working environment and remuneration, and work pressure. It is an important measure of human resource management, including labor remuneration, work autonomy, decision-making participation, working environment, organizational atmosphere, work pressure and so on. All employees can feel the material and psychological rewards from their work.
Homework 2: What is an leaderless group discussing what problems should be paid attention to when using scenario simulation test?
Leaderless group discussion means that many candidates (5-7 people) get together to discuss a certain problem without a moderator, which tests the candidates' organizational and coordination skills, leadership skills, interpersonal skills, material application skills, thoroughness of thinking, self-confidence and team spirit.
(1) document processing
An effective method to measure the potential ability of managers. Test the ability of organization, planning, coordination and leadership when managers face a pile of official documents to be processed.
According to different positions, it can be divided into marketing copywriting test, financial copywriting test and office copywriting test. It is based on job analysis, and it is best to use ready-made documents for proper modification and processing.
(2) There is no leading group discussion.
A number of candidates (5-7 people) get together to discuss a certain problem, without a moderator, and test the candidates' organization and coordination ability, leadership ability, interpersonal skills, information utilization ability, thoroughness of thinking, self-confidence and team spirit.
Problems needing attention in scenario simulation design
① Based on job analysis.
② Factor analysis
③ Preliminary scene design
④ Evaluation standard design
⑤ Operating program design
⑥ Training of examiners
⑦ Scheme trial operation
(8) Modify and improve the scheme.
Chapter X Financial Management
Homework 1: What issues should be considered when choosing a financing method?
How to choose financing mode is related to capital cost, capital structure and financing risk.
Homework 2: What is the function of financial leverage?
When the return on total assets of an enterprise is greater than the loan interest rate, it can improve the rate of return on its own funds by increasing liabilities, which has a positive effect on financial leverage. However, with the increase of debt ratio, on the one hand, excessive debt interest can not increase the possibility of repayment; On the other hand, due to the role of financial leverage, when earnings before interest and tax falls, after-tax profits will fall faster, thus bringing financial risks to enterprises.
Assignment 3: What are the company's profit distribution policies? Try to evaluate various policies.
(1) The surplus policy means that enterprises pay more attention to increasing investors' rights and interests (i.e. capital increase or accumulation fund), and only when the increased capital reaches the predetermined target capital structure (optimal capital structure) will the surplus profits be distributed to investors. Its advantage is that it can make full use of the capital source with the lowest financing cost, maintain the ideal capital structure and minimize the comprehensive capital cost.
(2) Fixed dividend policy: Benefits: ① Fixed dividend is conducive to the company to establish a good image and the stability of the company's share price, thus enhancing investors' confidence in the company.
Fixed dividends are beneficial for investors to arrange their income and expenditure, especially for those shareholders who have strong dependence on dividends.
The main disadvantage is that dividends are out of touch with the company's profitability. When the profit is low, it is still necessary to pay a higher dividend, which is easy to cause the company's capital shortage and lead to the deterioration of its financial situation.
(3) Fixed dividend ratio policy
Adopting this policy requires the company to pay dividends from the net profit at a fixed proportion every year, which reflects the equivalence between venture capital and risk return, but it is not conducive to the stability and rise of the stock price.
(4) normal dividend plus extra dividend policy
Advantages: it has greater flexibility and can give enterprises greater flexibility. It is conducive to avoiding the risk of stock price decline and raising the stock price.
Homework 4: What are the factors that affect the product cost?
Labor productivity level
Material and power utilization effect
Utilization effect of production equipment
Product quality level