III. Specific Management Methods
Machinery and Equipment
Detailed Equipment Manuals: Gain an in-depth understanding of each machine’s performance and operation to create a “Machine Operation Guide” for each machine, ensuring technicians can use them effectively and efficiently.
Common Alerts and Solutions: Compile frequent operational alerts and their solutions into a “Common Alerts and Solutions Guide” and train all operators, enabling them to troubleshoot common issues.
Maintenance and Consumable Guidelines: Develop a “Machine Maintenance Program” based on manufacturer recommendations and real-world requirements to ensure machines maintain consistent accuracy.
Tools and Fixtures
Gauging and Measuring Tool Management: Provide a “Tool Usage and Maintenance Guide” for indicators, center rods, calipers, tool setters, electronic probes, and sine tables. Ensure technicians know how to use and maintain tools properly, with disciplinary measures for misuse or damage.
Fixture Management: Regularly grind fixtures such as round irons, clamp boards, and clamps to maintain accuracy (and record any size adjustments). Create a “Fixture Usage and Maintenance Guide” for items like vises, magnets, EROWA, and wire-cutting fixtures so every technician can use them proficiently.
Tool Management: To maintain accuracy and manage costs, centralize the storage of cutting heads, collets, tool holders, cutting tools, and inserts. Separate storage for rough, semi-finished, and finished tools, as well as the workshop and inventory. Regularly conduct tool inventories, reconciliation, and purchase requests, and record evaluations of new tools to understand the efficiency of different tools on various materials.
Computer Systems
Network Configuration: Set up a local network within the company, with access restrictions for supervisors, office staff, programmers, and transmission computers.
Software and Hardware: Equip computers according to job requirements, installing only work-related software to prevent misuse of company resources.
Document Management: Establish a “Document Management Standard” with uniform naming conventions for easy organization and retrieval.
5S Workshop Environment Management
Good work environments contribute to high-quality production. Establish cleaning schedules and assign responsibilities for each area to maintain a clean and organized workspace, adhering to the 5S principles:
- Sort (Seiri): Clear out unnecessary items.
- Set in Order (Seiton): Arrange items in a structured way.
- Shine (Seiso): Regular cleaning.
- Standardize (Seiketsu): Maintain cleanliness and organization.
- Sustain (Shitsuke): Foster discipline and habit.
Production Site Management
Area Designation and Labeling: Define and label zones such as machinery areas, clamping zones, in-progress and completed work areas, tool cabinets, and walkways. Assign cleanliness and order responsibilities to specific individuals and implement a “Workshop 5S Management Standard.”
Transparency in Management: Display daily production schedules, production status, summaries, quality metrics, and efficiency benchmarks on a workshop bulletin board to foster a collaborative and motivated environment.
6. Personnel Management
Effective hardware resources require skilled operators, as personnel quality directly impacts efficiency and product quality. Improving technician qualifications can focus on five key areas:
Work Attitude: Cultivate a positive work environment through effective communication. Foster a team spirit by building rapport and encouraging a responsible, detail-oriented work ethic.
Basic Knowledge: Ensure all technicians understand fundamental practices, such as part orientation and calibration procedures. Use warning signs and standard operation methods to prevent basic errors.
Skills Training: Develop operation manuals for various machines and provide on-site training for new hires, while experienced staff should mentor them to promote seamless production.
Quality and Efficiency Awareness: Instill a sense of responsibility for product quality by establishing clear quality standards for components. Analyze and address issues with non-conforming products, documenting preventive measures to avoid recurrence.
Promotion Management: To retain talented programmers, consider transferring high-performing technicians from other departments after 1-3 years, fostering motivation and growth.
Absolute Obedience: Emphasize the importance of following management directives without delay or dissent.
7. System Regulations
To complement hardware and personnel quality, clear regulations are essential for creating a fair and positive work atmosphere:
Communication Protocols: Implement “handover forms” during workflow transitions to ensure clear communication.
Daily Reporting: Require employees to complete “Daily Work Reports” to track machine utilization, performance evaluations, and cost statistics.
Performance Standards: Use daily reports to assess and enhance employee performance.
8. Technical Reserves
In a technical field, it’s crucial to develop a pool of key personnel and create a valuable repository of technical documentation to ensure efficient production continuity despite personnel changes:
Machine Operation Manuals.
Work Procedures for Technicians.
Programming Technical Documents.
9. Production Arrangements
The company’s profitability stems from product manufacturing; thus, effective workshop management is vital for high-quality output:
Production Planning: Upon receiving customer orders, promptly hold processing review meetings to create detailed timelines for every stage, including material procurement, design, programming, and assembly.
Progress Monitoring: Conduct regular department meetings to review production status and adjust schedules in line with overall plans.
Network Management: Implement a computer network to log each part’s status and regularly patrol the workshop to resolve issues. Ensure strict self-inspection for completed parts and maintain inspection records.
Data Tracking: Monitor each mold’s progress closely, ensuring accurate and comprehensive data entry into the computer system for transparent access by authorized personnel.
Weekly Reviews: Summarize departmental production performance, analyze deviations, and share new process learnings to foster a transparent understanding of areas for improvement.
