The basic content of production schedule control mainly includes: input schedule control Process progress control And production schedule control. The basic process mainly includes: assigning work, measuring gaps, dealing with gaps, putting forward reports, etc. Production schedule control runs through the whole process Production process , from production technology preparation to Finished products All production activities up to receipt are related to production progress. Traditionally, people equate production progress with production progress. This is because customers are concerned about getting finished products on time, so enterprises also focus on the completion progress of finished products, that is, production progress. It is often used in theoretical discussions Production control system The concept of Production activities It is difficult to find the control system from the organizational structure of the production system. Production management personnel are often unaware of the existence of the control system. However, the control system does exist objectively, especially the function of progress control is very powerful, just a lot of Control function Scattered in several management departments. The reasons for this phenomenon are: on the one hand, enterprises recognize the importance of production progress and send special personnel to deal with this issue; On the other hand, it reflects the lack of understanding of control theory and exposes the characteristics of poor systematicness in practical operation. Functional department that formulates progress control objectives
The progress control goal is the progress plan, which is completed by the planning department. From the content of progress control, Schedule Including factories workshop There are three different levels of planning objects, namely, and teams, which involve different levels of management departments. The factory level production planning department (such as the production planning department or section) is responsible for formulating the production schedule and input schedule of products and main components.
The workshop planner shall factory headquarters The plan is further refined and the input-output schedule of parts and components is prepared. Many workshops also undertake the process schedule. If the workshop is large, the product structure is complex, and there are many varieties, the process schedule can be prepared by the team. In actual production, these plans are Production operation plan , that is, it can be found in the production operation plan. This analysis here is mainly to elaborate the production control function of the enterprise. Functional department performing measurement comparison
There is a strong measurement record of production achievements in the enterprise Functional departments It is the production statistics department (such as the production statistics department or section). The production plan is made level by level from top to bottom, while the production statistics are made from bottom to top Level by level summary 。 Each team has a part-time statistician who mainly counts the production results of the day, including Schedule Implementation status, production completion of each equipment (or equipment group), and statistics of work completion and working hours of each worker. The team statistics shall be conducted before the end of each shift, and the statistical results shall be submitted to the workshop. Some key data can be reported to the production statistics department at the same time. The team statistics is the basis of the work of the whole plant, and the collected raw data are almost first-hand. The quality of work directly affects the accuracy of statistical data. There are several full-time production statisticians in the workshop, whose number depends on the workload. Their task is to summarize and process the statistical data reported by the team and make statistics of the production of the whole workshop Schedule Implementation. Workshop statistics shall be conducted once a day. If the workshop implements the three shift system, each shift of the team shall make statistics on the work completion of this shift, and the workshop shall be responsible for summarizing. So the workshop statistical work It is usually carried out the next day, one day late. There is a special production statistics organization at the factory level Statistical report Further summarize and sort out the implementation of the production progress of the whole plant, including the input and production progress of various products, the production progress of each workshop, the matching of product parts, and may also make separate statistics on individual key equipment and important parts. It is obvious that the statistical results at the factory level are at least two days behind the actual production situation. Production statistics are the main basis for control decisions, but not the only basis. Department formulating control measures and implementing them
In theory, it can be divided into two departments: formulating measures and implementing measures. In reality, the two functions are Production scheduling department One family undertakes. Enterprise scheduling is generally divided into two levels, plant level and workshop level. At the factory level, independent organizations can be set up, such as the Dispatching Department (Section), and smaller enterprises can also set up the Planning and Dispatching Section. The workshop is equipped with a dispatching room (group), and small workshops can be equipped with full-time dispatchers. Production scheduling is responsible for production control Most of the workload. The generation of control measures and the issuance of scheduling instructions are mostly completed in the form of production scheduling meetings. The workshop production scheduling meeting shall be held at least once a week, which shall be presided over by the workshop director or the production scheduling team leader Foreman Participate in, study and discuss the production progress and existing problems, formulate control measures, implement the person in charge of the measures and the completion date. The factory level production dispatching meeting is held once a week, which is convened and presided over by the head of the dispatching department (section). The director in charge of the production factory is present, and the workshop directors, dispatchers, and heads of relevant functional departments at the factory level (such as statistics, materials, finance, quality management, etc.) are present. The factory level meeting focuses on solving Production process Horizontal connection and coordination between departments and workshops. Before the meeting, sufficient preparations should be made, such as statistical analysis of production scheduling implementation and preliminary measures to solve problems, so as to facilitate the discussion and formation of the final plan at the meeting. In addition, enterprises often hold some on-site scheduling meetings, daily meetings, etc. to solve some specialized problems or daily coordination problems.
Material Management Department
They are responsible for the procurement of raw materials and purchased parts to ensure the timely implementation of the investment schedule; Equipment and power departments, whose role is to ensure the starting rate of equipment; The labor and personnel department needs to ensure training and provision of qualified production personnel; The quality management department needs to control the defective product rate within the allowable range of the plan. The relationship with these functional departments is horizontal. In the process of enterprise operation, there is more collaboration and coordination between them.
1. Inventory should be changed
Impact on production Schedule In the end, the reason is that the equipment is effective Operation time Inadequate to affect production progress. For example, as planned, the equipment should operate normally for 7.5 hours per shift. Now, due to various reasons, the production is stopped too much. If the operation time is less than 7.5 hours per shift, the production will be delayed. Establish sufficient Inventory It is the simplest way to use insufficient inventory when production is in arrears. This is also a very effective way to deal with underproduction. However, enterprises also pay a heavy price for this. A huge inventory system takes up a lot of inventory losses. The solution is not to solve the problem from the root cause, but to let Inventory management It is unreasonable for the department to take full responsibility for progress control. Nevertheless, this is still the main means for enterprises to deal with the underproduction. 2. Emergency repair equipment
Equipment failure is the main cause of production failure in many enterprises Equipment failure rate Shortening equipment repair time is also a common measure in progress control. Establishing a complete and strict equipment maintenance system is an effective measure to reduce equipment failure rate. However, most enterprises believe that the probability of equipment failure is random and unpredictable, and they often pay little attention to it because of busy production tasks Equipment maintenance The maintenance work and system are virtually nonexistent, so we should focus on the emergency repair after the failure. In order to shorten the rush repair time and adopt the repair method of replacing parts, it is necessary to establish a large spare parts warehouse. 3. Overtime
Time resources are rigid, and the lost time cannot be recovered. The lost time can only be recovered through overtime, which requires overtime pay. However, if the equipment is operated in three shifts, there is no possibility of overtime, and the loss is difficult to recover. There is also a way that you can't catch up even if you can work overtime Schedule This is when Key equipment Serious failure occurs, and the repair time is longer than stock When production can be maintained. This is because after the inventory is exhausted, the equipment has not been repaired, resulting in the production stoppage of the whole line. Even if the equipment is repaired, overtime production cannot make up for the loss of the production stoppage of the whole line. 4. Cultivate versatile workers
When key equipment operators are absent from work, other workers shall be sent to support them. As long as the enterprise seriously considers this matter, it is entirely possible for a worker to master multiple skills.
From the current situation of Chinese enterprises, the preferred measure for schedule control is still to use sufficient inventory to cope with various random disturbances, which needs further improvement. The ideas for improvement are:
(1) Control the most basic reasons affecting the production progress, and fundamentally eliminate hidden dangers;
(2) Improve information processing means and timely feedback. According to the current information processing and transmission methods of production statistics, control opportunities will be lost;
(3) Due to the rigidity of time resources, more Prior control The way is the most active, active and effective; (4) We should have a systematic concept of the whole and pursue effective control of the overall interests.
Different Production type Of Production process There are great differences. The main factors affecting the progress are different, and the control focus and method are also different. 1. Why real-time feedback
With the development of information tools, consumers have more and more personalized demands for products. With the intensification of market competition, enterprises must improve their market sensitivity, speed up the market launch of new products Supply chain The response speed of manufacturers on the Internet is also required to be faster and faster, which forces manufacturers to pay more attention to the production progress in a more real-time manner. From the feedback of yesterday's production progress in the morning meeting every day to the requirement that the progress information feedback be synchronized with production and updated at any time. From feedback on the progress of each workshop to feedback on the progress of each process and position. Shorter time and higher precision.
The competition of speed is the competition of time and market advantage. Through competition, the manufacturing industry is also carrying out the survival of the fittest.
2. Basic principle of real-time feedback
U SN personnel, machines and work orders and print them bar code ； U Break down the work order to generate smaller unique SN batch numbers (each batch number roughly contains the following information: order number, work order number, product number, batch number, batch number, production date) and print SN barcode label paper in advance;
U After a batch of production, the staff will stick SN label paper in the corresponding tray or container;
U The water spider scans the employee card and machine number when transferring goods, and the data collection is completed;
U The system notifies the corresponding QC Personnel inspection; U After passing the inspection, the system informs relevant personnel that the semi-finished products are transferred to the next processing procedure;
U Relevant data are recorded by the system, and the completion and flow of the product are fed back from Kanban at any time.
(At the same time, it can also achieve process control, such as error proof, fool proof, leak proof station, quality status control, etc.)
3. How to make the real-time feedback data clearer
Set a certain workflow for the work order products, such as sheet metal processing: cutting>bending>drilling 1>drilling 2>stamping....., When the product flows on the production line, the system will be able to display the flow and in-process status of each work order in each operation through the electronic kanban.
4. Application examples
There are about 500 people in an injection molding factory in Shenzhen. There are 70 injection molding machines and plastic shells of main communication equipment.
Status quo: The staff fills in the completion status of their own station, and the statistician will go to each station to make statistics on the completion progress, prepare a report, and report every half day Production supervisor once. 2 employees per machine, workshop Material clerk 1 person, 3 statisticians (three workshops) Problem: The data filled in by employees are often wrong, resulting in inaccurate report data, and it takes too long to report once every half day;
Import the real-time production progress of Chenghan Technology feedback system in the future: Employees do not need to fill in the completion status of their own station, statisticians do not need to count progress reports, and do not need to report every half day. They can be checked at any time in the system, and three statisticians are omitted.
Problem solving: report data Accuracy 99.9%, keep abreast of production progress. 5. Professional production progress feedback system supplier Shenzhen Chenghan Technology, based on the Pearl River Delta, specializes in developing for SMEs: visualization Production scheduling tools 、 Production schedule management system 、 On site quality control system 、 Process control system 、 Anti cross shipment system And improve the enterprise's ERP management system. 
