“Six concerns” and “four basic principles” of plywood supplier site inspection

“Six concerns” and “four basic principles” of plywood supplier site inspection

In the process of plywood supplier management, on-site audit is a very important link. In the process of potential plywood supplier evaluation, new product development, plywood production parts approval, plywood supplier system development, problem analysis and solution, it is necessary to audit the plywood supplier’s plywood production and manufacturing site. However, the audit time is limited, which requires auditors with rich experience and skilled audit skills to effectively evaluate the plywood supplier’s plywood production site in limited time.

1、 Why should we pay attention to plywood production and manufacturing site?

Enterprise operation is a large system, all links are closely related and influence each other. For plywood production-oriented enterprises, through any details of the scene, we can see that there is little to see. The root cause of any major problem can be found from the scene. Even in the limited time, as long as we grasp the key points, we can fully grasp the key information of plywood manufacturing process.

2、 Focus 1: on site atmosphere

First of all, the employees’ morale can be seen in a vivid contrast with the employees’ apathy. Talking to the workers on site can also get important first impressions from their facial expressions and body language, because these directly reflect the workers’ mood and satisfaction with the plywood factory. There is a plywood factory, most of the workshops are playing happy music. At first glance, the workers are very enthusiastic about labor. Working in such a relaxed and pleasant environment, the efficiency is relatively higher, and the quality of products will also make people more confident.

Walking around the workshop, you can pay attention to observe whether there is uneven free and idle phenomenon. For example, when the machine is in automatic processing, the workers are idle for a long time, or some workers on the work station are waiting for materials for a long time. The existence of this phenomenon shows that the plywood factory is lack of lean management, personnel utilization rate is low, idle staff will also affect the working atmosphere of other people, the overall work efficiency is low, and the cost is bound to be higher.

In addition, we should pay attention to whether the workshop has sufficient light, whether the air circulation is smooth, whether there is odor on the site, whether the noise is too big, and whether the workshop is clean, because these will directly affect the mood of workers, and then affect the plywood production efficiency and product quality. It’s hard to imagine a plywood factory with lazy, low and indifferent atmosphere, employees or resentful or idle, which can produce good products and create benefits.

3、 Focus 2: space utilization and layout

Many plywood factories in China are very happy. The larger the plywood production workshop, the better. As a result, the utilization rate is very low and the layout of equipment and process is very scattered. In addition to wasting space, materials are also transported in a large number of unnecessary plywood factories. Most of the plywood factories in Japan look less spectacular, even a little cramped, but the space utilization rate is high, and the circulation efficiency is also very high.

If the plywood production workshop is large and the logistics line design is unreasonable, there will be: the same batch of parts in the plywood production process are moved from area a to area B for processing, then moved back to area a for subsequent processing, and then moved to area C for processing, and finally moved back to area B, resulting in serious logistics waste.

In principle, the plywood production materials used on the same day should be stored along the plywood production line instead of separated storage in several inventory areas. Tools and tooling should be placed as close to the machine as possible. Plywood plant layout should ensure smooth flow of products and avoid any partition as far as possible. In a plywood factory, if the material handling distance is long, the transportation route is repeated, or the handling times are too many, it indicates that the layout is not reasonable and there are problems in space utilization.

4、 Focus 3: standardization management

The standard is the best state and unified execution reference. Without standards, there is no way to implement, there is no focus for improvement. Plywood production site should have many standards, including operation and quality standards, 5S and safety standards, operation and maintenance standards, process and rework standards, safety stock standards and so on.

Whether there are many breakpoints (SOP) of plywood and whether there are breakpoints in the process of standardization in the factory. Check whether the writing, speaking and doing are consistent, and whether the quality control points are highlighted with eye-catching signs or colors.

By observing the specific operation process of different employees in the same process, we can find out whether there are differences, including the sequence of actions, the strength of operation, whether there are omissions and so on. The difference shows that employees lack standardized operation training, and the possibility of product variation is greatly increased. During the audit process of plywood suppliers, it was found that the sequence of tightening the four bolts by different workers was different, and there was no standard torque reference. It was entirely based on the feeling that some workers would tighten the four bolts twice, while some workers only operated once, which was very easy to cause the bolts to fall off due to insufficient tightening torque, or the excessive tightening torque would cause sliding buckle.

5、 Focus 4: quality control

The on-site observation should pay attention to the treatment of the defective products in the workshop. A good plywood factory will expose the problem, rather than cover up the defective products and waste products. For example, by focusing on the waste with light or by highlighting it with a red label, you can immediately know whether the waste is increasing or whether some part of the plywood production process is producing defective plywood.

Some plywood factories store a lot of defective products in the corner, and the dust on them has accumulated for quite a long time, but there is no sign to explain the causes and problems of the defects. Asked the workers at the scene and said that the things had been for months, and no one knew what the problem was and no one had dealt with it. Asked how to deal with defective products, the answer is that there is a special person to rework, and no one goes to investigate the causes of the defects. Who dares to cooperate with plywood factories with such chaotic quality management?

The traceability of work in process and semi-finished products can also be easily seen on site. Each part should be followed by a card or a document, indicating the source, the personnel who have been processed, the equipment used and other information. Problems found in any process can be traced back to the source easily, which is also convenient for improvement.

The site can judge the fineness of quality management by the protection degree of workers for parts. There is a motor factory will rotor randomly placed on the cement floor, there is no protection measures, and the stator is placed vertically on the wooden workbench, workers in the upper part of the shaping, the lower part of the enameled copper wire is easy to damage the insulation paint due to friction, so the quality of the finished motor can be imagined.

By observing the number and proportion of defective products, we can also preliminarily judge whether the quality control process of a plywood factory is qualified. During the audit of plywood suppliers, a large number of unqualified products were found. After asking the workers, the average daily output of this assembly line is 1000 pieces. According to this estimate, there are about 50 pieces of defective products every day, and the defective rate of finished products is as high as 5%. This shows that there are a lot of quality problems not found in the previous processes, and the defective products have been flowing to the end. The quality control is very weak, and the cost of manufacturing defects must be very high.

6、 Focus 5: visual management

Visual management is the basis of many advanced management means, and it is an intuitive communication of the management level of a plywood production enterprise. In a well managed plywood factory, visual tools can be found everywhere. It includes organization and standardization of workplace, visualization of outcome indicators, visualization of standard work, visualization of control indicators, visualization of automatic error prevention and error correction, alarm mechanism, etc. During the audit, attention should be paid to various visual tools.

Visual management Kanban can be divided into static and dynamic management kanban. Static Kanban mainly conveys the long-term management concept of the organization, while dynamic Kanban is the management information that managers should grasp at any time, which can better reflect the management level and ability of a plywood factory.

5S is the embodiment of site organization and standardization, and the bottom application of visualization. However, due to various reasons, most of Chinese enterprises in reality have gone into the misunderstanding in 5S management. In a large motor factory, the plywood production workshop is almost spotless at a glance. All the floors are painted with beautiful paint. All kinds of visual lines and signs are very similar, but there is only a lack of safety warning signs. If the road surface is too smooth and the friction is not enough, people will slip if they walk on it, and the wheelbarrow and forklift may also slip. This kind of ostensible work is enough, but there are still many security risks.

7、 Focus 6: tool equipment status

In the plywood manufacturing process with quality control in place, the equipment is clean and well maintained, and the equipment related information is clear at a glance and updated immediately. In the machining workshop of a foundry, although all kinds of lathes are not very advanced and even have a long history, they are all in good condition. On the side of each machine, there is a card, which records the model, purchase date, price, plywood supplier, repair record, maintenance record, etc. In addition, the daily spot check list is also well recorded. Some spot check lists clearly record the hidden dangers found by operators, as well as the signature and treatment scheme of the equipment department. This shows that equipment management and maintenance has formed a benign system.

And a plywood factory, the level of automation is very high, but the equipment is often in a state of waiting for repair, there is no maintenance record on these equipment. Although there is a daily spot check list, it is only found when the equipment stops running due to failure, indicating that the spot check is not in place or perfunctory. Equipment failure can have early warning and make corresponding preparations to avoid long-term downtime and seriously affect product delivery.

On site, we can also learn from employees whether the operators and product developers are involved in the purchase decision of the equipment. Front line workers and those involved in product development and plywood production are most aware of the advantages and disadvantages of the new equipment and the actual needs of the plywood production line. In many plywood factories, the equipment procurement is decided by the high-level or equipment department, and the opinions of front-line personnel are rarely consulted, which leads to a large number of follow-up problems.

8、 Notes on site audit

The on-site audit of plywood suppliers is the most direct means to find problems. Most of the problems will be shown on the site. It can quickly make a preliminary assessment of the plywood suppliers on site, so as to trace the source and reduce the blindness of many work. This paper discusses only a small part of the numerous contents of on-site observation. There are many ways and methods for on-site audit, but the basic principles and matters needing attention are consistent

1. You can’t come to the scene with colored glasses, and you can’t go to the scene with conclusions to find evidence, which is often biased.

2. We can’t just look at the surface of the scene. We need to check whether what we say, what we write and what we do are consistent. We need to ask more about why.

3. At the same time, the macro and micro perspectives should be used to focus on the details, and the macro way should be used to view the whole.

4. Try not to take notes as much as possible, which will affect the continuity of observation and thinking, and make the field personnel feel nervous.

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