"Unlike the push production model, the production plan of the pull production model is directly handed down to the last process of the entire production line. He will make decisions for the next process based on the actual needs of his own process in terms of variety, quantity, time, etc.
Materials." Niu Xiaobai continued.
Production foreman Hu Hongxiang asked: "So, how do the personnel in these two processes communicate with each other? If the notification is only verbal, will sometimes mistakes be made while busy, which will ultimately affect the production plan?"
Niu Xiaobai explained: "This is a very good question! The pull production model relies on kanban cards to communicate between the two processes. This card indicates the types of materials required for this process.
quantity."
A kanban card is a card that indicates when a certain process will take place, what materials are needed, and how much materials are needed. It is also called a subpoena card. It is a tool for transmitting signals between various processes. Kanban cards are divided into two types: transmission kanban and production kanban: transmission
Kanban is used to direct parts to move between the front and back processes; production kanban is used to direct when and how much of a specific part to be produced in subsequent processes.
Niu Xiaobai introduced the concept of kanban cards to everyone in detail, then looked around at the people present for a week and asked: "Do you have any questions about the pull production model? Tiancheng, tell me.
Niu Xiaobai pointed at Zhang Tiancheng, the production foreman who had his head lowered and was looking at his mobile phone.
Zhang Tiancheng quickly put down his mobile phone, touched the sparse yellow hair on his head, opened his small eyes wide, and his short face was filled with a smile: "I have no objection! Manager Niu, what do you do anyway?
Just tell us what to do."
Niu Xiaobai chuckled and said in a kind tone: "I don't want you to express your determination. I want you to express your personal views on the pull production model and see what difficulties there will be in the implementation process. You combine your own
Can you tell me more about the actual work situation?"
"Ah? Is it like this? Haha..." Zhang Tiancheng touched his hair again out of habit and said with a flattering smile: "If I say everything that is in my heart, Manager Niu, don't
Angry!" Zhang Tiancheng's words made everyone present couldn't help but cover their mouths and snicker.
Niu Xiaobai waved his hand and said cheerfully: "No! Just say it. If you have any different opinions, speak up and let everyone discuss it together."
Zhang Tiancheng didn't pay attention to everyone's reactions. He sat up straight, coughed twice to clear his throat, and said loudly: "Then I'll say it... I think what you just said, Manager Niu,
It sounds rich, but it is very skinny when implemented, and it is difficult to achieve any substantive effect! Whether it is a pull production model or a Kanban card, regarding these concepts related to lean production, Jiang Hui and Tang who later joined the company
Cheng may not know; for us production foremen who have been working for more than ten years, this is not the first time we have heard of it. Manager Zhang also found people to train us outside before, and every time during the training, everyone would be excited.
, the blood is boiling, but in the end it will be nothing... Manager Niu, why don't we study something more practical?"
Zhang Tiancheng's speaking style is very familiar to Niu Xiaobai. It seems to be the style shared by many old employees of Fuma Company. Since Fuma Company is an old company that has been in operation for more than ten years, during these ten years,
The managers at that time tried a variety of reforms and improvement measures, but they all failed due to various reasons, which seriously dampened the confidence and enthusiasm of employees. As a result, employees were all familiar with management concepts similar to lean production.
But inside I was very resistant.
Niu Xiaobai encountered the same situation when he implemented the "5S on-site management method" in the machine shop last month. When he heard about 5S, everyone thought they were right.
I am already very familiar with it, and I feel that after so many years of trying, 5S has finally become a mere form and has no effect at all. Without Niu Xiaobai’s vigorous promotion at that time, it would be impossible to have such a machine shop today.
Despite earth-shaking changes, the "5S on-site management method" will not be successfully implemented.
"Haha... Tiancheng, don't object in a hurry. Please come and talk. Do you think it is not feasible for us to implement the pull production model? What are the specific reasons?" Niu Xiaobai looked at Zhang Tiancheng with a smile and asked.
.
Zhang Tiancheng stood up, looked at everyone and replied loudly: "Everyone knows that balanced production is the premise of pull production. This balance refers not only to the quantity of products produced, but also to the variety of products and the production of each process.
cycle, load of various equipment, etc. In the past few days, everyone has been concerned about the production of the bottleneck process. Before we took control measures, there was a lot of work-in-process inventory piled up in front of the bottleneck process. Have you ever thought about it?
Why does the bottleneck process appear? Isn’t it because the production capacity of each process in our production line is too unbalanced? Manager Niu, I don’t want to pour cold water on you. According to the current balance level of our production line, it is simply impossible to convert the pull-type
The production model was successfully implemented!”
After saying that, Zhang Tiancheng sat down and looked at the production foreman Wang Yuanming sitting on the left, and then at the production foreman Lin Xiangshan sitting on the right. His short face was full of pride.
After listening to Zhang Tiancheng's words, production foreman Wang Yuanming also stood up and echoed: "Isn't it true? Those training teachers have told us long ago that to achieve pull production, flow is the foundation; there must be flow first.
, can there be pulling; pulling is a flow under a controlled state... And what about us? We have only just figured out where the bottleneck process is, and we have not considered effective flow at all, let alone single-piece flow...
…”
Having said this, Wang Yuanming shook his head and said decisively: "I think that the conditions for promoting pull production in our machine shop are not yet met, and it is too early to introduce some lean production concepts! Lin Xiangshan, what do you think?
?" Wang Yuanming's usually red face looked even redder now, not sure if it was due to nervousness or excitement.
The big man Lin Xiangshan touched his broad forehead and said with a loud smile in his loud voice: "This... I think Zhang Tiancheng and Wang Yuanming are both right! In addition to what they said, the production line
The stability of process capabilities is also a very important prerequisite, including the stability of the quality of raw materials, the stability of the technical level and attendance rate of operators, the stability of the operating status of equipment and tooling, etc. And what about us? Haha! Let me hold my conscience
Let’s put it this way, these production equipment break down every now and then, and raw materials are often reworked. Although the operators are more motivated than before and their attendance rate has improved, the technical level of operating the machines varies... Let me see, our machine
The processing workshop is still a long way from being in a 'stable' state!"...
Except for the production foreman Hu Hongxiang who lowered his head and remained silent, the other three production foremen spoke one after another like a wheel battle. They all said that the current actual conditions of the machine processing workshop are too poor and do not have the prerequisites for the pull production model.
Moreover, he also gave an exaggerated description of the past failed experiences, saying that doing so would only waste time, manpower and material resources, and in the end it would definitely not achieve any results...
Niu Xiaobai said nothing and watched the production foremen with cold eyes. When their speeches were over, Niu Xiaobai turned to Tang Cheng and asked: "Mr. Tang, what do you think?"
"Me?" Tang Cheng raised his chubby face and looked at everyone, then said with a shy smile: "Actually, I, this... doesn't matter! Manager Niu, we will do whatever you tell us."
I saw that Zhang Tiancheng was not happy to vote for him.
With a look in his eyes, Tang Cheng coughed lightly and continued: "This... I don't know much about lean production, but I also know some general concepts. It requires the production line to achieve low inventory and uninterrupted processes. If
If there is a problem in any link, the entire production line will stop. This is too risky for us. We need to think about it carefully... Also, lean production requires high quality in the entire process. Employees
The product must be made right the first time, otherwise lean production is just empty talk. Are we? Haha... Comparing the quality awareness of our employees, we do not yet have this condition."
Hu Xiuping, who was sitting next to Tang Cheng, looked at him with disdain and cursed: "Useless soft-legged crab! If you are in trouble, you don't have to work? You are a bit promising, okay! Damn it! Company
What is the purpose of this production project of yours? It’s not just to solve the problems you mentioned.”
Being scolded in front of so many people - especially in front of his girlfriend Jiang Hui - Tang Cheng couldn't stand it anymore. He put away his smile and retorted loudly: "I'm worthless, what's wrong?"
?What do you want to do with me? If you have the ability, you can solve all these problems for me!"
Hu Xiuping crossed his arms and raised his face and said: "Solve it as long as it's solved, who's afraid of who? I've done all your work for you, do you want me to collect your salary for you too?"
Seeing that the two were about to have a physical conflict, Niu Xiaobai frowned and slammed the table twice, and said loudly: "Okay, okay! We are discussing work, not swearing! You two
He is a production engineer and an important technical force in our machine shop. Can you set a good example for everyone?"
Niu Xiaobai paused and said to everyone: "I think the difficulties you just mentioned exist objectively. We need to take action to solve them one by one in a targeted manner. However, I am here to express my position: In order to effectively
To reduce the inventory level of work-in-progress, reduce manufacturing costs and management costs, and in order to shorten the production and manufacturing cycle, we must introduce a pull production model. No matter what difficulties are ahead, we must overcome them and face them head on. I am confident that,
With the joint efforts of everyone, we will definitely achieve success!”…
…
After the meeting dispersed, only Niu Xiaobai and Hu Xiuping were left in the conference room - Hu Xiuping took the initiative to stay and wanted to communicate his thoughts with Niu Xiaobai again.
Hu Xiuping raised his huge fist and said loudly: "Manager Niu, our great leader once said: Political power comes from the barrel of a gun! In this broken company with chaotic management and no one who wants to make progress, no matter how good you are personally
Excellent, what a great insight. If you don’t have your own team, everything will just stay at the level of ideas. I have a turtle friend who is very talented and knowledgeable. I have been with their company for nearly a year and have put forward many good ideas.
suggestions, but none of them can be implemented. In fact, a very important point is that you don’t have your own guns! If you don’t have your own people in the team, there is no basic support for doing things. Therefore, no matter what company you are in, it is best to
If you have your own team, you can get twice the result with half the effort.”
Hu Xiuping pointed in the direction of the conference room door and said with disdain: "These old fools! With such a high salary and used to living a comfortable life, of course they don't want any changes in the company. What if you...
Does the reform threaten their vital interests or jobs? Let me see, Manager Niu, you should find an excuse to fire them all, and reorganize a team that only takes orders from you!"
Hu Xiuping looked around and whispered to Niu Xiaobai: "However, don't act too hastily, lest the general manager sees that you are forming a clique too early and thinks that you have some evil intentions and want to take her place...
…”
Niu Xiaobai listened solemnly, neither nodding nor shaking his head...