生产部5月份月度工作汇报

,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,单击此处编辑母版标题样式,无锡,绿缘,生产部,Production,Wuxi Lvyuan Automotive Parts Co.,Ltd.,生产部月度工作汇报,Monthy reports on the work,生产计划完成率,劳动生产率,一次生产合格率,在制品金额,设备利用率,设备完好率,工装模具完好率,生产安全及安全技改,人员流动率,能耗,持 续 改 进,持 续 改 进,生产计划完成率,Production plan completion rate,甲班,乙班,平均,增长率,2013,年,02,月份,96.90%,97.51%,97.20%,-0.18%,2013,年,03,月份,97.25%,97.65%,97.41%,0.21%,2013,年,04,月份,98.13%,97.90%,98.01%,0.6%,2013,年,05,月份,97.14%,93.84%,95.3%,-2.71%,生产计划完成率,Production plan completion rate,Your Text Here,Your Text Here,Your Text Here,Your Text Here,生产计划完成率,1,Production,plan completion rate,完成率低于,97%,的原因,日期,班别,员工,机台,产品,完成率,原因分析,5.2,乙,钱涛,A02,701320E,18%,模具喷砂修机,钱涛,A07,701320B,58%,模具喷砂,5.4,乙,娄伟,A02,701320E,83.35%,产品歪头胶料不好,甲,吕文平,A02,701320E,69.72%,产品歪头调试,5.6,乙,营小旁,A06,708090,81.33%,修模具,1.25,小时,刘莹,B04,50795,91.67%,维修设备,1,小时,甲,吴学林,A05,701320G,65.15%,喷砂保温,4,小时,5.7,乙,赵丕贵,A03,701320D,95.65%,新手做清理模具,0.5,小时,5.8,甲,陆信 生,A07,701320B,80.65%,喷砂保温,2.3,小时,邓金旗,B03,686820E,47%,胶料份量不足停机,5.10,甲,李永奇,A02,701320E,68.33%,胶料不好歪头,生产计划完成率,2,Production plan completion rate,完成率低于,97%,的原因,日期,班别,员工,机台,产品,完成率,原因分析,5.11,甲,李永奇,A03,701320D,91.3%,真空不好修理,1H,5.11,乙,刘海燕,A01,025578B,44%,停电,7H,5.13,乙,喻得田,A04,701320A,60.56%,模具喷砂,5H,杨淑丽,B05,586A,87.5%,胶料做完停机,1.5H,刘莹,B08,56JA,72%,修理模具定位销,3H,5.14,乙,营小旁,A03,701320D,86.95%,停电加温,0.5H,5.16,营小旁,A03,701320D,72.46%,模具喷砂,3H,5.17,乙,刘莹,B03,7200,43%,停机等料,5H,甲,李永奇,A03,701320D,88%,身体不适休息,1.5H,5.18,乙,刘海燕,A06,870820,45%,无铁件,4H,生产计划完成率,3,Production plan completion rate,日期,班别,员工,机台,产品,完成率,原因分析,5.18,甲,王万虎,A06,870820,83%,等铁件,1.5H,5.20,乙,营小旁,A03,701320D,27%,机器掉压停机,8H,5.21,甲,王万虎,A06,974781,42.86%,换模具加温,5.23,乙,赵丕贵,A06,974781,44%,无铁件停机,9H,甲,赵秀蓉,B02,686550,58%,加热试模,5H,5.24,甲,李金凤,A06,870820,76%,换模保温,4H,5.25,乙,蔡存敬,A05,701320G,42.4%,无压力模具打不开停机,8H,5.27,甲,吴学林,A06,871220,70.52%,没内芯停机,4H,5.29,乙,刘莹,B03,235,51%,修模具,8H,5.31,甲,申恕红,B01,686550,92.5%,模具加温,1H,完成率低于,97%,的原因,生产计划完成率,4,Production plan completion rate,其他：培训、打扫卫生、停电等原因。,计划完成低于,97%,的原因统计,设备原因,模具喷砂,工艺,无铁件,其他,总数,影响时间,/,小时,83,92,22,50,87,334,百分比,/%,24.85%,27.54%,6.5%,14.97%,26.05%,100%,劳动生产率,Labour productivity,年份,.,月份,2013.01,2013.02,2013.03,2013.4,2013.5,产值,/,元,3200000,3665867,2700000,3460000,2640000,用工,/,（人*时）,6124,5278,9144,6384,5808,劳动生产率,元,/,（人*时）,522.5,694.56,295.27,541.98,454.78,一次生产合格率,Once qualified rate of production,1,、,2013.03,月份一次合格率为,98.58%,；,2,、,2013.04,月份一次合格率为,98.61%,3,、,2013.05,月份一次合格率为,98.57%,一次生产合格率,Once qualified rate of production,产品,总数,次品,次品率,产品,总数,次品,次品率,61991,2464,266,10.8%,025720D,3192,47,1.47%,718540,304,38,12.5%,缓冲垫,8532,118,1.38%,722130,264,19,7.2%,73001,22736,286,1.26%,58959,8058,362,4.49%,145,3600,47,1.31 %,173A,7072,290,4.1%,586A,191000,2032,1.06%,7200,31500,1366,4.34%,56JA,1784,57,3.2%,50795,37872,1209,3.19%,686550,72100,2180,3.02%,235,21240,498,2.34%,686820,8592,149,1.73%,686820E,8960,136,1.52%,一次生产合格率,Once qualified rate of production,产品,总数,次品,比率,现象统计,主要原因,已采取对策,实施效果,61991,2464,266,10.80 %,缺料,266,胶料摆放困难,已让员工剪成小条摆放,略有成效但耗时太长模具易冷最好根据模具型腔进行开料,718540,304,38,12.5 %,缺料,23,气泡,9,熟料,6,气泡为温度高,缺料为试模时产生,调低温度。,已解决气泡,722130,264,19,7.2 %,夹皮,13,脱胶,2,熟料,3,打磨坏,1,试生产温度高,调低硫化温度,已解决夹皮问题,58959,8058,363,4.49%,缺料,363,胶料份量不足,目前未生产,173A,7072,290,4.1%,产品流痕,290,塑料粒子不好工艺不好模具不好,调整工艺，换供应商,未见成效下一步修理模具,7200,31500,1366,4.34%,气泡烂肉,1366,模具结构问题,调整压力调整排气调整机器平整度,未见成效，下一步换成,300T,压机并改预成型方案,56JA,1784,57,3.2%,开裂,38,烂肉,13,欠硫,4,熟料,2,回料生产强度低,降低工艺温度增加排气次数,有成效，下一步加流动助剂以增加胶料流动性加,CTP,防止焦烧,50795,37872,1209,3.19%,缺料,1033,烂肉,42,欠硫,72,设备故障,72,成型工艺不好胶料宽度不均,调整刀与口模距离,25mm,，继续跟踪,目前未生产,686550,72100,2180,3.02%,缺料,1874,烂肉,306,模具挤头与料缸配合不好跑料焦烧时间短也是缺料的原因之一,胶料焦烧时间略短改为普通硫磺硫化体系硫化时间,1,分,40,秒（,160,度）左右,未能解决，下一步调整配方延长胶料的焦烧时间,235,21240,498,2.34%,缺料,34,拉坏,233,熟料,230,模具开模距离短不好清理，拉坏为模具刀口不好修剪不当造成,调整开模距离以便于清理橡胶废边，指导员工修剪以减少修剪坏的产品,基本解决熟料问题，部分解决撕边拉坏，下一步修理模具刀口,686820,8592,149,1.73%,缺料,110,顶坏,13,烂肉,10,停电坏,16,胶料份量不对,正和天纳克协商加料,继续跟踪,025720D,3192,47,1.47%,熟料,30,撕裂,3,烂肉,14,新手操作模具未清理干净操作时间长,培训操作工，并在工艺允许范围内适当降低温度,目前未生产,145,3600,47,1.31%,缺料顶坏,47,模具结构问题导致缺料，顶出工装问题,让操作工在产品顶出前先清理产品受力面周围的橡胶废边便于顶出,有成效，顶坏现象减少，下一步跟技术部协商修理模具,在制品金额,WIP value,1,、,2013.02,月份在制品金额为,357882,元；,2,、,2013.03,月份在制品金额为,750369,元 ；,3,、,2013.04,月份在制品金额为,404257,元；,4,、,2013.05,月份在制品金额为,864120,元。,在制品金额,WIP value,序号,产品型号,在制品金额,/,元,所占比例,序号,产品型号,在制品金额,/,元,所占比例,1,701320,649372,75.15%,14,686550,2291,0.26%,2,974781,20525,2.38%,15,3,602700,17630,2.04%,16,4,025578B,17070,1.98%,17,5,708090,12359,1.43%,18,6,867912,8188,0.95%,19,7,235,6047,0.7%,20,8,870820,5263,0.61%,21,9,173A,3631,0.42%,22,10,718540,3533,0.41%,11,025578A,3273,0.37%,12,864230,2845,0.32%,13,722130,2812,0.32%,设备利用率,-,注射机,Rate of equipment utilization,机台,A01,A02,A03,A04,A05,A06,A07,平均,利用率,81.48%,82.36%,90.38%,100%,83.57 %,64.81%,100 %,86%,设备利用率,-,模压机,Rate of equipment utilization,机台,B01,B02,B03,B04,B05,B06,B07,B08,平均,利用率,%,7,16.67,61.11,33.33,35.19,9.26,10.17,49.85,27.82,设备利用率,-,平均,Rate of equipment utilization,1,、,2013.01,月份机台平均利用率为,75.86%,；,2,、,2013.02,月份机台平均利用率为,58.74%,；,3,、,2013.03,月份机台平均利用率为,70.53%,。,4,、,2013.04,月份机台平均利用率为,69.89%,。,5,、,2013.05,月份机台平均利用率为,56.91%,设备利用率,-,分析,Rate of equipment utilization,备注：,1,、无计划：主要是小机台硫化产品需求减少；,无计划,模具,无铁件,设备故障,其他,合计,影响时间数,H,4032,24,36,204,24,4320,影响比例,93.33%,0.5%,0.83%,4.7%,0.5%,100%,设备完好率,Rate of equipment in good condition,1,、,2013.02,月份设备完好率为,97.17%,；,2,、,2013.03,月份设备完好率为,97.79%;,3,、,2013.04,月份设备完好率为,99.72%;,4,、,2013.05,月份设备完好率为,98.76%,。,工装,/,模具完好率,Tooling / die intact rate,1,、,2013.02,月份工装,/,模具完好率为,97.95%,；,2,、,2013.03,月份工装,/,模具完好率为,96.27%,；,3,、,2013.04,月份工装,/,模具完好率为,97.31%,；,4,、,2013.05,月份工装,/,模具完好率为,97.90%,。,工装,/,模具完好率,Tooling / die intact rate,模具号,停用日期,修复日期,维修原因,56JA,5.13,5.20,料缸定位销损坏,697,5.17,5.25,模具压伤,生产安全及安全技改,Production safety and security technology,安全事故,1,2013,年,5,月,20,日中午,13,时左右，模具工杨林依用铁棒撬模具时被模具对铁棒突然的反作用力划伤手掌关节处。,2,2013,年,5,月,25,日中午,12,时,30,分左右，胡豪同事在做,701320,产品破坏试验时铁芯压偏弹出打到了胡豪的头部。造成面部两处划伤。,整,改,措施,1,2,做好模具库的整理整顿工作,对压破坏工装进行调整,对车间员工进行安全教育培训，强化员工的安全操作意识,对压装设备加装防护装置,成立安全领导小组对生产现场进行日常巡视，发现不安全的操作及时制止,对车间员工进行安全教育培训，强化员工的安全意识,Click to edit title style,-7,42,+0,月 初 人 数,人员流动率,Staff turnover,月初,月末,差额,新进,离职,流失率,上月流失率,42,35,-7,0,7,18.18%,7.14%,备注,流失率,=,离职人数,/,月平均人数*,100%,，月平均数,=,（期初人数,+,期末人数）,/2,能耗,Energy consumption,1,、,2103.02,月份万元电力能耗为,199.7,元；,2,、,2103.03,月份万元电力能耗为,300.4,元（能耗为,2.26,日,-3.26,日）；,3,、,2013.04,月份万元电力能耗为,282.74,元。,4,、,2013.05,月份万元电力能耗为,257.72,元。,持续改进,Continuous Improvement,本月已完成：,1,、新车间的整理整顿工作；,2,、喷砂机位置调整完毕；,3,、完善投入产出整改工作，已制定出相应的考核制度并实施；,4,、制定出,701320A,模标准操作和考核制度并已交给硫化班长作正式推出前的准备工作；,5,、已完成,701320D,、,701320A,、,701320E,、,711380,、,870820,、,C0007200,、,50795,、,025578A,、,025578B,、,708090,工艺卡的更换。,6,月份计划：,1,、进行车间,6“S”,持续改进；,2,、逐步推出各产品的标准操作及考核制度；,3,、实施解决,686550,，,7200,等产品缺陷问题，提高一次合格率；,4,、配合技术部找出,145,D28B208,61991,等新品在批产中所遇问题的解决方案。,Thank You!,谢谢,观赏,Wuxi Lvyuan Automotive Parts Co.,Ltd.,无锡绿缘汽车零部件有限公司,