多品种小批量制造企业生产管理流程精益化研究与应用
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摘要
全球化趋势的加剧,使得制造企业面临着越来越多的不确定性因素。企业生产管理信息的透明化管理,对企业面对不可预测的外部变化和内部扰动,能够及时地、高质量、低成本地满足客户需求,具有十分重要的意义。对企业业务流程进行管理是企业提高竞争力和创新能力的必要条件,这有助于企业快速、灵活地应对不断变化的客户需求和市场发展趋势。精益的流程对企业来讲非常重要,因此企业需要一种优秀的管理手段去高效经营自己的流程,让流程在企业的运转中发挥到最佳。
论文在吸收国内外相关研究成果的基础上,在对我国多品种小批量制造企业生产管理和生产管理流程现状进行分析后,引入流程优化(Process optimization)、精益流程(Lean process)和精益生产(Lean production)的思想,提出了研究多品种小批量制造企业生产管理流程精益化的课题。
论文首先分析研究了多品种小批量制造企业的生产环境和生产管理模式,并且对现行模式下生产管理流程存在的问题和利弊进行了分析,结合精益流程管理,提出了生产管理流程精益化。其次论文详细分析了流程精益化的特点和要求,在此基础上从流程精益化的思路、方法、构架和实施步骤等方面,详细阐述了生产管理流程精益化方案。论文最终将以上研究方案运用到X公司流程管理中,从组织结构优化出发,对企业核心生产管理流程进行了规划和实施,为柔性生产管理模式的建立奠定了基础。论文的研究内容在X公司得到了实施应用,取得了较好的应用效果。
本文的研究成果为其它多品种小批量制造企业实施精益流程管理提供了参考和借鉴。
There are increasingly uncertainties in manufacturing enterprise due to the trend of global market competition. The transparent management of the manufacturing process, which is good for achieving customers’satisfaction high-quality and low-costly, has become an important issue when the enterprises face unforeseeable external changes and internal disturbance. The good management of the company’s business process is the necessary condition for improvement of competitiveness and innovation, which makes company to response quickly and flexibly to change of customs’requirement and market development’s trends. Therefore, companies need an excellent method to manage process, which makes company running in its best condition.
Domestic and foreign research achievements are reviewed in this paper. Based on the analysis of Chinese multi-item and small-batch manufacturing enterprise production management situation, lean production, referred to as LP, and its ideas were introduced and the issue of lean production management process in multi-item and small-batch manufacturing enterprise had been proposed. The main research contents are listed as followings.
In the beginning of this paper, from the direction of lean process management, the advantage and disadvantage of the current production environment and production management mode is studied. Then the thesis designs and analyzes the characterization and requirement of lean process. Basing on this point, lean process is presented in the direction of idea, method, architecture and procedure. The theory achievement in this thesis eventually was applied in the process management of Aerospace Precision Products Corporation. It started with the organizational structure, went with core production management process of the company. The research achievement in this paper has been effectively implemented into the manufacturing workshop of Aerospace Precision Products Corporation.
The achievement of this thesis could provide for other multi-item and small-batch manufacturing enterprises in the field of lean process management as reference.
论文在吸收国内外相关研究成果的基础上,在对我国多品种小批量制造企业生产管理和生产管理流程现状进行分析后,引入流程优化(Process optimization)、精益流程(Lean process)和精益生产(Lean production)的思想,提出了研究多品种小批量制造企业生产管理流程精益化的课题。
论文首先分析研究了多品种小批量制造企业的生产环境和生产管理模式,并且对现行模式下生产管理流程存在的问题和利弊进行了分析,结合精益流程管理,提出了生产管理流程精益化。其次论文详细分析了流程精益化的特点和要求,在此基础上从流程精益化的思路、方法、构架和实施步骤等方面,详细阐述了生产管理流程精益化方案。论文最终将以上研究方案运用到X公司流程管理中,从组织结构优化出发,对企业核心生产管理流程进行了规划和实施,为柔性生产管理模式的建立奠定了基础。论文的研究内容在X公司得到了实施应用,取得了较好的应用效果。
本文的研究成果为其它多品种小批量制造企业实施精益流程管理提供了参考和借鉴。
There are increasingly uncertainties in manufacturing enterprise due to the trend of global market competition. The transparent management of the manufacturing process, which is good for achieving customers’satisfaction high-quality and low-costly, has become an important issue when the enterprises face unforeseeable external changes and internal disturbance. The good management of the company’s business process is the necessary condition for improvement of competitiveness and innovation, which makes company to response quickly and flexibly to change of customs’requirement and market development’s trends. Therefore, companies need an excellent method to manage process, which makes company running in its best condition.
Domestic and foreign research achievements are reviewed in this paper. Based on the analysis of Chinese multi-item and small-batch manufacturing enterprise production management situation, lean production, referred to as LP, and its ideas were introduced and the issue of lean production management process in multi-item and small-batch manufacturing enterprise had been proposed. The main research contents are listed as followings.
In the beginning of this paper, from the direction of lean process management, the advantage and disadvantage of the current production environment and production management mode is studied. Then the thesis designs and analyzes the characterization and requirement of lean process. Basing on this point, lean process is presented in the direction of idea, method, architecture and procedure. The theory achievement in this thesis eventually was applied in the process management of Aerospace Precision Products Corporation. It started with the organizational structure, went with core production management process of the company. The research achievement in this paper has been effectively implemented into the manufacturing workshop of Aerospace Precision Products Corporation.
The achievement of this thesis could provide for other multi-item and small-batch manufacturing enterprises in the field of lean process management as reference.
引文
[1]朱云龙,李伟平,李红信等.业务过程重组分析方法研究[J].中国机械工程,2002,13(10):887- 890.
[2]宋克勤,陈文安.工业企业生产管理与控制[M].上海:立信会计出版社,1997.
[3]易力力.多品种小批量环境下精益生产管理信息系统的研究和开发[D].重庆:重庆大学硕士学位论文, 2009.
[4]陈国顺. 6西格玛在产品测试流程优化(BPI)项目中的应用研究[D].厦门:厦门大学硕士学位论文, 2008.
[5]王永辉.JZS制造企业业务流程优化研究[D].重庆:重庆大学硕士学位论文, 2008.
[6] W. Edwards Deming. Out of Crisis [M]. Cambridge University Press, 1986.
[7]戚晓耀.及时生产制(JIT)应用的探讨[J].工业工程,2004, 7(1): 47-51.
[8]袁刚.多品种小批量机械制造企业生产管理流程优化研究[D].天津:天津大学硕士学位论文,2005.
[9] David J. Collis,Cynthia Montgmery. Corporate Strategy:Resources and the Scope of the Firm [M]. MeGraw一Hill Com Panies,Inc., 1997.
[10] Michael Hammer, James Champy. Reengineering the Corporation-A Manifesto for Business Revolution [M]. Nieholas Brealey Publishing, 1993.
[11] R.Burgess. Avoiding supply management failure: lessons from business process re-engineering [J].The International Journal of Logistics Management, 1998, 13(4): 52-57.
[12]郭家瑜.基于精益思想的Y公司生产流程再造研究[D].济南:山东大学硕士学位论文,2009.
[13]黄忠全.制造企业生产运作流程优化研究[D].合肥:合肥工业大学硕士学位论文,2009.
[14] Yannis A. Pollalis. A. Systemic Approach to Change Management [J] .Information Systems Management, 2006, 13 (2):19-26.
[15] Rhian Sliverstro, Charles Westly. Challenging the paradigm of the process enterprise: a case-study analysis of BPR implementation [J]. European Journal of Operational Research, 2002,(3): 215-225.
[16] Rotab Khan. Business process reengineering of an air cargo handing process [J]. International Journal of Product Economics, 2000, (1):99-108.
[17]朱云龙,李伟平,李红信等.业务过程重组分析方法研究[J].中国机械工程,2002,13(10):887- 890.
[18] S.Wesley Changehien, Hsiao-Yun Shen. Supply chain reengineering using a core process analysis matrix and object-oriented simulation [J]. Information & Management, 2002,(3):345-358.
[19] Peter K. Goal-based business process models: creation and evaluation [J]. Business Process Management Journal, 1997, 3(1):17-21.
[20] Funk P. Through put planning instead of capacity planning is next logical step after MRPII [J]. Industrial Engineering,1989,21(1):40-43.
[21]李福玉.流程优化理论在企业ERP实施中的应用[D].南京:东南大学工程硕士学位论文,2005.
[22]郭磊.基于Petri网的冷链物流企业配送流程优化研究[D].北京:北京交通大学工程硕士学位论文,2010.
[23]杨世宏.海尔集团业务流程再造研究[J].武汉理工大学学报,2006,(2):165-170.
[24]高婷.A物流公司业务流程优化研究[D].北京:北京交通大学工程硕士学位论文,2010.
[25]肖智军等,精益生产方式JIT[M],深圳:深圳海天出版社,2002.
[26]刘胜军,精益生产——现代IE[M],深圳:海天出版社,2003.
[27] Dennis P.,P. Hobbs. Lean Manufacturing Implementation: A Complete Execution Manual for Any Size Manufacturer Ross [M], J. Publishing Incorporated, 2003.
[28]梁红月.丰田生产方式的起源与演化[J].中国质量, 2004,(4): 36-38.
[29]毕宝庆.现代管理科学热点——浅析精益生产方式[J].运筹与管理,1996,(12):P96-98.
[30]齐二石.推动与拉动式生产系统建模及其性能分析[D].天津:天津大学博士学位论文,1992.
[31]齐二石,邓修权,霍艳芳,潘涛.装配型拉动生产系统离散事件模型及扰动分析[J].系统工程学报,1998, 13(4): 52-57.
[32]潘涛. JIT环境下的拉动生产系统建模及其应用研究[D].天津:天津大学硕士学位论文, 1996.
[33]倪伟英,杨光薰. JIT最终装配计划中投产顺序的研究[J].中国机械工程,2000,13(7): 589-591.
[34]胡查辉,陆静平.精益生产流程构筑与看板管理[J].管理观察,2008,(21):143-144.
[35]张冬匀.基于精益生产理论的生产现场改善方法的应用[J].机电工程,2008,(10):110-112.
[36]马彤兵,马可.基于精益生产的车间设施规划改善设计[J].管理技术,2005,(11):110-112.
[37]郭立伟,张新元.中国制造业新路的探索──精益生产与MRPII的并行实施[J].科技人才市场,2000,(5):68-73.
[38]朱培军,刘飞,曹乐. MRPⅡ、JIT与TOC集成生产管理模式研究及应用[J].现代制造工程,2008,(9):123-128.
[39]余建峰.浅谈精益制造过程中的目视管理[M].西飞科技,2003,(4): 30-32.
[40]宋克勤,陈文安.工业企业生产管理与控制.上海:立信会计出版社,1997.
[41]陈荣秋.生产与运作管理[M].北京:高等教育出版社,2005.
[42]李明.基于批次管理的产品追踪技术及溯源机理研究[D].重庆:重庆大学硕士学位论文,2008, .
[43] H. James Harrington.项目管理变革[M].北京:机械工业出版社,2001.
[44]沃麦克Y.P,琼斯D.T.精益思想[M].北京:商务印书馆,1999.
[2]宋克勤,陈文安.工业企业生产管理与控制[M].上海:立信会计出版社,1997.
[3]易力力.多品种小批量环境下精益生产管理信息系统的研究和开发[D].重庆:重庆大学硕士学位论文, 2009.
[4]陈国顺. 6西格玛在产品测试流程优化(BPI)项目中的应用研究[D].厦门:厦门大学硕士学位论文, 2008.
[5]王永辉.JZS制造企业业务流程优化研究[D].重庆:重庆大学硕士学位论文, 2008.
[6] W. Edwards Deming. Out of Crisis [M]. Cambridge University Press, 1986.
[7]戚晓耀.及时生产制(JIT)应用的探讨[J].工业工程,2004, 7(1): 47-51.
[8]袁刚.多品种小批量机械制造企业生产管理流程优化研究[D].天津:天津大学硕士学位论文,2005.
[9] David J. Collis,Cynthia Montgmery. Corporate Strategy:Resources and the Scope of the Firm [M]. MeGraw一Hill Com Panies,Inc., 1997.
[10] Michael Hammer, James Champy. Reengineering the Corporation-A Manifesto for Business Revolution [M]. Nieholas Brealey Publishing, 1993.
[11] R.Burgess. Avoiding supply management failure: lessons from business process re-engineering [J].The International Journal of Logistics Management, 1998, 13(4): 52-57.
[12]郭家瑜.基于精益思想的Y公司生产流程再造研究[D].济南:山东大学硕士学位论文,2009.
[13]黄忠全.制造企业生产运作流程优化研究[D].合肥:合肥工业大学硕士学位论文,2009.
[14] Yannis A. Pollalis. A. Systemic Approach to Change Management [J] .Information Systems Management, 2006, 13 (2):19-26.
[15] Rhian Sliverstro, Charles Westly. Challenging the paradigm of the process enterprise: a case-study analysis of BPR implementation [J]. European Journal of Operational Research, 2002,(3): 215-225.
[16] Rotab Khan. Business process reengineering of an air cargo handing process [J]. International Journal of Product Economics, 2000, (1):99-108.
[17]朱云龙,李伟平,李红信等.业务过程重组分析方法研究[J].中国机械工程,2002,13(10):887- 890.
[18] S.Wesley Changehien, Hsiao-Yun Shen. Supply chain reengineering using a core process analysis matrix and object-oriented simulation [J]. Information & Management, 2002,(3):345-358.
[19] Peter K. Goal-based business process models: creation and evaluation [J]. Business Process Management Journal, 1997, 3(1):17-21.
[20] Funk P. Through put planning instead of capacity planning is next logical step after MRPII [J]. Industrial Engineering,1989,21(1):40-43.
[21]李福玉.流程优化理论在企业ERP实施中的应用[D].南京:东南大学工程硕士学位论文,2005.
[22]郭磊.基于Petri网的冷链物流企业配送流程优化研究[D].北京:北京交通大学工程硕士学位论文,2010.
[23]杨世宏.海尔集团业务流程再造研究[J].武汉理工大学学报,2006,(2):165-170.
[24]高婷.A物流公司业务流程优化研究[D].北京:北京交通大学工程硕士学位论文,2010.
[25]肖智军等,精益生产方式JIT[M],深圳:深圳海天出版社,2002.
[26]刘胜军,精益生产——现代IE[M],深圳:海天出版社,2003.
[27] Dennis P.,P. Hobbs. Lean Manufacturing Implementation: A Complete Execution Manual for Any Size Manufacturer Ross [M], J. Publishing Incorporated, 2003.
[28]梁红月.丰田生产方式的起源与演化[J].中国质量, 2004,(4): 36-38.
[29]毕宝庆.现代管理科学热点——浅析精益生产方式[J].运筹与管理,1996,(12):P96-98.
[30]齐二石.推动与拉动式生产系统建模及其性能分析[D].天津:天津大学博士学位论文,1992.
[31]齐二石,邓修权,霍艳芳,潘涛.装配型拉动生产系统离散事件模型及扰动分析[J].系统工程学报,1998, 13(4): 52-57.
[32]潘涛. JIT环境下的拉动生产系统建模及其应用研究[D].天津:天津大学硕士学位论文, 1996.
[33]倪伟英,杨光薰. JIT最终装配计划中投产顺序的研究[J].中国机械工程,2000,13(7): 589-591.
[34]胡查辉,陆静平.精益生产流程构筑与看板管理[J].管理观察,2008,(21):143-144.
[35]张冬匀.基于精益生产理论的生产现场改善方法的应用[J].机电工程,2008,(10):110-112.
[36]马彤兵,马可.基于精益生产的车间设施规划改善设计[J].管理技术,2005,(11):110-112.
[37]郭立伟,张新元.中国制造业新路的探索──精益生产与MRPII的并行实施[J].科技人才市场,2000,(5):68-73.
[38]朱培军,刘飞,曹乐. MRPⅡ、JIT与TOC集成生产管理模式研究及应用[J].现代制造工程,2008,(9):123-128.
[39]余建峰.浅谈精益制造过程中的目视管理[M].西飞科技,2003,(4): 30-32.
[40]宋克勤,陈文安.工业企业生产管理与控制.上海:立信会计出版社,1997.
[41]陈荣秋.生产与运作管理[M].北京:高等教育出版社,2005.
[42]李明.基于批次管理的产品追踪技术及溯源机理研究[D].重庆:重庆大学硕士学位论文,2008, .
[43] H. James Harrington.项目管理变革[M].北京:机械工业出版社,2001.
[44]沃麦克Y.P,琼斯D.T.精益思想[M].北京:商务印书馆,1999.