Hua Bin: The development trend of tool management in SMEs

Jiangling Axle Factory Huabin

In front of a strong enemy, the company sent an excellent sniper, far-reaching shot to the enemy's key figures, so that the battlefield situation immediately changed; tool management is a sniper in the processing industry, in the difficult time of processing Good tool management will bring relatively rich benefits to the company. To achieve a system of enemies, we must gradually create a management system that suits the corporate environment; especially in the case of SMEs facing numerous pressures and abrupt factors, tool management that can adapt to environmental changes is a good magic weapon!

The tool management system is a system engineering in the processing industry, such as equipment selection and rigidity, process-to-product and tool requirements and existing equipment matching, fixture rigidity and tool overhang and related interference design requirements for the tool Will affect the use of the tool, the cost of processing, the efficiency of the production, whether the tool itself is properly selected, whether it is used reasonably, whether the ideal quantity is purchased, whether the manufacturing and grinding tool delivery time is determined, and how to prevent installation errors. It is an important factor that restricts the user's processing and manufacturing, and is also the focus of tool management.

Therefore, it is possible to start from the tool entering the factory to the tool use, problem feedback and solution, update the tool, improve the tool, and use several basic points after the tool is used to analyze and establish the corresponding mode:

1. Tool inspection and technical support:

Faced with the increasing number of types and models of the company, non-standard tools designed to improve efficiency and adapt to the requirements of the parts, if the details of the tool details are slightly different, it may cause difficulties or even stop production. To prevent this, set up the tool to enter the factory. The necessity of detection is further improved, the possibility of scrapping the first piece in batch processing is reduced, and the problem of line stoppage caused by incorrect delivery model of the batch due to delivery or packing error is reduced.

2. Technical reserve for tool installation and commissioning:

The installation and pre-adjustment of the tool must be handled by a person. With the development of technology, some tools are installed in a more precise manner with the usual knives and installation requirements, and this will directly affect the service life of the tool, sometimes in parallel with subsequent tool application information to ensure subsequent inventory. Statistical information, tool life statistics, etc. This pipeline-like operation will increase the pre-conditioning efficiency of the tool and the level of expertise in the installation will continue to increase.

3, unified tool use problem information feedback path and method:

Set up the "Tools Questionnaire", at least for 3 years, and give each team and team members the process and method of training the system, and identify who should go to the feedback, who to report to, who to solve, and after solving the problem. What feedback is needed for information, and relevant departments such as equipment division, sharpening class, logistics department, technical department, etc. must keep the manuscript for record. Do not repeat the problem, there are guidelines for handling the incident.

4. Process specifications for new tool trials:

Tool engineers try to use new tool targets with clear objectives, path and feasibility analysis, and fill out the “Process and Tool Change Request Form” in time. Each department should have an understanding of the reasons for the changes, the ways to improve, and the possible problems and opportunities before and after the improvement. A consensus is reached.

5. Implement the verification phase after the “Process and Tool Change Request Form” is formulated:

Before and after the tool is confirmed to be improved, the craftsman and the team responsible person carefully fill in the “Cutter Usage Comparison Table”, and after the small batch verification, the relevant departments will confirm the collected information, and notify the departments according to the in-plant document change procedure. Personnel change related documents, such as "tool consumption quota", "work unit table WES", "quality process system QPS", "potential failure mode and consequence analysis FMEA", "inventory adjustment table" and other related documents are revised.

6. Development and improvement of sharpening work

In-house tool sharpening is one of the effective ways to reduce costs. Enterprises can carry out some repair work by themselves; this requires some equipment investment, personnel input, and technical reserves. The benefits can be achieved immediately; while grinding It can verify tool design, provide opportunities to improve parameters, improve tool outsourcing grinding costs, and improve the efficiency of grinding and returning to the production line.

7. Improve the formulation of “Tool Consumption Quota” and improve the minimum inventory quantity to achieve the best quantity:

Related departments: workshop, logistics, technology, financial confirmation, issued, and according to the "tool problem feedback form", "process, tool change application form" "tool use comparison table" to dynamically update the status of the implementation of the quota.

8. Forward-looking selection of new parts, new equipment, and new process tools:

Try to use tools with good results (refer to "Process, Tool Change Request Form", "Tool Problem Feedback Table", "Tool Usage Comparison Table", "Tool Consumption Quota") to reduce the phenomenon of the same type and multi-factory Reduce the number of stock tools and improve the versatility of the tools used in the factory.

9. Recovery and verification evaluation after tool use:

In order to reduce the tool consumption of the whole plant as much as possible, understand the distribution of wear, breakage and normal consumption of the whole factory tool, implement the trade-in measures for the tool distribution, and the tool engineer will carry out the failure assessment and improvement measures for the recovery tool on a monthly or quarterly basis. According to the "Technology, Tool Change Request Form" application for change; in order to be green, the tool is returned to the library and sold to the tool manufacturers with recycling qualifications to achieve recycling, reduce pollution, and increase direct benefits.

10. Monthly and annual evaluation of tool improvement:

Evaluate the effect record of each tool improvement item, train the incorrect form, rectify the problem with the improvement method, promote the use of good income, and carry out special project rectification for the unsatisfactory effect.

11, perfect incentive mechanism

According to the monthly and annual improvement assessment, the necessary suggestions for improvement, the proposed improvement personnel and the project related personnel shall be encouraged and rewarded. A good incentive mechanism will push tool management to a new climax! (For details, please read "Inquiry about Enterprise Incentives")

12. Development and application of new tools:

Every year, the application of new tools must have the necessary study, investigation and investigation. The future applicable tools can be classified and stored, and the relevant promotion and promotion efforts should be adjusted according to the production situation. Sometimes it is possible to change the process of the tool! (See two cases in the article "Tool Change Process")

Conclusion

The ship is in full swing and the boat is turning around. SMEs will not implement the “full outsourcing” model like large enterprises. It is impossible to invest tens of millions of “vertical integration” tool management modes at one time; To do "partial outsourcing", it may be half the cost of a year's tool, which means that you can't make a return in just one or two years. But it does not mean that SMEs do not need tool management, and the weakness of SMEs is also an advantage: it is to create a tool management model with enterprise characteristics according to its own characteristics. After so many years of social development, each enterprise's tool management basically has its own pattern. With the changes in production situation and equipment, the tool management system needs to be adjusted and updated accordingly to adapt to the ever-evolving social needs. And more serious challenges.

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