Anhui ERA aims to standardize processes, stabilize quality, improve efficiency, reduce customer complaints, and enhance customer satisfaction. According to the company's production and operation plan, the lean special activity "Process Standardization Battle" was promoted, and the company organized a comprehensive review of the processes of each production line, which lasted for more than 70 days.

01 Mobilize and start with everyone's participation

   Manager Yu of the Technical Department conducted training on the requirements for process standardization operations and the introduction of technology for the managers, deputy managers, directors, deputy directors and technicians of the production department.

02 Check the progress of the activity
The workshop office formulates a plan for the activities of the process operation, and assigns responsibility to the person to conduct a comprehensive investigation and rectification of the process operation. A total of 320 problems were found.
The technical department has carried out about 25 sessions of process change process, process card publicity, and key point counseling and training, and issued 260 copies of the new version of the process card, including more than 20 temporary process cards, and more than 50 copies of formula cards.
In view of the progress and difficulties of each workshop, the process counseling is carried out at two levels, and the first level is discussed and point-to-point counseling by the members of the promotion and implementation team on the process change system and visual specifications.
In the second stage, the leaders of the General Manager's Office were invited to provide guidance in the form of group inspections.

03Highlight and refinement
From the billowing summer to the cooling autumn, it took more than two months, yielding solid and substantial results. The "wizards" in the workshop have experienced five "major battles" and summed up their own beliefs. They never lose heart and the process of improvement shows their patience, carefulness and vision. The equipment, electrical equipment and operators are linked with each other, closely cooperate with each other, and move quickly, successfully completing the visualization of raw material area, mold visualization, process area visualization and file perfection, effectively reducing the defects caused by equipment, and further improving the workshop site.
The achievements of workshop improvement can not be separated from the achievements quietly paid by the technical department. Eleven copies of technical system and documents (technical change management system, numbering rules of process cards and recipe cards, and work instructions for special procedures) have been completed, and the mold ledger, formula change resume, and abnormal resume for returning materials have been further improved, covering the whole production process in a normative way.
This activity has the longest span and the widest coverage among all previous lean combat activities in Anhui AD. The factors affecting the process standardization were classified, sorted, documented and solidified. The production self-inspection improved 118 items, and 78 items were found to be improved. The account of mold repair, the resume of formula change and the resume of abnormal use of raw and auxiliary materials were improved, which fully standardized the whole process of production technology.
The coincidence rate of process consistency in production workshops (except seven workshops and ten workshops) has increased from 67% before improvement to 87%, and the comprehensive improvement rate is about 30%.
The coincidence rate of process consistency in production workshops (except seven workshops and ten workshops) has increased from 67% before improvement to 87%, and the comprehensive improvement rate is about 30%.

04The growingly better rating
On the morning of October 17, the special activities were accepted, and the combat results were reported at 14: 00 pm. General manager office led Zhu Jianhua, Shi Qinglin and Huang Jianfeng to lead the heads of technical department, production department, quality control department, power department and lean department to conduct the activity acceptance appraisal.

After three comprehensive evaluations, namely, spot check during the activity, spot check for acceptance and report of results, the fourth workshop, the fifth workshop and the ninth workshop won the first prize, the second prize and the third prize respectively. At the same time, Feng Xiaming, a technician of the technical department, was awarded the "Excellent Promotion Award".

He summarized the following four points: First, turn abstraction into image. The preliminary work has been discussed by various departments for many times, and the process of each workshop has been checked for missing and missing, and traced back to the source. Second, turn randomness into norms. With the aging of equipment, the big problems encountered in the past process are standardized. Third, turn experience into standards. Sort out the working standards of the workshop and simplify the complex. Fourth, turn the monomer into multidimensional. Hard-won achievements, hard-won achievements, should be discussed by multiple departments, find the law, find the key points and solve problems. At the same time, Mr. Zhu pointed out that the end of this operation is only the starting point, and there is no end point for process control. He put forward five requirements for the next continuous work: 1. Unswervingly consolidate the hard-won operational achievements. The combat results are the result of the active cooperation of many departments, and the result of hard work and enterprising in the workshop. It is hard to keep the results at all times. 2. Be unconventional and do a good job of follow-up and steady improvement. On the premise of controlling quality and reducing cost, we will gradually improve steadily. 3, mechanics, do a good job of publicity. Do a good job in the training of all employees in the process, and focus on strengthening the landing. 4, eye to eye communication and coordination. Multi-department linkage, coordinate quickly and efficiently, and reach a consensus. 5. Solve sudden problems quickly. Encounter sudden problems, to track in place, thoroughly solve, improve efficiency.

After the meeting, the participants further clarified the key points of process standardization management and control, learned from benchmarking, learned from each other's strengths, and laid a solid foundation for the improvement of product quality.