Control method and device based on lean production system

Abstract

This invention provides a control method and apparatus based on a lean manufacturing system, comprising: calculating the operational maturity value of a target lean manufacturing system to identify problems to be improved; constructing manufacturing strategic goals by comparing the target factory with business objectives based on pre-built quantitative indicators; streamlining the organizational structure based on pre-built lean processes, lean organizational structure, and lean departmental functions and responsibilities; constructing a multi-level key performance indicator system and a facilitating management meeting mechanism; and finally, constructing an implementation plan and controlling the target factory according to the implementation plan to achieve the optimization goals. This invention solves the problems of high deployment costs and poor application effects in existing technologies.

Description

Technical Field

[0001] This invention relates to the field of data processing technology, and in particular to a control method and apparatus based on a lean manufacturing system. Background Technology

[0002] Currently, the lean production systems implemented in advanced manufacturing plants around the world remain largely at the tactical tool level, focusing primarily on learning from Toyota's TPS system and the tools and methods related to lean production systems in advanced Western companies. However, Toyota's TPS system and the lean production systems of advanced Western companies are not suitable for local Chinese factories, easily leading to failures in lean production implementation, significant backlash, and difficulty in solidifying the system.

[0003] Meanwhile, implementing a complete Toyota TPS system or a lean production system from a leading Western company requires a long deployment period (at least one year) and is expensive.

[0004] In summary, the application of existing lean manufacturing systems suffers from high costs and poor results. Summary of the Invention

[0005] This invention provides a control method and apparatus based on a lean production system to overcome the shortcomings of high cost and poor performance in the prior art, and to realize the application of a lean production system with low cost and good performance.

[0006] This invention provides a control method based on a lean manufacturing system, comprising the following steps:

[0007] The operational data of the target factory is input into the target lean production system to obtain the operational maturity value of the target factory, and based on the operational maturity value and the business objectives of the target factory, the problems to be improved faced by the target factory are identified.

[0008] Based on pre-built quantitative indicators, the target factory is compared with the business objectives according to the problems to be improved and the operational data, and manufacturing strategic objectives are constructed based on the comparison results;

[0009] Based on pre-built lean processes, lean organizational structure, and lean departmental functions and responsibilities, the organizational structure of the target factory is streamlined.

[0010] Based on the streamlined organizational structure of the target factory, a multi-level key performance indicator system is constructed.

[0011] Based on the aforementioned multi-level key performance indicator system, the manufacturing strategic objectives establish a facilitating management meeting mechanism;

[0012] An implementation plan is constructed based on the aforementioned manufacturing strategic objectives, the aforementioned multi-level key performance indicator system, and the aforementioned facilitating management meeting mechanism.

[0013] According to a control method based on a lean production system provided by the present invention, the organizational structure of the target factory is simplified based on pre-built lean processes, lean organizational structure, and lean departmental functions and responsibilities, including:

[0014] The preset process of the target factory is compared with the pre-set lean process. Waste nodes are identified based on the comparison results and optimized to obtain the improved process.

[0015] The organizational structure of the target factory is compared with a pre-set lean organizational structure. Redundant organizational structures are identified based on the comparison results and optimized to obtain an improved organizational structure. The organizational structure of the target factory is constructed by dividing and segmenting the core business processes of the target factory.

[0016] The departmental functions and responsibilities of the target factory are compared with the pre-set lean departmental functions and responsibilities. Based on the comparison results, redundant departments and / or personnel are identified and optimized to obtain improved departmental functions and responsibilities.

[0017] According to a control method based on a lean manufacturing system provided by the present invention, the method further includes:

[0018] Based on the implementation plan and the basic qualifications of the personnel in the target factory, a training plan is constructed based on a pre-set key skills knowledge base.

[0019] The personnel of the target factory are trained in accordance with the training plan.

[0020] According to a control method based on a lean manufacturing system provided by the present invention, an implementation plan is constructed based on the manufacturing strategic objectives, the multi-level key performance indicator system, and the facilitating management meeting mechanism, including:

[0021] The manufacturing strategic objectives are broken down into multiple project tasks;

[0022] The project tasks are evaluated to determine resource requirements, resource usage time and quantity, and a schedule is developed.

[0023] Risks are identified based on the aforementioned schedule, and countermeasures are formulated based on the risk identification results.

[0024] The implementation plan comprises the schedules of the various project tasks and the corresponding countermeasures.

[0025] According to a control method based on a lean production system provided by the present invention, an implementation plan is constructed based on the manufacturing strategic objectives, the multi-level key performance indicator system, and the facilitating management meeting mechanism, and the method further includes:

[0026] During the execution of the schedule, the execution status is monitored based on the facilitating management meeting mechanism and / or a pre-established communication mechanism; and / or

[0027] After the project task or preset project node is completed, the implementation is summarized and reviewed to obtain project implementation experience, and the project implementation experience is stored in the experience database.

[0028] According to a control method based on a lean production system provided by the present invention, after inputting the operational data of a target factory into a target lean production system to obtain the operational maturity value of the target factory, and determining the problems to be improved faced by the target factory based on the operational maturity value and the business objectives of the target factory, the method further includes:

[0029] Based on the target lean production system, multiple issues to be improved are scored, and a preset number of issues to be improved are selected as key issues to be improved.

[0030] The key issues requiring improvement are prioritized and addressed in that order.

[0031] According to a control method based on a lean production system provided by the present invention, the departmental functions and responsibilities of the target factory are compared with pre-set lean departmental functions and responsibilities. Based on the comparison results, redundant departments and / or personnel are identified and optimized to obtain improved departmental functions and responsibilities, including:

[0032] The departmental functions and responsibilities of the target factory are compared with the pre-set lean departmental functions and responsibilities;

[0033] Based on the comparison results, the industrial engineering process analysis method is used to identify the departments and / or personnel through which business processes overlap or are not reflected in the organizational structure, thereby obtaining redundant departments and / or personnel.

[0034] The present invention also provides a control device based on a lean manufacturing system, comprising the following modules:

[0035] The problem detection unit is used to input the operational data of the target factory into the target lean production system to obtain the operational maturity value of the target factory, and to identify the problems to be improved faced by the target factory based on the operational maturity value and the business objectives of the target factory.

[0036] The manufacturing strategy design unit is used to compare the target factory with the business objectives based on pre-built quantitative indicators, the problems to be improved and the operational data, and to construct manufacturing strategic objectives based on the comparison results.

[0037] The organizational structure optimization unit is used to streamline the organizational structure of the target factory based on pre-built lean processes, lean organizational structure, and lean departmental functions and responsibilities.

[0038] The performance indicator construction unit is used to construct a multi-level key performance indicator system based on the simplified organizational structure of the target factory.

[0039] The meeting mechanism construction unit constructs a promotional management meeting mechanism based on the multi-level key performance indicator system and the manufacturing strategic objectives.

[0040] The implementation plan construction unit is used to construct an implementation plan based on the manufacturing strategic objectives, the multi-level key performance indicator system, and the facilitating management meeting mechanism.

[0041] The present invention also provides an electronic device, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the program to implement the control method based on the lean manufacturing system as described above.

[0042] The present invention also provides a non-transitory computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the control method based on the lean manufacturing system as described above.

[0043] The present invention also provides a computer program product, including a computer program that, when executed by a processor, implements the control method based on the lean manufacturing system as described above.

[0044] This invention provides a control method and apparatus based on a lean manufacturing system. It calculates the operational maturity value of a target lean manufacturing system to identify problems requiring improvement. Based on pre-built quantitative indicators, it compares the target factory with business objectives to construct manufacturing strategic goals. Based on pre-built lean processes, lean architecture diagrams, and lean departmental functions and responsibilities, it streamlines the organizational structure, thereby constructing a multi-level key performance indicator system and a facilitating management meeting mechanism. Based on the obtained manufacturing strategic goals, multi-level key performance indicator system, and facilitating management meeting mechanism, it constructs an implementation plan and controls the target factory according to the implementation plan to achieve optimization goals. This invention solves the problems of high deployment costs and poor application effects in existing technologies. Attached Figure Description

[0045] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0046] Figure 1 This is one of the flowcharts illustrating the control method based on a lean production system provided by the present invention;

[0047] Figure 2 This is a schematic diagram of the architecture and responsibilities of a factory target group based on a lean production system provided by the present invention;

[0048] Figure 3 This is the second flowchart of the control method based on the lean production system provided by the present invention;

[0049] Figure 4 This is a schematic diagram of the control device based on the lean production system provided by the present invention;

[0050] Figure 5 This is a schematic diagram of the structure of the electronic device provided by the present invention. Detailed Implementation

[0051] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0052] The following is combined Figures 1-3 The present invention describes a control method based on a lean manufacturing system. Figure 1 This is one of the flowcharts illustrating the control method based on a lean production system provided by the present invention, such as... Figure 1 As shown, the method includes:

[0053] Step 110: Input the operational data of the target factory into the target lean production system to obtain the operational maturity value of the target factory, and based on the operational maturity value and the business objectives of the target factory, determine the problems to be improved faced by the target factory.

[0054] Understandably, the target lean manufacturing system can choose from various existing lean manufacturing systems, such as the Toyota Production System (TPS), the Schneider Electric Production System (SPS), the Midea Business System (MBS), the Volkswagen Konzern Production System (KPS), and the Elitebond Operation System (EBOS).

[0055] Based on the target lean manufacturing system, a systematic diagnosis of the target factory is performed. By inputting the client's operational data, the system automatically diagnoses the maturity value of the factory's operations.

[0056] Based on the maturity score, clients can clearly recognize their shortcomings and the gap between themselves and their business goals (such as becoming a world-class factory). Therefore, based on the operational maturity score and the target factory's business goals (such as becoming a world-class factory), the issues requiring improvement for the target factory can be identified.

[0057] In one specific embodiment, the Extreme Manufacturing EBOS system is selected as the target lean manufacturing system. Based on EBOS, a systematic diagnosis of the factory is conducted. The current status of the client (i.e., operational data) is input into the EBOS factory operation maturity diagnosis checklist. The checklist categorizes the maturity levels of various management details related to people, machines, materials, methods, environment, and safety in factory operations, assigning each level a score. After the client's actual achievement is input into the checklist, a corresponding score is obtained, thereby calculating the factory operation maturity score.

[0058] Step 120: Based on pre-built quantitative indicators, compare the target factory with the business objectives according to the problems to be improved and the operational data, and construct manufacturing strategic objectives based on the comparison results.

[0059] Based on the company's business development plan (i.e. business objectives) and the main problems currently facing the factory (i.e. problems to be improved), a manufacturing strategy is defined.

[0060] It should be explained that manufacturing strategy can be developed from five dimensions: quality, cost, delivery, safety, and team. The manufacturing strategy may vary depending on the stage of enterprise development. Manufacturing strategy can be carried out in a single dimension or in combination with multiple dimensions.

[0061] Based on this, the present invention quantifies indicators from five dimensions—quality, cost, delivery, safety, and team—when designing manufacturing strategies. By comparing the target gaps and data change trends after management optimization based on the client's operational data achievement, the present invention can identify the target gaps and the data change trends after management optimization.

[0062] In some embodiments, the pre-built quantitative metrics include:

[0063] Quality FPY = Product of yield rates of each process;

[0064] Customer return rate = Number of returned goods / Number of goods shipped;

[0065] Cost of quality failure = cost of reworking defective products + cost of scrapping defective products + ...;

[0066] Raw material cost as a percentage of turnover = Monthly or annual raw material cost / Monthly or annual turnover;

[0067] Labor cost as a percentage of revenue = Monthly or annual labor cost / Monthly or annual revenue;

[0068] Delivery cycle = the time from order acceptance to shipment;

[0069] Inventory turnover rate = Cost of goods sold ÷ [(Beginning inventory + Ending inventory) ÷ 2];

[0070] Turnover rate = Number of employees who left / [(Beginning number of employees + Ending number of employees) / 2] × 100%.

[0071] Step 130: Based on the pre-built lean processes, lean organizational structure, and lean departmental functions and responsibilities, streamline the organizational structure of the target factory.

[0072] Based on the pre-built lean processes, lean architecture diagrams, and lean department functions and responsibilities, the core business processes of the target factory are reviewed and re-engineered to eliminate hidden organizations.

[0073] Step 140: Based on the simplified organizational structure of the target factory, construct a multi-level key performance indicator system.

[0074] Design key performance indicators based on the core responsibilities of the target factory's organizational structure.

[0075] In some embodiments, key performance indicators (KPIs) are constructed from the factory level down to the workshop, department, and team levels, resulting in a multi-level KPI system. During the construction process, KPIs are decomposed layer by layer from top to bottom and converged layer by layer from bottom to top. The KPI system should revolve around core functional responsibilities and be measurable to ensure the achievement of manufacturing strategic goals.

[0076] In one specific embodiment, factory-level indicators include: gross profit margin, customer return rate, and delivery date achievement rate; production department-level indicators include: product batch qualification rate, plan achievement rate, OPE, etc.; quality department-level indicators include: DPPM, quality failure cost, etc.; and team-level indicators include: single product OPE, single machine OEE, single machine type plan achievement rate, etc.

[0077] Step 150: Based on the multi-level key performance indicator system, a promotional management meeting mechanism is established for the manufacturing strategic objectives.

[0078] It should be noted that the facilitative management mechanism revolves around two main dimensions: performance achievement and problem-solving. The facilitative management meeting mechanism includes the frequency, content, and timing of meetings at each level.

[0079] In some embodiments, the target factory holds a daily factory-level facilitated management meeting to discuss key performance indicator (KPI) achievement, improvement initiatives, and key tasks. Each production area holds a daily workshop-level facilitated management meeting to discuss KPI achievement, improvement initiatives, and key tasks. Each work team holds a work team-level facilitated management meeting before each shift to discuss KPI achievement, improvement initiatives, and key tasks. The company holds a weekly or monthly company-wide facilitated management meeting. Through this cascading review, attention, and improvement, performance indicators are improved, and a culture of continuous improvement is established.

[0080] This invention establishes a promotional management meeting mechanism at the company, department, and team levels, making performance indicators data-driven and transparent. Through layer-by-layer review, attention, and improvement of performance indicators, a culture of continuous improvement is formed.

[0081] In one specific embodiment, the facilitative management meeting mechanism includes:

[0082] P1 Team Level: 10-minute daily morning meeting to review team performance indicators and explain key points for improvement measures;

[0083] P2 Department Level: Daily meetings of 30-60 minutes, focusing on reviewing department-level performance indicators and reporting on the progress of improvement measures;

[0084] P3 Company Level: Weekly meetings lasting 60-120 minutes, focusing on reviewing company-level performance indicators and reporting on the progress of improvement measures;

[0085] P4 supervisors hold one-on-one closed-door meetings with their subordinates once a month. These meetings focus on communicating and exchanging information about the subordinate's individual performance, acknowledging and encouraging achievements, correcting shortcomings, and understanding the subordinate's mindset and work attitude.

[0086] Step 160: Based on the manufacturing strategic objectives, the multi-level key performance indicator system, and the facilitating management meeting mechanism, construct an implementation plan.

[0087] Based on the requirements of manufacturing strategy, key issues, and management system construction, an overall implementation plan was formulated, and the actual progress was collected and compared with the plan to urge the company to achieve its goals.

[0088] Furthermore, in some embodiments, step 110 is preceded by: constructing a target group based on an organizational structure template.

[0089] It should be explained that the target group is responsible for the entire deployment / control process (i.e. optimization process). The main members of the target group include the general manager, the factory manager, and heads of functional departments such as production, quality, logistics, planning, and process, involving all departments of the target factory to ensure the smooth implementation of optimization.

[0090] In some embodiments, the organizational structure template includes: rules for the formation and functional membership structure of the target group, responsibilities of the group leader and members, and group communication mechanisms, etc.

[0091] Furthermore, in one specific embodiment, the rules for the formation and functional member structure of the target group are as follows: Figure 2 As shown, the target group includes the target group president, the target group executive leader, the marketing department executive officer, the research department executive officer, the process department executive officer, the planning department executive officer, the purchasing department executive officer, the manufacturing department executive officer, the quality department executive officer, the finance department executive officer, and the human resources department executive officer, etc.

[0092] The responsibilities of the target group leader include: formulating optimization strategies; appointing, authorizing, and evaluating target group members; assessing and correcting the progress of optimization; and coordinating various resources to support optimization activities.

[0093] The responsibilities of the target group executive team leader include: assisting the target group president in various optimization and management tasks; being responsible for the implementation and process monitoring of the optimization plan; and coordinating the work of executive officers in various departments, organizing regular meetings and reporting.

[0094] The responsibilities of executive officers in each department include: assisting the target group executive leader in various optimization management tasks; being responsible for the implementation and process monitoring of the department's optimization plan; conducting data statistics and analysis to improve optimization indicators; and reporting work progress at regular meetings.

[0095] Furthermore, in one specific embodiment, the group communication mechanism includes daily meetings and weekly meetings; wherein, the daily meetings are chaired by the executive team leader, with the optimization indicators of each department as the core of the review, and the daily progress of the indicators and key matters are analyzed; the weekly meetings are chaired by the chairman, and the weekly optimization progress is reviewed, with the indicators as the core of the review, and the executive team leader gives an overall report, with the executive officer providing details.

[0096] This invention provides a control method based on a lean manufacturing system. It calculates the operational maturity value of the target lean manufacturing system to identify areas for improvement. Based on pre-built quantitative indicators, it compares the target factory with business objectives to construct manufacturing strategic goals. Based on pre-built lean processes, lean architecture diagrams, and lean departmental functions and responsibilities, it streamlines the organizational structure, thereby constructing a multi-level key performance indicator system and a facilitating management meeting mechanism. Based on the obtained manufacturing strategic goals, multi-level key performance indicator system, and facilitating management meeting mechanism, it constructs an implementation plan and controls the target factory according to the implementation plan to achieve optimization goals. This invention solves the problems of high deployment costs and poor application effects in existing technologies, offering low deployment costs and short deployment time.

[0097] The following provides further explanation of step 140. In some embodiments, based on pre-built lean processes, lean organizational structures, and lean departmental functions and responsibilities, the organizational structure of the target factory is streamlined, including:

[0098] Step 141: Compare the preset process of the target factory with the pre-set lean process, identify waste nodes based on the comparison results, and optimize the waste nodes to obtain the improved process.

[0099] In step 141, in some embodiments, the preset process includes a new product development business process and an order delivery business process for the mass production stage.

[0100] Based on the above embodiments, step 141 is essentially a process of streamlining and reengineering the core business processes based on the entire product value chain.

[0101] Understandably, the entire product value chain can be broadly divided into new product development processes and order delivery processes during mass production. By streamlining and re-engineering these processes, core business processes can be made closed-loop and streamlined, preventing bottlenecks and disruptions.

[0102] In practical implementation, by collecting data from existing new product development and order delivery processes on the client side and comparing them with pre-set lean processes, wasteful nodes are identified. Through process streamlining and reengineering, the core business processes are closed-loop and streamlined, avoiding turbulence and interruptions. This invention does not limit the specific algorithms for identifying and optimizing wasteful nodes; in actual implementation, they can be selected according to the circumstances.

[0103] Furthermore, in some embodiments, the pre-set lean process is to extract and refine a management system suitable for small and medium-sized enterprises from the TPS management system.

[0104] Furthermore, in the process of identifying and optimizing waste points, some implementations use industrial engineering process analysis to identify waste points in the customer's current process, and use industrial engineering problem optimization methods such as 5 Whys analysis and ECRS to streamline and reengineer the process.

[0105] Step 142: Compare the organizational structure of the target factory with the pre-set lean organizational structure, identify redundant organizational structures based on the comparison results, and optimize the redundant organizational structures to obtain an improved organizational structure; wherein, the organizational structure of the target factory is constructed based on the core business processes of the target factory.

[0106] In step 142, the core business processes are effectively segmented through organizational structure design. It is important to emphasize that when designing the organizational structure, the clarity of boundaries and the relative completeness of business processes (functional responsibilities) should be considered to facilitate evaluation and measurement.

[0107] In the specific implementation process, based on the pre-set standardized design of the organizational structure (i.e. lean organizational structure), the organizational structure of the target factory is collected for comparison and optimization to achieve effective segmentation of core business processes.

[0108] Furthermore, in some embodiments, the process of identifying and optimizing redundant organizational structures includes: comparing the collected organizational structure of the target factory with the lean organizational structure to obtain differences; performing functional value analysis on departments that are redundant in the lean organizational structure; removing valueless functions; and classifying valuable functions into the corresponding departments defined by the lean organizational structure.

[0109] The organizational structure of the target factory is constructed by dividing and building upon its core business processes.

[0110] During the construction process, it is first necessary to clarify the core business processes of the target factory, and design the organizational structure with processes as the guide. According to the main stages and functions of the core business processes, corresponding departments should be established. For example, for the product development process, R&D department, testing department, etc. can be set up; for the order delivery process, sales department, planning department, purchasing department, production department, etc. can be set up.

[0111] Step 143: Compare the departmental functions and responsibilities of the target factory with the pre-set lean departmental functions and responsibilities, identify redundant departments and / or personnel based on the comparison results, and optimize the redundant departments and / or personnel to obtain improved departmental functions and responsibilities.

[0112] It should be noted that there are many hidden tissues in the factory, which are eliminated through steps 141-143.

[0113] This invention predefines the core responsibilities of functional departments (i.e., pre-set lean departmental functional responsibilities). By collecting and comparing the existing departmental functional responsibilities of the target factory, it identifies management waste phenomena such as hidden organizations and overlapping functions (i.e., redundant departments and / or personnel), and helps enterprises eliminate management waste. This invention does not limit the specific algorithms for identifying and optimizing redundant departments and / or personnel; in actual implementation, the appropriate algorithm can be selected based on the circumstances.

[0114] The existing departmental functions and responsibilities of the target factory are derived from the organizational structure and core business process scenarios of the target factory, and are obtained by clarifying the core functions and responsibilities of the departments.

[0115] Furthermore, in some embodiments, the method further includes:

[0116] Step 180: Based on the implementation plan and the basic qualifications of the personnel in the target factory, construct a training plan using a pre-set key skills knowledge base.

[0117] Specifically, in step 180, a training plan is developed based on the requirements of the implementation plan and the current basic qualifications of the personnel to supplement the lack of theoretical knowledge and enable them to have the operational ability to implement the plan.

[0118] This invention pre-sets a key skills knowledge reserve and customizes a training plan based on the project implementation process and the basic quality of the company's personnel, according to the needs of project implementation.

[0119] It should be noted that in the process of developing the training plan, it is first necessary to assess the capabilities of the personnel in the target factory. This assessment may include, but is not limited to, questionnaires and on-site interviews. Based on the assessment results, the knowledge gaps of the personnel in the target factory in project implementation should be identified, and training courses should be designed to address these gaps in the training plan.

[0120] Step 190: Train the personnel of the target factory according to the training plan.

[0121] The following provides further explanation of step 170. In some embodiments, an implementation plan is constructed based on the manufacturing strategic objectives, the multi-level key performance indicator system, and the facilitating management meeting mechanism, including:

[0122] Step 171: Decompose the manufacturing strategic objectives into multiple project tasks.

[0123] Specifically, each goal is broken down into specific project tasks or project activities.

[0124] For example, improving overall equipment efficiency (OEE) can be broken down into tasks such as identifying key equipment, statistically analyzing the current OEE level of key equipment, statistically analyzing factors affecting OEE, and analyzing and developing improvement measures for each influencing factor.

[0125] Step 172: Evaluate the project tasks, determine resource requirements, resource usage time and quantity, and develop a schedule.

[0126] Based on the breakdown of project tasks, assess the demand for human and material resources, as well as the time and quantity of use. Develop a schedule based on the determined resource requirements, usage time, and quantity.

[0127] In some embodiments, tools such as Gantt charts are used to develop a schedule based on resource requirements, resource usage time and quantity, and to define key milestones.

[0128] Step 173: Based on the schedule, identify risks and formulate countermeasures based on the risk identification results.

[0129] In step 173, it is necessary to identify potential risks in the project and formulate countermeasures for different risks. During the risk identification process, algorithms such as brainstorming, SWOT (Strengths (S), Weaknesses (W), Opportunities (O), Threats (T)) analysis, and the Delphi method can be used. Alternatively, matching based on pre-defined risks can be performed, or other algorithms can be employed for identification; this invention does not limit the scope of these methods.

[0130] Step 174: The implementation plan consists of the schedules for the multiple project tasks and the corresponding countermeasures.

[0131] Furthermore, based on the above embodiments, in some embodiments, the implementation plan is constructed according to the manufacturing strategic objectives, the multi-level key performance indicator system, and the facilitating management meeting mechanism, and further includes steps 175 and / or 176.

[0132] Step 175: During the execution of the schedule, monitor the execution status based on the facilitating management meeting mechanism and / or the pre-established communication mechanism.

[0133] Specifically, we understand the project progress through on-site visits and regular meeting reports, and promptly identify and correct problems.

[0134] On-site visits and regular meeting reports can be achieved based on the facilitating management meeting mechanism and / or a pre-established communication mechanism.

[0135] Based on the above embodiments, monitoring of execution can also be implemented based on target groups.

[0136] The steps for building a pre-established communication mechanism include: identifying the stakeholders involved in the project tasks, clarifying the content, methods, and frequency of communication among stakeholders during the project implementation process, and forming a pre-established communication mechanism.

[0137] Step 176: After the project task or preset project node is completed, summarize and review the implementation to obtain project implementation experience, and store the project implementation experience in the experience database.

[0138] Specifically, at each project milestone or after the completion of the entire project, a project debriefing meeting is held to summarize the experiences and lessons learned during the project implementation process as project implementation experience, and to include the project implementation experience in the experience library for subsequent processes.

[0139] Furthermore, step 176 also includes recognizing projects and individuals who have made outstanding contributions.

[0140] Furthermore, the implementation plan also includes addressing new issues requiring improvement, such as those related to target groups and facilitating management meetings.

[0141] Furthermore, such as Figure 3 As shown, the method also includes: repeatedly executing steps 110-170, various problems in the factory will be continuously identified and eliminated one by one through their own function, and in the long run, the factory can achieve continuous improvement.

[0142] Furthermore, the control method based on a lean manufacturing system provided by this invention can be viewed as an ultimate manufacturing system. Unlike the introduction of application tools, this invention has a wide scope and will significantly impact existing organizational structures, business processes, personnel, and ideologies. Factories will also face numerous problems that need to be addressed. Typically, a factory operational maturity diagnosis identifies at least five or seven hundred issues. Addressing all issues without prioritizing them will increase resistance. Therefore, it is necessary to identify key problems and quickly resolve them.

[0143] Based on this, in some embodiments, the operational data of the target factory is input into the target lean production system to obtain the operational maturity value of the target factory. After determining the problems to be improved faced by the target factory based on the operational maturity value and the business objectives of the target factory, steps 121 and 122 are also included.

[0144] Step 121: Based on the target lean production system, score the multiple issues to be improved, and select a preset number of issues to be improved as key issues to be improved.

[0145] The scoring of key issues to be improved can be achieved based on dimensions such as the impact of the issue, the occurrence rate, and the detectability. After weighting the scores of each dimension, the issues with higher scores are listed as key issues to be improved.

[0146] Step 122: Sort the key issues to be improved and process them in order.

[0147] In this embodiment, the diagnosed problems to be improved are "infused" into the Extreme Manufacturing Invincible System. By leveraging the Invincible System's own capabilities, these problems are eliminated, and the Invincible System's abilities are trained.

[0148] The following provides a further explanation of step 143. In some embodiments, the departmental functions and responsibilities of the target factory are compared with pre-set lean departmental functions and responsibilities. Based on the comparison results, redundant departments and / or personnel are identified and optimized to obtain improved departmental functions and responsibilities, including:

[0149] Step 1431: Compare the departmental functions and responsibilities of the target factory with the pre-set lean departmental functions and responsibilities.

[0150] Step 1432: Based on the comparison results, use industrial engineering process analysis to identify the departments and / or personnel through which business processes overlap or are not reflected in the organizational structure, thereby obtaining redundant departments and / or personnel.

[0151] Specifically, by combining the pre-defined lean departmental functions and responsibilities with the work responsibilities of each department, and using industrial engineering process analysis, we can identify redundant departments and / or personnel involved in business processes that overlap or are not reflected in the organizational structure. In this way, we can merge redundant departments and / or personnel involved in business processes that overlap with the organizational structure, and delete redundant departments and / or personnel involved in business processes that are not reflected in the organizational structure, thereby improving departmental functions and responsibilities.

[0152] The lean production system-based control method provided in this application effectively unifies continuous improvement and a people-oriented approach, helping factories build self-sustaining and continuous improvement capabilities. This lean production system-based control method is inexpensive and has a short deployment cycle, reducing deployment costs for SMEs. Experiments have shown that the solution design can be completed within one month, and significant performance improvement occurs within six months of deployment. Furthermore, this lean production system-based control method removes obstacles to digitalization and automation transformation, enabling tactical projects (such as 5S and visual management) to be implemented sustainably in factories.

[0153] According to some embodiments, experiments have shown that the control method based on the lean production system provided in this application can help customers improve key performance indicators such as quality, cost, and delivery by more than 10% to 20% within 6 months, with an annual return on investment of more than 5 to 10 times.

[0154] The control device based on the lean production system provided by the present invention is described below. The control device based on the lean production system described below and the control method based on the lean production system described above can be referred to in correspondence. Figure 4 This is a schematic diagram of the control device based on the lean production system provided by the present invention, as shown below. Figure 4 As shown, the device includes the following modules:

[0155] Problem detection unit 410 is used to input the operational data of the target factory into the target lean production system to obtain the operational maturity value of the target factory, and to identify the problems to be improved faced by the target factory based on the operational maturity value and the business objectives of the target factory.

[0156] Manufacturing strategy design unit 420 is used to compare the target factory with the business objectives based on pre-built quantitative indicators, according to the problems to be improved and the operational data, and to construct manufacturing strategic objectives based on the comparison results;

[0157] Organizational structure optimization unit 430 is used to streamline the organizational structure of the target factory based on pre-built lean processes, lean organizational structure and lean departmental functions and responsibilities;

[0158] The performance indicator construction unit 440 is used to construct a multi-level key performance indicator system based on the simplified organizational structure of the target factory.

[0159] Meeting mechanism construction unit 450, based on the multi-level key performance indicator system and the manufacturing strategic goals, constructs a promotional management meeting mechanism;

[0160] The implementation plan construction unit 460 is used to construct an implementation plan based on the manufacturing strategic objectives, the multi-level key performance indicator system, and the facilitating management meeting mechanism.

[0161] According to the present invention, a control device based on a lean production system simplifies the organizational structure of the target factory based on pre-built lean processes, lean organizational structure, and lean departmental functions and responsibilities, including:

[0162] The preset process of the target factory is compared with the pre-set lean process. Waste nodes are identified based on the comparison results and optimized to obtain the improved process.

[0163] The organizational structure of the target factory is compared with a pre-set lean organizational structure. Redundant organizational structures are identified based on the comparison results and optimized to obtain an improved organizational structure. The organizational structure of the target factory is constructed by dividing and segmenting the core business processes of the target factory.

[0164] The departmental functions and responsibilities of the target factory are compared with the pre-set lean departmental functions and responsibilities. Based on the comparison results, redundant departments and / or personnel are identified and optimized to obtain improved departmental functions and responsibilities.

[0165] According to a control device based on a lean manufacturing system provided by the present invention, the method further includes:

[0166] Based on the implementation plan and the basic qualifications of the personnel in the target factory, a training plan is constructed based on a pre-set key skills knowledge base.

[0167] The personnel of the target factory are trained in accordance with the training plan.

[0168] According to the present invention, a control device based on a lean manufacturing system constructs an implementation plan based on the manufacturing strategic objectives, the multi-level key performance indicator system, and the facilitating management meeting mechanism, including:

[0169] The manufacturing strategic objectives are broken down into multiple project tasks;

[0170] The project tasks are evaluated to determine resource requirements, resource usage time and quantity, and a schedule is developed.

[0171] Risks are identified based on the aforementioned schedule, and countermeasures are formulated based on the risk identification results.

[0172] The implementation plan comprises the schedules of the various project tasks and the corresponding countermeasures.

[0173] According to the control device based on a lean production system provided by the present invention, an implementation plan is constructed based on the manufacturing strategic objectives, the multi-level key performance indicator system, and the facilitating management meeting mechanism, and further includes:

[0174] During the execution of the schedule, the execution status is monitored based on the facilitating management meeting mechanism and / or a pre-established communication mechanism; and / or

[0175] After the project task or preset project node is completed, the implementation is summarized and reviewed to obtain project implementation experience, and the project implementation experience is stored in the experience database.

[0176] According to a control device based on a lean production system provided by the present invention, after inputting the operational data of a target factory into a target lean production system to obtain the operational maturity value of the target factory, and determining the problems to be improved faced by the target factory based on the operational maturity value and the business objectives of the target factory, the device further includes:

[0177] Based on the target lean production system, multiple issues to be improved are scored, and a preset number of issues to be improved are selected as key issues to be improved.

[0178] The key issues requiring improvement are prioritized and addressed in that order.

[0179] According to a control device based on a lean production system provided by the present invention, the departmental functions and responsibilities of the target factory are compared with pre-set lean departmental functions and responsibilities. Based on the comparison results, redundant departments and / or personnel are identified and optimized to obtain improved departmental functions and responsibilities, including:

[0180] The departmental functions and responsibilities of the target factory are compared with the pre-set lean departmental functions and responsibilities;

[0181] Based on the comparison results, the industrial engineering process analysis method is used to identify the departments and / or personnel through which business processes overlap or are not reflected in the organizational structure, thereby obtaining redundant departments and / or personnel.

[0182] Figure 5 An example is a schematic diagram of the physical structure of an electronic device, such as... Figure 5As shown, the electronic device may include: a processor 510, a communication interface 520, a memory 530, and a communication bus 540, wherein the processor 510, the communication interface 520, and the memory 530 communicate with each other through the communication bus 540. The processor 510 can call logic instructions in the memory 530 to execute a control method based on a lean manufacturing system. This method includes: inputting operational data of the target factory into the target lean manufacturing system to obtain the operational maturity value of the target factory; and, based on the operational maturity value and the business objectives of the target factory, identifying the problems to be improved faced by the target factory; comparing the target factory with the business objectives based on pre-built quantitative indicators, the problems to be improved, and the operational data, and constructing manufacturing strategic objectives based on the comparison results; streamlining the organizational structure of the target factory based on pre-built lean processes, lean organizational structure, and lean departmental functions and responsibilities; constructing a multi-level key performance indicator system based on the streamlined organizational structure of the target factory; establishing a facilitating management meeting mechanism based on the multi-level key performance indicator system and the facilitating management meeting mechanism; and constructing an implementation plan based on the manufacturing strategic objectives, the multi-level key performance indicator system, and the facilitating management meeting mechanism.

[0183] Furthermore, the logical instructions in the aforementioned memory 530 can be implemented as software functional units and, when sold or used as independent products, can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, essentially, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0184] On the other hand, the present invention also provides a computer program product, which includes a computer program that can be stored on a non-transitory computer-readable storage medium. When the computer program is executed by a processor, the computer can execute the control method based on the lean production system provided by the above methods. The method includes: inputting the operational data of the target factory into the target lean production system to obtain the operational maturity value of the target factory, and obtaining the problems to be improved faced by the target factory based on the operational maturity value and the business objectives of the target factory; comparing the target factory with the business objectives based on pre-constructed quantitative indicators, the problems to be improved, and the operational data, and constructing manufacturing strategic objectives based on the comparison results; streamlining the organizational structure of the target factory based on pre-constructed lean processes, lean organizational structure, and lean departmental functions and responsibilities; constructing a multi-level key performance indicator system based on the streamlined organizational structure of the target factory; constructing a promotional management meeting mechanism for the manufacturing strategic objectives based on the multi-level key performance indicator system; and constructing an implementation plan based on the manufacturing strategic objectives, the multi-level key performance indicator system, and the promotional management meeting mechanism.

[0185] In another aspect, the present invention also provides a non-transitory computer-readable storage medium storing a computer program thereon, which, when executed by a processor, is implemented to perform the control method based on the lean manufacturing system provided by the above methods. This method includes: inputting operational data of a target factory into a target lean manufacturing system to obtain an operational maturity value of the target factory; and, based on the operational maturity value and the business objectives of the target factory, determining the problems to be improved faced by the target factory; comparing the target factory with the business objectives based on pre-constructed quantitative indicators, the problems to be improved, and the operational data, and constructing manufacturing strategic objectives based on the comparison results; streamlining the organizational structure of the target factory based on pre-constructed lean processes, lean organizational structure, and lean departmental functions and responsibilities; constructing a multi-level key performance indicator system based on the streamlined organizational structure of the target factory; establishing a facilitating management meeting mechanism based on the multi-level key performance indicator system and the facilitating management meeting mechanism; and constructing an implementation plan based on the manufacturing strategic objectives, the multi-level key performance indicator system, and the facilitating management meeting mechanism.

[0186] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs. Those skilled in the art can understand and implement this without any creative effort.

[0187] Through the above description of the embodiments, those skilled in the art can clearly understand that each embodiment can be implemented by means of software plus necessary general-purpose hardware platforms, and of course, it can also be implemented by hardware. Based on this understanding, the above technical solutions, in essence or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, magnetic disk, optical disk, etc., and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute the methods described in the various embodiments or some parts of the embodiments.

[0188] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A control method based on a lean manufacturing system, characterized in that, include: Step 110: Input the operational data of the target factory into the target lean production system to obtain the operational maturity value of the target factory, and based on the operational maturity value and the business objectives of the target factory, determine the problems to be improved faced by the target factory; Step 120: Based on the pre-built quantitative indicators, compare the target factory with the business objectives according to the problems to be improved and the operational data, and construct manufacturing strategic objectives based on the comparison results; the quantitative indicators include FPY, customer return rate, and quality failure cost in the quality dimension; raw material cost as a percentage of revenue and labor cost as a percentage of revenue in the cost dimension; delivery cycle and inventory turnover rate in the delivery dimension; and turnover rate in the team dimension. Step 130: Based on pre-built lean processes, lean organizational structures, and lean departmental functions and responsibilities, streamline the organizational structure of the target factory; this includes: comparing the target factory's preset processes with pre-set lean processes, identifying wasteful nodes based on the comparison results, and optimizing the wasteful nodes to obtain improved processes; comparing the target factory's organizational structure with pre-set lean organizational structures, identifying redundant organizational structures based on the comparison results, and optimizing the redundant organizational structures to obtain improved organizational structures; wherein, the target factory's organizational structure is constructed based on the core business processes of the target factory; comparing the target factory's departmental functions and responsibilities with pre-set lean departmental functions and responsibilities, identifying redundant departments and / or personnel based on the comparison results, and optimizing the redundant departments and / or personnel to obtain improved departmental functions and responsibilities; this includes: comparing the target factory's departmental functions and responsibilities with pre-set lean departmental functions and responsibilities. Based on the comparison results, the industrial engineering process analysis method is used to identify the departments and / or personnel through which business processes overlap or are not reflected in the organizational structure, thereby obtaining redundant departments and / or personnel. Step 140: Based on the simplified organizational structure of the target factory, construct a multi-level key performance indicator system that is decomposed from top to bottom and converged from bottom to top at the factory, workshop, department, and team levels. Step 150: Based on the multi-level key performance indicator system and the manufacturing strategic goals, construct a promotional management meeting mechanism that includes daily meetings at the team level, daily meetings at the department level, weekly meetings at the company level, and one-on-one monthly closed-door meetings between supervisors and subordinates. Step 160: Based on the manufacturing strategic objectives, the multi-level key performance indicator system, and the facilitating management meeting mechanism, construct an implementation plan; including: decomposing the manufacturing strategic objectives into multiple project tasks; evaluating the project tasks, determining resource requirements, resource usage time and quantity, and developing a schedule; identifying risks based on the schedule, and developing countermeasures based on the risk identification results; the schedules of multiple project tasks and the countermeasures constitute the implementation plan; during the execution of the schedule, monitoring the execution status based on the facilitating management meeting mechanism and / or a pre-established communication mechanism; and / or summarizing and reviewing the implementation status after the completion of the project tasks or preset project milestones to obtain project implementation experience, and storing the project implementation experience in an experience database; Repeat step 110 160, to achieve continuous improvement of the target factory.

2. The control method based on a lean production system according to claim 1, characterized in that, The method further includes: Based on the implementation plan and the basic qualifications of the personnel in the target factory, a training plan is constructed based on a pre-set key skills knowledge base. The personnel of the target factory are trained in accordance with the training plan.

3. The control method based on a lean production system according to claim 1, characterized in that, After inputting the target factory's operational data into the target lean manufacturing system to obtain the target factory's operational maturity value, and based on the operational maturity value and the target factory's business objectives, identifying the issues to be improved in the target factory, the process further includes: Based on the target lean production system, multiple issues to be improved are scored, and a preset number of issues to be improved are selected as key issues to be improved. The key issues requiring improvement are prioritized and addressed in that order.

4. A control device based on a lean manufacturing system, based on the method described in any one of claims 1-3, characterized in that, The control device includes: The problem detection unit is used to input the operational data of the target factory into the target lean production system to obtain the operational maturity value of the target factory, and to identify the problems to be improved faced by the target factory based on the operational maturity value and the business objectives of the target factory. The manufacturing strategy design unit is used to compare the target factory with the business objectives based on pre-built quantitative indicators, the problems to be improved and the operational data, and to construct manufacturing strategic objectives based on the comparison results. The organizational structure optimization unit is used to streamline the organizational structure of the target factory based on pre-built lean processes, lean organizational structure, and lean departmental functions and responsibilities. The performance indicator construction unit is used to construct a multi-level key performance indicator system based on the simplified organizational structure of the target factory. The meeting mechanism construction unit constructs a promotional management meeting mechanism based on the multi-level key performance indicator system and the manufacturing strategic objectives. The implementation plan construction unit is used to construct an implementation plan based on the manufacturing strategic objectives, the multi-level key performance indicator system, and the facilitating management meeting mechanism.

5. An electronic device, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the program, it implements the control method based on the lean manufacturing system as described in any one of claims 1 to 3.

6. A non-transitory computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by the processor, it implements the control method based on the lean manufacturing system as described in any one of claims 1 to 3.

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