With the intensification of market competition, the market environment of modern enterprises has undergone profound changes, and enterprise competition increasingly emphasizes competition based on customer needs. Therefore, the production methods of enterprises have gradually shifted to various advanced production modes based on flexible automated production. The current production types can be roughly divided into three types: mass flow production, multi-variety small-batch multi-variety production, and single piece production.
01
The concept of multi-variety, small batch production
Multi-variety, small-batch production refers to a production method in which there are many types of products (specifications, models, sizes, shapes, colors, etc.) as the production target during the specified production period, and a small number of products of each type are produced. .
Generally speaking, compared with mass production methods, this production method is low in efficiency, high in cost, difficult to achieve automation, and production planning and organization are more complicated. However, under the conditions of a market economy, consumers tend to diversify their hobbies, pursuing advanced, unique and popular products that are different from others. New products are emerging in endlessly. In order to expand market share, companies must adapt to this change in the market. The diversification of enterprise products has become an inevitable trend. Of course, we should see the diversification of products and the endless emergence of new products, which will also cause some products to be eliminated before they are outdated and still have use value, which greatly wastes social resources. This phenomenon should arouse people’s attention.
02
Features of multi-variety, small batch production
01
Multiple varieties in parallel
Since many companies’ products are configured for customers, different products have different needs, and the resources of companies are in multiple varieties.
02
Resource Sharing
Every task in the production process requires resources, but the resources that can be used in the actual process are very limited. For example, the problem of equipment conflicts often encountered in the production process is caused by the sharing of project resources. Therefore, the limited resources must be properly deployed to meet project requirements.
03
Uncertainty of order result and production cycle
Due to the instability of customer demand, the clearly planned nodes are inconsistent with the complete cycle of human, machine, material, method, and environment, etc., the production cycle is often uncertain, and projects with insufficient cycles require more resources , Increasing the difficulty of production control.
04
Material demand changes frequently, leading to serious procurement delays
Due to the insertion or change of the order, it is difficult for external processing and procurement to reflect the delivery time of the order. Due to the small batch and single source of supply, the supply risk is extremely high.
03
Difficulties in multi-variety, small batch production
1. Dynamic process path planning and virtual unit line deployment: emergency order insertion, equipment failure, bottleneck drift.
2. Identification and drift of bottlenecks: before and during production
3. Multi-level bottlenecks: the bottleneck of the assembly line, the bottleneck of the virtual line of parts, how to coordinate and couple.
4. Buffer size: either backlog or poor anti-interference. Production batch, transfer batch, etc.
5. Production scheduling: not only consider the bottleneck, but also consider the impact of non-bottleneck resources.
The multi-variety and small-batch production model will also encounter many problems in corporate practice, such as:
Multi-variety and small-batch production makes mixed scheduling difficult
Unable to deliver on time, too many “fire-fighting” overtime
Order requires too much follow-up
The production priority is frequently changed and the original plan cannot be implemented
Increasing inventory, but often lack of key materials
The production cycle is too long, and the lead time is infinitely expanded
04
Preparation method of multi-variety, small batch production plan
01
Comprehensive balance method
The comprehensive balance method is based on the requirements of objective laws, in order to achieve the plan objectives, to ensure that the relevant aspects or indicators in the planning period are properly proportioned, connected and coordinated with each other, using the form of a balance sheet to determine through repeated balance analysis and calculations. Plan indicators. From the perspective of system theory, it means to keep the internal structure of the system orderly and reasonable. The characteristic of the comprehensive balance method is to carry out a comprehensive and repeated comprehensive balance through indicators and production conditions, maintaining a balance between tasks, resources and needs, between parts and the whole, and between goals and long-term. Suitable for preparing long-term production plans. It is conducive to tap the potential of the enterprise’s human, financial and material.
02
Quota method
The quota method is to calculate and determine the relevant indicators of the planning period based on the relevant technical and economic quota. It is characterized by simple calculation and high accuracy. The disadvantage is that it is greatly affected by product technology and technological progress.
03 Rolling plan method
The rolling plan method is a dynamic method of preparing a plan. It adjusts the plan in a timely manner based on the implementation of the plan in a certain period of time, considering the changes in the internal and external environmental conditions of the organization, and accordingly extends the plan for a period, combining the short-term plan with the long-term plan It is a method of planning.
The rolling plan method has the following characteristics:
The plan is divided into several execution periods, among which short-term plans must be detailed and specific, while long-term plans are relatively rough;
After the plan is implemented for a certain period of time, the content of the plan and related indicators will be revised, adjusted and supplemented according to the implementation and environmental changes;
The rolling planning method avoids the solidification of the plan, improves the adaptability of the plan and the guidance to the actual work, and is a flexible and flexible production planning method;
The principle of preparing the rolling plan is “near fine and far rough”, and the operation mode is “implementation, adjustment, and rolling”.
The above characteristics show that the rolling plan method is constantly adjusted and revised with the changes in market demand, which coincides with the multi-variety, small-batch production method that adapts to the changes in market demand. Using the rolling plan method to guide the production of multiple varieties and small batches can not only improve the ability of enterprises to adapt to changes in market demand, but also maintain the stability and balance of their own production, which is an optimal method.