I. Importance and complexity of equipment manufacturing
The equipment manufacturing industry is a manufacturing industry that provides equipment for the national economy and national security and provides rich products for the people's material and cultural life. In the national economy, both the proportion of GDP and the inductance of other industries are very large. The equipment manufacturing industry is the basis for the sustainable development of the national economy, the engine and power source for industrialization and modernization, the magic weapon for winning in international competition, the source of income for increasing per capita income, the guarantee for national security, and the material for developing modern civilization. basis. Without the advanced equipment manufacturing industry to continuously and continuously arm and upgrade the equipment and production operation level of various industrial sectors, and to achieve environmentally friendly sustainable development, there is no modernization, so people’s attention to the equipment manufacturing industry is not to be said. Yu. The following is only about the difficulties, priorities, problems and countermeasures of the management informationization of the equipment manufacturing industry.
The management of the equipment manufacturing industry is very complicated and faces severe challenges.
1. The product structure is complex. There are tens of thousands of parts and components in a power station steam turbine. There are thousands of parts and components in a medium-complexity machine tool. In general, there are tens of thousands of raw materials and purchased parts, so many materials are purchased. Production and inventory planning and control are very difficult.
2. The production process is complicated. One part often needs to go through multiple workshops. The products flow between the workshops and on multiple machine tools inside the workshop. How to arrange the workshop operation plan and make rational use of resources to ensure on-time delivery is also very difficult.
3. Different types of production modes are different. In the equipment manufacturing industry, with the production batch and production organization, it is divided into single-piece production, multi-variety small-batch production, large-scale water production, mass customization, and different production type production plans. Unlike the controlled mode, there are also a mix of multiple modes.
4. Different types of production workshops, different management modes, workshops for equipment manufacturing, such as casting, forging, welding, machining, assembly, heat treatment and surface treatment. Due to different production processes, production operations plans, cost accounting is different. The same process of workshop water production and mass production is different.
5. The rapid growth of requirements for order design and mass customization requires high flexibility in manufacturing capabilities and resources, as well as management methods and management tools appropriate to them.
6. The product life cycle is getting shorter and shorter, requiring us to speed up the development of new products and new technology applications, and accelerate the time to market new products.
7. Demand changes rapidly, requiring minimum production product preparation time, shortened procurement lead time and manufacturing lead time, and respond quickly to customer needs.
8. Raw material prices and manufacturing costs are rising, and the profitability of the equipment manufacturing industry is not high. How to reduce costs has become a matter of great concern to enterprises.
The above-mentioned characteristics and challenges faced by the equipment manufacturing industry have made the equipment manufacturing industry have high hopes for ERP, and have high requirements for software products and implementation.
2. Status of current management informationization in equipment manufacturing industry
Although there has always been an "outdated" speculation in the ERP industry, and the confusion of "failure theory", through the vigorous promotion of the state, the large investment of enterprises, the unremitting efforts of ERP providers, and the informatization of equipment manufacturing management have made gratifying achievements. ,appears in:
1. Rationalize demand. In some enterprises, ERP is for advanced evaluation and peer comparison. In order to “face projectâ€, some are for the state-funded projects. Due to the incorrect purpose, the implementation effect is greatly reduced. Now the enterprise ERP is from the enterprise. The demand is for the needs of competition, so the implementation of the work, the implementation effect is obvious and lasting.
2. The software product is mature. After many years of tempering, the concept of foreign ERP, the best business practice and China's national conditions are combined. Some products have established a firm foothold in equipment manufacturing enterprises and the products are mature.
3. Consulting services are accepted by more and more companies. Before implementing ERP, through management consulting, designing advanced and applicable management models and business processes, organization, performance management, and compensation system to form a complete management control system, laid a good foundation for the implementation of ERP.
4. A number of equipment manufacturing industry information has achieved good results. A group of automobile manufacturing, tobacco machinery industry, China South Locomotive Group's truck manufacturing industry, they have achieved good results in the core value of ERP - production and operation management, on-time production, advanced cost management.
But we also see that there are still many problems in the ERP implementation of the equipment manufacturing industry.
3. The current problems in the information management of equipment manufacturing management.
Although the equipment manufacturing management information has achieved gratifying results, we also see that development is unbalanced, and some enterprises still have many problems in informationization:
1. Problems in current production management. The production plan is a static, decentralized, discontinuous, and set-by-segment plan. It cannot be rationally merged with common parts, and lacks scientific planning policies, batch policies, reserve policies, lead time and other production planning parameters. Due to the backward planning method, enterprises generally have a long production cycle, high stocks in stocks, large liquidity, and cannot be delivered on time. Most enterprises implement monthly plans, and the plans are relatively thick. The upper and lower processes lack precise integration, due to work in process and inventory. The material quota data is not timely, inaccurate, and the accuracy of the plan is poor. Due to poor planning control, the production is not balanced, the complete set of parts is poor, and the delivery cannot be delivered on time. The production scheduling workload is large, and the pieces are spared every day.
2. Problems in logistics management. The procurement plan is inaccurate, the material control is not rigorous, and there are many links that do not add value, often resulting in backlog or shortage of materials. Inventory data, consumption quota data, work-in-progress data, and in-transit data are not timely and inaccurate, which is the reason for the material control is not strict. Procurement planning and production planning are not synchronized and separated, and there is a lack of coordination in the supply chain. Logistics management cannot provide accurate and timely information for production planning, finance, and cost.
3. Management mode with financial accounting as the core is not advisable. Many enterprises have implemented the financial plus supply and sales system, which is undoubtedly the basis of ERP, it is necessary, but the management model, business process and system designed by many enterprises in implementing these systems are based on financial accounting. Mode, China's logistics and capital flow are not synchronized, no purchase invoices can not be put into the warehouse, not open sales invoices can not be out of the library, although there are valuations into the warehouse, valuation out of the warehouse, but in order to avoid inventory funds assessment or unwilling to do complex valuation If you do not intend to enter the warehouse, the various restrictions within the enterprise will not be allowed to enter the warehouse. In order to make a financial statement at the end of the month, the ultimate goal of management is to issue financial statements at the end of the month. The most basic inventory data is not timely and inaccurate. Inaccurate inventory leads to lack of basis for production, procurement planning, production scheduling, and cost accounting. Logistics and finance have not created conditions for the in-depth implementation of ERP.
4. Financial management has remained at the stage of accounting and has not reached the level of management accounting. Total budget management is only carried out in a small number of companies. The cost planning and control are not realized, the cost calculation simulates the manual accounting mode, and the cost accounting object is coarse. Generally, only the product can be calculated, the parts cannot be calculated, there is no standard cost, and the necessary cost analysis is lacking. The collection of a large amount of cost data is not based on manufacturing data, inventory, and shop floor data, but is manually entered by workshop accounting. Since the data is inaccurate and cannot be proofread, cost distortion is common.
5. Lack of supply chain management and collaborative commerce. Most of the enterprises that implement informatization are internal informationization. Most enterprises only stay at the level of website promotion and e-mail, and the level of e-commerce is still very low.
Due to the above-mentioned management problems, the economic and technical indicators of Chinese enterprises have lower labor productivity, slower liquidity turnover, poor cost control, large inventory capital, and poor ability of enterprises to respond quickly to the market.
4. The focus of equipment manufacturing management informationization
Each manufacturing enterprise will write the following objectives in its management informationization plan or project report:
Shorten product production cycle and procurement lead time Reduce inventory and work capital utilization Improve on-time delivery rate Quickly respond to customer demand, improve customer satisfaction, increase production capacity, reduce overtime hours, reduce product cost, increase labor productivity, increase capital turnover rate, increase production and operation data Timeliness, accuracy, and sharing
How can these goals be achieved? Except for the last one, it can be realized through the management of supply, sales, deposit and financial systems. It is impossible to save the rest of the articles through supply and marketing. Even if your inventory data accuracy rate is 100%, but you don't know if the inventory is more or less, the financial account is not bad, but you can't solve the problem of how to reduce inventory funds and reduce production costs. Some enterprises control The stock funds are used to give the warehousing department and the production workshop the evaluation index of the capital occupation. The result is that there are countermeasures under the policy. The warehousing is not included in the warehouse, and the rear is not expected to enter the warehouse. The produced product workshop is reported to be completed. It is not allowed to enter the warehouse. Otherwise, the inventory of the goods will be increased. The inventory of the enterprises will not be reduced at all. The assessment indicators for the capital occupation of each unit will be completed as usual. The comprehensive budget will control some non-production funds, but the control of production funds is very weak because You don't have a voice, what should you buy, why not buy, when to buy, how much? Who has the final say?
In manufacturing enterprises, production operation management, especially production planning and control at all levels is the core value of ERP. Through demand management, main production planning, material demand planning, workshop task management, workshop operation planning, on-time production, project management, etc., it converts sales demand into production plans, material procurement plans, and outsourcing plans for various production departments within the company. To achieve planning coordination and optimization of the supply chain. It answers what time, what is produced, what is purchased, how much is produced, and how much is purchased. All of this must be based on different types of production, production volume, and production organization, and adopt different planning policies, reserve policies, and schedule standards to minimize product production cycle, purchase lead time, and reduce inventory and work-in-progress funds. , quickly respond to customer needs. Japanese people talk about manufacturing management, talk about lean production LP, Toyota production management TPM, in fact, the important means to achieve lean production is the supply chain planning synergy and optimization, is to adopt different production plan control mode for different production types, the other is people The management of consciousness and behavior, the author believes that the appeal and focus of the informationization of equipment manufacturing industry is here.
V. Countermeasures for informationization of equipment manufacturing industry
Knowing the problem and focus of equipment manufacturing management informationization, how to achieve the goal of informationization?
1. First of all, we must take informationization as the strategy of the enterprise, combine informationization and management consulting, and combine informationization with enterprise management reform and process optimization. Informatization is a management project, not a technology project. Overcome the extreme and incorrect implementation methods of “wearing new shoes and walking the old road†and “cutting the feetâ€. Overcome the mistakes of paying attention to technology, light management; heavy hardware, light software, and light consulting services.
2. Establish a complete production plan control system for different production types. Break the traditional manual production plan to control the scattered, discontinuous, static, and inaccurate planning model. Establish a centralized, continuous, dynamic, and accurate production planning control model from sales, production, procurement, and the entire supply chain. Optimize planning policies, batch policies, volume standards, and reserve policies to minimize production cycle and procurement lead time, reduce inventory capital usage, and respond quickly to customer needs.
3. The construction of logistics and capital flows should coordinate and optimize the planning of the entire supply chain. The entire logistics activity is commanded by the production planning control system. All financial data changes with the movement, value-added, and impairment of logistics. It is impossible to control production and operation activities with simple financial indicators.
4. Establish a scientific cost management system. Do pre-planning, control in the event, and analyze afterwards. Establish a closed-loop control system for standard cost, actual cost, and cost analysis. Use the step-by-step method to refine the costing objects. The cost data is basically obtained from the engineering data management system, the inventory management system, the workshop management system, and the financial accounting system. Instead of manual input by the workshop accountant. This will ensure the objectivity and accuracy of the data.
5. Expand the information technology of the equipment manufacturing industry to customer relationship management. Strengthen market information, customer information, after-sales service information, and self-service management. Improve customer satisfaction, loyalty and goodwill. Develop supplier relationship management, strengthen certification, management, and evaluation of suppliers, and quickly communicate supply and demand information through the Internet to realize electronic supply.
The management informationization of the equipment manufacturing industry is complicated, management is difficult, and the management potential is also great. Only when we grasp the key points of management and adopt scientific countermeasures, the management informationization of equipment manufacturing industry will certainly improve the economic efficiency of enterprises and the competitiveness of enterprises.
The Beijing Institute of Machinery Industry Automation has been dedicated to the management of equipment manufacturing in the past 30 years. Based on management consulting, optimizing the company's management model, business process, organization, performance, and compensation, they use advanced ERP software RS10 as a tool, and take production and operation management as the core to realize logistics and capital flow throughout the supply chain. Information flow, responsibility flow optimization and collaboration, comprehensive integration of PDM/PLM, MES, enterprise information portal, providing complete solutions for equipment manufacturing management informationization, bringing tangible economic benefits to multiple equipment manufacturing enterprises And competitiveness.
The equipment manufacturing industry is a manufacturing industry that provides equipment for the national economy and national security and provides rich products for the people's material and cultural life. In the national economy, both the proportion of GDP and the inductance of other industries are very large. The equipment manufacturing industry is the basis for the sustainable development of the national economy, the engine and power source for industrialization and modernization, the magic weapon for winning in international competition, the source of income for increasing per capita income, the guarantee for national security, and the material for developing modern civilization. basis. Without the advanced equipment manufacturing industry to continuously and continuously arm and upgrade the equipment and production operation level of various industrial sectors, and to achieve environmentally friendly sustainable development, there is no modernization, so people’s attention to the equipment manufacturing industry is not to be said. Yu. The following is only about the difficulties, priorities, problems and countermeasures of the management informationization of the equipment manufacturing industry.
The management of the equipment manufacturing industry is very complicated and faces severe challenges.
1. The product structure is complex. There are tens of thousands of parts and components in a power station steam turbine. There are thousands of parts and components in a medium-complexity machine tool. In general, there are tens of thousands of raw materials and purchased parts, so many materials are purchased. Production and inventory planning and control are very difficult.
2. The production process is complicated. One part often needs to go through multiple workshops. The products flow between the workshops and on multiple machine tools inside the workshop. How to arrange the workshop operation plan and make rational use of resources to ensure on-time delivery is also very difficult.
3. Different types of production modes are different. In the equipment manufacturing industry, with the production batch and production organization, it is divided into single-piece production, multi-variety small-batch production, large-scale water production, mass customization, and different production type production plans. Unlike the controlled mode, there are also a mix of multiple modes.
4. Different types of production workshops, different management modes, workshops for equipment manufacturing, such as casting, forging, welding, machining, assembly, heat treatment and surface treatment. Due to different production processes, production operations plans, cost accounting is different. The same process of workshop water production and mass production is different.
5. The rapid growth of requirements for order design and mass customization requires high flexibility in manufacturing capabilities and resources, as well as management methods and management tools appropriate to them.
6. The product life cycle is getting shorter and shorter, requiring us to speed up the development of new products and new technology applications, and accelerate the time to market new products.
7. Demand changes rapidly, requiring minimum production product preparation time, shortened procurement lead time and manufacturing lead time, and respond quickly to customer needs.
8. Raw material prices and manufacturing costs are rising, and the profitability of the equipment manufacturing industry is not high. How to reduce costs has become a matter of great concern to enterprises.
The above-mentioned characteristics and challenges faced by the equipment manufacturing industry have made the equipment manufacturing industry have high hopes for ERP, and have high requirements for software products and implementation.
2. Status of current management informationization in equipment manufacturing industry
Although there has always been an "outdated" speculation in the ERP industry, and the confusion of "failure theory", through the vigorous promotion of the state, the large investment of enterprises, the unremitting efforts of ERP providers, and the informatization of equipment manufacturing management have made gratifying achievements. ,appears in:
1. Rationalize demand. In some enterprises, ERP is for advanced evaluation and peer comparison. In order to “face projectâ€, some are for the state-funded projects. Due to the incorrect purpose, the implementation effect is greatly reduced. Now the enterprise ERP is from the enterprise. The demand is for the needs of competition, so the implementation of the work, the implementation effect is obvious and lasting.
2. The software product is mature. After many years of tempering, the concept of foreign ERP, the best business practice and China's national conditions are combined. Some products have established a firm foothold in equipment manufacturing enterprises and the products are mature.
3. Consulting services are accepted by more and more companies. Before implementing ERP, through management consulting, designing advanced and applicable management models and business processes, organization, performance management, and compensation system to form a complete management control system, laid a good foundation for the implementation of ERP.
4. A number of equipment manufacturing industry information has achieved good results. A group of automobile manufacturing, tobacco machinery industry, China South Locomotive Group's truck manufacturing industry, they have achieved good results in the core value of ERP - production and operation management, on-time production, advanced cost management.
But we also see that there are still many problems in the ERP implementation of the equipment manufacturing industry.
3. The current problems in the information management of equipment manufacturing management.
Although the equipment manufacturing management information has achieved gratifying results, we also see that development is unbalanced, and some enterprises still have many problems in informationization:
1. Problems in current production management. The production plan is a static, decentralized, discontinuous, and set-by-segment plan. It cannot be rationally merged with common parts, and lacks scientific planning policies, batch policies, reserve policies, lead time and other production planning parameters. Due to the backward planning method, enterprises generally have a long production cycle, high stocks in stocks, large liquidity, and cannot be delivered on time. Most enterprises implement monthly plans, and the plans are relatively thick. The upper and lower processes lack precise integration, due to work in process and inventory. The material quota data is not timely, inaccurate, and the accuracy of the plan is poor. Due to poor planning control, the production is not balanced, the complete set of parts is poor, and the delivery cannot be delivered on time. The production scheduling workload is large, and the pieces are spared every day.
2. Problems in logistics management. The procurement plan is inaccurate, the material control is not rigorous, and there are many links that do not add value, often resulting in backlog or shortage of materials. Inventory data, consumption quota data, work-in-progress data, and in-transit data are not timely and inaccurate, which is the reason for the material control is not strict. Procurement planning and production planning are not synchronized and separated, and there is a lack of coordination in the supply chain. Logistics management cannot provide accurate and timely information for production planning, finance, and cost.
3. Management mode with financial accounting as the core is not advisable. Many enterprises have implemented the financial plus supply and sales system, which is undoubtedly the basis of ERP, it is necessary, but the management model, business process and system designed by many enterprises in implementing these systems are based on financial accounting. Mode, China's logistics and capital flow are not synchronized, no purchase invoices can not be put into the warehouse, not open sales invoices can not be out of the library, although there are valuations into the warehouse, valuation out of the warehouse, but in order to avoid inventory funds assessment or unwilling to do complex valuation If you do not intend to enter the warehouse, the various restrictions within the enterprise will not be allowed to enter the warehouse. In order to make a financial statement at the end of the month, the ultimate goal of management is to issue financial statements at the end of the month. The most basic inventory data is not timely and inaccurate. Inaccurate inventory leads to lack of basis for production, procurement planning, production scheduling, and cost accounting. Logistics and finance have not created conditions for the in-depth implementation of ERP.
4. Financial management has remained at the stage of accounting and has not reached the level of management accounting. Total budget management is only carried out in a small number of companies. The cost planning and control are not realized, the cost calculation simulates the manual accounting mode, and the cost accounting object is coarse. Generally, only the product can be calculated, the parts cannot be calculated, there is no standard cost, and the necessary cost analysis is lacking. The collection of a large amount of cost data is not based on manufacturing data, inventory, and shop floor data, but is manually entered by workshop accounting. Since the data is inaccurate and cannot be proofread, cost distortion is common.
5. Lack of supply chain management and collaborative commerce. Most of the enterprises that implement informatization are internal informationization. Most enterprises only stay at the level of website promotion and e-mail, and the level of e-commerce is still very low.
Due to the above-mentioned management problems, the economic and technical indicators of Chinese enterprises have lower labor productivity, slower liquidity turnover, poor cost control, large inventory capital, and poor ability of enterprises to respond quickly to the market.
4. The focus of equipment manufacturing management informationization
Each manufacturing enterprise will write the following objectives in its management informationization plan or project report:
Shorten product production cycle and procurement lead time Reduce inventory and work capital utilization Improve on-time delivery rate Quickly respond to customer demand, improve customer satisfaction, increase production capacity, reduce overtime hours, reduce product cost, increase labor productivity, increase capital turnover rate, increase production and operation data Timeliness, accuracy, and sharing
How can these goals be achieved? Except for the last one, it can be realized through the management of supply, sales, deposit and financial systems. It is impossible to save the rest of the articles through supply and marketing. Even if your inventory data accuracy rate is 100%, but you don't know if the inventory is more or less, the financial account is not bad, but you can't solve the problem of how to reduce inventory funds and reduce production costs. Some enterprises control The stock funds are used to give the warehousing department and the production workshop the evaluation index of the capital occupation. The result is that there are countermeasures under the policy. The warehousing is not included in the warehouse, and the rear is not expected to enter the warehouse. The produced product workshop is reported to be completed. It is not allowed to enter the warehouse. Otherwise, the inventory of the goods will be increased. The inventory of the enterprises will not be reduced at all. The assessment indicators for the capital occupation of each unit will be completed as usual. The comprehensive budget will control some non-production funds, but the control of production funds is very weak because You don't have a voice, what should you buy, why not buy, when to buy, how much? Who has the final say?
In manufacturing enterprises, production operation management, especially production planning and control at all levels is the core value of ERP. Through demand management, main production planning, material demand planning, workshop task management, workshop operation planning, on-time production, project management, etc., it converts sales demand into production plans, material procurement plans, and outsourcing plans for various production departments within the company. To achieve planning coordination and optimization of the supply chain. It answers what time, what is produced, what is purchased, how much is produced, and how much is purchased. All of this must be based on different types of production, production volume, and production organization, and adopt different planning policies, reserve policies, and schedule standards to minimize product production cycle, purchase lead time, and reduce inventory and work-in-progress funds. , quickly respond to customer needs. Japanese people talk about manufacturing management, talk about lean production LP, Toyota production management TPM, in fact, the important means to achieve lean production is the supply chain planning synergy and optimization, is to adopt different production plan control mode for different production types, the other is people The management of consciousness and behavior, the author believes that the appeal and focus of the informationization of equipment manufacturing industry is here.
V. Countermeasures for informationization of equipment manufacturing industry
Knowing the problem and focus of equipment manufacturing management informationization, how to achieve the goal of informationization?
1. First of all, we must take informationization as the strategy of the enterprise, combine informationization and management consulting, and combine informationization with enterprise management reform and process optimization. Informatization is a management project, not a technology project. Overcome the extreme and incorrect implementation methods of “wearing new shoes and walking the old road†and “cutting the feetâ€. Overcome the mistakes of paying attention to technology, light management; heavy hardware, light software, and light consulting services.
2. Establish a complete production plan control system for different production types. Break the traditional manual production plan to control the scattered, discontinuous, static, and inaccurate planning model. Establish a centralized, continuous, dynamic, and accurate production planning control model from sales, production, procurement, and the entire supply chain. Optimize planning policies, batch policies, volume standards, and reserve policies to minimize production cycle and procurement lead time, reduce inventory capital usage, and respond quickly to customer needs.
3. The construction of logistics and capital flows should coordinate and optimize the planning of the entire supply chain. The entire logistics activity is commanded by the production planning control system. All financial data changes with the movement, value-added, and impairment of logistics. It is impossible to control production and operation activities with simple financial indicators.
4. Establish a scientific cost management system. Do pre-planning, control in the event, and analyze afterwards. Establish a closed-loop control system for standard cost, actual cost, and cost analysis. Use the step-by-step method to refine the costing objects. The cost data is basically obtained from the engineering data management system, the inventory management system, the workshop management system, and the financial accounting system. Instead of manual input by the workshop accountant. This will ensure the objectivity and accuracy of the data.
5. Expand the information technology of the equipment manufacturing industry to customer relationship management. Strengthen market information, customer information, after-sales service information, and self-service management. Improve customer satisfaction, loyalty and goodwill. Develop supplier relationship management, strengthen certification, management, and evaluation of suppliers, and quickly communicate supply and demand information through the Internet to realize electronic supply.
The management informationization of the equipment manufacturing industry is complicated, management is difficult, and the management potential is also great. Only when we grasp the key points of management and adopt scientific countermeasures, the management informationization of equipment manufacturing industry will certainly improve the economic efficiency of enterprises and the competitiveness of enterprises.
The Beijing Institute of Machinery Industry Automation has been dedicated to the management of equipment manufacturing in the past 30 years. Based on management consulting, optimizing the company's management model, business process, organization, performance, and compensation, they use advanced ERP software RS10 as a tool, and take production and operation management as the core to realize logistics and capital flow throughout the supply chain. Information flow, responsibility flow optimization and collaboration, comprehensive integration of PDM/PLM, MES, enterprise information portal, providing complete solutions for equipment manufacturing management informationization, bringing tangible economic benefits to multiple equipment manufacturing enterprises And competitiveness.
All Non-Standard Bearing,Slewing Bearing,Thin Section Bearing,Nylon Bearing For Garage Door
Shijiazhuang Longshu Mechanical & Electrical Equipment Trading Co., Ltd. , https://www.longsbearings.com