How to Use Statistical Charts (SPC) to Improve Print Quality and Efficiency (3)

Ii) How to formulate effective indicators

From the above example, we will put three leaflets in the annual report, put the annual report in the journal, and then put it in the envelope and seal it, and then attach the correct address label.

- If a worker completes all processes, it must take 55 seconds to complete.

- If you divide the entire process into four steps:

a) The first step is to put three leaflets in the annual report and spend 15 seconds

b) The second step is to put the annual report in the journal and spend 10 seconds

c) The third step is to put the entire book in an envelope and spend 20 seconds

d) The fourth second is affixed to the appropriate address ( minus the stamping factor ) and takes 10 seconds

- if we want to balance the entire production line, a step one to three, yield 7,200 per day, step two to 2, producing 7200 per day, step three to four people, producing 7200 per day, step four to 2, daily production 7200 .

In summary, if the production line is to be averaged, 11 people must be producing online. The total output is 7,200 per day . Therefore, even if people are added because of the rush, they must be multiplied by 11 workers.

- In addition to starting a few days, its standard indicator is 55 seconds to complete one.

- On a planned production line, each process, the number of workers, and the production steps are fixed. Therefore, the opening time has also changed from the previous 230 seconds to 110 seconds. The standard time is also 55 seconds.

- In summary, comparing the two, the former is one more than the latter, but the latter produces 20% more .

Iii) Efficiency Formula

Although we know that the best number is 11 people, its indicator is 55 seconds to produce one piece. How to know the most efficient production of workers is to use the following formula:

Efficiency = ( standard production time x total output / 3600 seconds ) / number of workers / 10 working hours x 100%

Example: (55 seconds x 7200 pieces / 3600 seconds ) / 11 workers / 10 hours x 100%

- If there are 11 workers on the day and more than 7,200 pieces are produced , the efficiency is excessive, otherwise it is analogized.

- Since production workers do not do the same job every day, this formula is the most objective and most effective way to monitor the efficiency of each group of workers.

- This is also the most effective way to improve quality. Because in the previous QC system, they only checked the finished product. If a defective product is found, all products must be reconstructed and packaged. In fact, they do not know which process is wrong and how to improve it.

Based on the above methods, each process has listed its production methods, sequence and precautions, etc.

- Production leaders, managers, QC, etc. can inspect each process according to the guidelines and do not have to wait until the entire process is completed before checking. Therefore, their chances of reversing work are also relatively low.

- Even if a product is found to be defective, the mistakes of one process can be immediately locked in and corrected, and the damage can be minimized.

Therefore, it is easy for QC to check whether workers have collected three leaflets in sequence and whether they have placed leaflets upside down. The most important thing is that QC can take the opportunity to check if the incoming materials are qualified, such as whether the printing is correct, clean, and not upside down.

- If we find that the location of the paste address is incorrect, we can correct the accuracy of the worker's gestures or fixtures.

- Because the workers spend the same amount of time each day doing 10 hours, they find it easier to find tips for improving their products than we do. TQM 's goal is to improve quality, and managers must listen to their opinions and study them.

Iv) Use Pre-Control Chart to monitor product quality

QC can use the production control list to monitor the quality of products and find improvement methods in real time.

- In the process of pasting the address, the correct position is 70mm from the seal and has a tolerance of +/- 1mm . If this level is exceeded, QC may request to stop production until improvement.

- From 11:00 a.m. to 2:00 p.m. , its level is constantly deviating from the standard level until 2:00 before it improves, but it goes to the other extreme.