PCBA Tech - Errors in 5S activities of SMT manufacturers

5S activities originating in Japan have been implemented in Japanese companies for more than 50 years. Japanese companies still regard them as key production and operation management tasks. This shows how much they attach importance to 5S. In 1986, Japan's 5S book gradually came out, which had a great impact on the entire on-site management model, and thus set off a wave of 5S implementation.

Today, 5S as an effective tool for on-site management has been widely concerned and recognized by the global business community. According to relevant statistics, 88.2% of Japanese and Taiwan-funded enterprises in my country currently incorporate 5S into their daily work, and 68.7% of Hong Kong-funded enterprises. Enterprises are implementing 5S activities, and 70.1% of enterprises in the Pearl River Delta and Yangtze River Delta understand 5S or are implementing 5S. 5S is becoming more and more admired by the majority of business circles with its strong attractiveness, especially manufacturing enterprises. SMT factories, as the main electronic processing enterprises in my country, are also gradually carrying out 5S management activities. Then, the development of 5S How about it? Like many "imported products", some SMT companies have mastered the essence of 5S implementation, and while bringing good economic benefits to themselves, they also created certain social benefits; but other SMT companies just grasped the surface of 5S. The things that "similar in appearance but not in gods", have done a lot of "image projects", but failed to grasp the essence of it and fundamentally improve the quality of "people", so that they can't be implemented if they are engaged in it. Why would such phenomenon happen? The answer is: There are some misunderstandings in the understanding of 5S. Let's start with the original intent of 5S, explore the main points to be grasped in the development of 5S, and then dig out the misunderstandings in 5S according to some examples.

5S refers to the effective management of work elements such as personnel, machines, materials, methods, and the environment in the work site. Through the actions of sorting, rectifying, and cleaning, a clean state is achieved, and the quality of all employees is gradually improved, and management activities are realized by Transformation from formalization to behavioralization, and then to habituation. With the in-depth development of 5S activities, the institutionalization, standardization and standardization of various work indicators are gradually realized, and a 5S standard system has been established, which is finally incorporated into daily management activities among. The result of this implementation is the best operating state of 5S activities. If we fail to fully understand the true meaning of 5S, fail to fully grasp the essentials of 5S implementation, have no correct implementation methods, effective implementation steps, and strong operation organization, then our 5S activities will definitely fall into a deadlock. The result is self-evident.

Each S of 5S has its own purpose and implementation skills. We must carefully understand their respective connotations, purposes and implementation methods, understand their interrelationships, and carry out each S activity step by step. The true meaning of sorting is to organize. According to the judging criteria of "must" and "not needed", effectively organize the "things" on the work site, resolutely clear out the "not needed" and leave the "required" to realize the value of space utilization The real meaning of rectification is rationalization. According to the "three-determination principle" and the "three-element method", the items "required" on the work site are placed in categories according to the corresponding signs to achieve The work site items are clear, creating an orderly workplace; the true meaning of cleaning is routine inspection, according to cleaning standards and work specifications, routinely sweeping, removing dirt, and investigating pollution sources to eliminate or isolate, and realize equipment operation "Zero failure", creating a clean workplace; the true meaning of cleanliness is standardization, in accordance with the 5S evaluation method and reward and punishment system, continuous inspections and diagnosis, supervise the implementation of the first three S, and realize the institutionalization of promotion activities. Standardization, to create a fresh and comfortable workplace; the true meaning of literacy is habituation, in accordance with the various regulations and etiquette rules of 5S, carry out education and training, polite sports, morning meetings and other activities to cultivate the habit of civility, politeness and observance of the rules., Realize the continuous improvement of the quality of all employees, and create an autonomously managed workplace.

The objects of tidying up, rectifying, cleaning and cleaning are "sites" and "articles", and the objects of literacy are "people", and "people" are the most important resource of an enterprise. Lenovo’s chairman Liu Chuanzhi once said: “Operating a business is about operating humanity. The human factor is the most critical, and the difficulty of investigating people is the most difficult.” As long as people are managed well, our company can operate well, and the implementation of 5S activities will also be successful. No exception. Why are some companies' 5S activities not progressing smoothly or failing halfway? The reason is not that there is a problem with 5S itself, but that our "people" have a problem, and that we have a misunderstanding of 5S. Next, we will focus on the analysis of the deviations in understanding that hinder the progress of SMT enterprises' 5S implementation activities.

smt faotory

Think it is doing "image project", which is a copy of formalism

Generally speaking, the implementation of 5S activities does require some forms, such as the delineation of regional lines, the placement of signboards, the hanging of slogans, the pasting of labels, the formulation of methods, etc. The establishment of these "image projects" is necessary. However, the development of 5S activities requires not only the dazzling "cu", but also the "beads" in the "cu". 5S activities are through the setting of the form and the repetition of trivial and monotonous actions to continuously change the minds of employees, make them develop good habits, and then act according to the rules, and gradually improve the quality of the employees. If we only think that 5S is a replica of formalism, then it is impossible to invest more passion, it is impossible to follow the rules, and it is inevitable to go to failure. Therefore, we have done the "image project", and we must formulate corresponding assessment methods and rewards and punishment systems to restrict and strengthen guidance and encouragement, so as to gradually make the essence of 5S deeply rooted in the hearts of the people. In this way, we can truly do this for the "exotic" 5S. When it comes to buying its "juice", you can get its "beads" even more.

Hurry for quick success, blindly catch up with progress, and pursue economic benefits

The existence of every SMT company pursues the goal of maximizing economic benefits, which is beyond reproach. After all, market competition is fierce, and we all hope to invest less capital and get rich harvests. Generally speaking, the initial stage of 5S activities requires a lot of investment, and it is difficult to bring about immediate economic results. However, as long as we persist in this activity for a long time, its effect can be expected. The development of every thing has its own laws. Once it violates the objective laws of the development of things, we can only do things based on our own subjective assumptions. Even though our intentions are good, the result will inevitably hit a wall and mess things up. Because pulling up the seedlings to help them grow is absolutely unworkable. Therefore, the development of 5S activities should not be rushed. The on-site environment has obviously changed, but our employees do not know the reason and just passively accept it, so that the desired effect will not be received. Therefore, systematic training must be done well, and it must not be carried out to make employees feel unsure. Otherwise, our 5S activities will become "castles in the sky", which will ultimately prevent the company from getting the long-term development benefits it deserves.

Divorced from reality, deliberately imitated, lack of innovation

5S activities are applicable to almost all industries, but it does not mean that 5S can "cure all diseases" and solve all internal problems of SMT enterprises. After all, 5S is only a basic skill for enterprise training. The scope of its effects only includes the cleanliness of the work site and the improvement of employee literacy, rather than a panacea for solving all problems. In order for SMT companies to achieve rapid development, in addition to carrying out 5S activities, they also need to pay attention to their own corporate culture, development strategy, management philosophy and other aspects. When introducing the "5S" management concept, you must purposefully retain the original more advanced site management experience, especially your own distinctive things, seek common ground while reserving differences, learn from each other's strengths, and not copy and learn to walk, otherwise others will have the advantages at that time I didn't learn well, and lost my strengths. In addition, we must combine our own actual situation, use our innovative spirit to solve the problems in the implementation process, and recognize that the result of mechanical and mechanical methods can only be shooting ourselves in the foot.

A taste of nothing but a counter-productive, can’t persevere

5S is a work of continuous advancement, with only the ongoing tense, without the past tense and perfect tense. "If you have done it, you don't need to do it again." This is a common misunderstanding. There are probably two possibilities for the so-called "done": one is that the person who said this does not understand 5S himself, and thinks that 5S is only a phased project, and it can be done once and for all; the other is that it has been done once. But now there is no persistence, or no effect, and finally failed. There is another reason for these two possibilities because of insufficient enforcement. Without good execution, no matter how good a company's policies and strategies are, everything is zero. When SMT companies implement 5S, it is necessary to clarify this point of view-5S is a test of all employees of the company, the quality of execution for basic-level employees, the test of management quality for middle-level managers, and the test of authoritative beliefs for high-level leaders. . Once a project is launched, you must work hard and go all out until you see results. I can’t take it for granted that it’s almost the case, and we have to start other projects, otherwise the previous work will still fluctuate, and the following projects will be unstable. In the end, the busier the enterprise and the more chaotic the employees, the more chaotic and busy the employees. So I had to abandon the project, giving people a taste of nothing but anticlimactic feelings. At first, it was carried out in full swing, but slowly it stopped. Therefore, when implementing 5S projects, remember not to fight unprepared battles. Before the activities start, you must make detailed plans and implementation steps, step by step, orderly, and implement them decisively and resolutely.

Ignore details, cope with inspections, lack of awareness of quality

"Details determine success or failure", a person's ignorance of the details can be dismissed as an individual's behavior, which cannot affect the overall situation. Many people ignore the details or a group ignores the details. It will be a very terrible phenomenon. Nowadays, customers are paying more and more attention to the details of their products. Of course, the details of our service standards also need to be improved step by step. There are many points and areas involved in 5S activities, and many details need to be carefully grasped. For example, some people think that 5S activities are clean-ups during the implementation, just to improve the appearance of the company and to cope with the activities carried out by leaders and foreign guests. In fact, 5S activities can not only keep the work site clean, but more importantly, clean everyone's "mind" to achieve the beauty of the people. Spring cleaning is a temporary activity, which is fundamentally different from continuous 5S activities. In addition, when implementing 5S activities, in order to cope with the inspections, some departments made the on-site environmental sanitation and basic records without flaws. After the inspections, they still went their own way, but the results of their surprise operations were not only inspected. Affirmed by the group, it also won the reward of 5S assessment results. Therefore, such an operation process will inevitably cause misleading to front-line employees, making them mistakenly believe that "5S" activities are surprise labor and "image project". Not only does the employee's professional quality fail to improve, but it also deviates from the company's implementation of "5S" management. Purpose, caused quite a bad influence. Therefore, we must treat every activity of the implementation of 5S as if we are playing with every fine product, and strive to fight every battle beautifully, to ensure that 5S activities continue to improve, rather than deal with things randomly.

Rigid thinking, thought to be "repetitive construction", lacking developmental vision

The civilized production activities carried out by Chinese enterprises are very similar to 5S activities. Although our civilized production activities have not been carried out in a big way as a management concept, the majority of employees have a certain degree of understanding of it. Now I am engaged in 5S activities, thinking that this is a kind of "repetitive construction". In fact, this understanding is wrong. 5S is to improve our current situation from a new level on the basis of previous management concepts, rather than denying the original. Concept. In addition, repetition is not meaningless. Why don’t we repeat many simple actions every day? A "good" action is repeated more often, and it becomes a "good" habit. "Our company is still small, so it doesn’t make much sense to develop 5S." This kind of understanding is also wrong. Carrying out 5S activities does not matter whether the company is large or small. It is the basis of on-site management. When a company is young, every employee can develop well. The 5S habit is to cultivate a good 5S culture as soon as possible, and form a 5S management system. When the company grows, it is natural to start work. Because the power of culture is endless, through it to regulate employees, new employees will be the best Quickly integrate into our organization. After all, things are always evolving and changing. When we think about problems and do things, we should take this change into consideration and be suitable for the needs of this change. Because 5S also needs to be further extended to 6S, 7S, 10S, etc., we use development vision and innovative methods to extend and implement, so that "5S" activities can be more suitable for SMT production and all aspects of enterprise management.

Participants are vague, 5S consciousness is weak, lack of autonomy

5S is a global group activity led by the leadership and full participation of all employees. Not only must every employee participate, but every department cannot engage in special activities. Only when the leader takes the lead and all employees participate can the 5S activities achieve good results. Because the 5S activities of a single department are difficult to achieve the expected results on a global scale. The viewpoints that "5S is only a matter of production site" and "5S is only a matter of front-line employees" are wrong. The development of 5S depends on each employee himself, because his own 5S work can only be done by himself, and others cannot replace it. If everyone does their own 5S work well, then the 5S work of our entire enterprise can be carried out vigorously. The low enthusiasm of employees to participate is one reason for the failure of the implementation of 5S activities, but not all. The implementation of 5S activities cannot rely on employees’ spontaneous behavior, but is mandatory. Employees must follow 5S implementation standards to act. Therefore, in the implementation of 5S activities, while we emphasize the participation of all employees, we must also promote and supervise the company’s top management from top to bottom. When 5S is implemented to a certain level, inspection and supervision are no longer needed, and everyone can do their job in an orderly manner, which has also reached the realm of independent management.

The misunderstanding of 5S has always plagued the smooth implementation of 5S activities in our SMT enterprises, but this does not mean that we cannot engage in 5S or fail 5S. Many successful examples of the implementation of 5S have clearly proved that 5S is with its strong vitality. Growing up sturdily, as long as we have a firm belief and get out of the misunderstanding of 5S, we will be able to make 5S bloom gratifying flowers under our hard work.