the samples were perfect during trial production, and the yield rate plummeted by 30% in the first week of mass production; the technical department complained that "workers did not do it according to the standard", and the production line roared that "the process does not land at all"; Photos of defects complained by customers circulating in conference rooms, while process documents lie in folders and eat ash – does this scene suffocate you?

Process supervisorThe dilemma is:The perfect solution in the laboratory is often difficult to implement on the production line！ Having experienced the history of 200+ factory processes and blood and tears, I have refined the process to land"Nine must manage" iron law, every sentence is bloody.

1. Manage the source: stifle the problem in the drawing stage

1. DFM reviewMust manage
Don't wait for mass production to find out that the parts can't be installed! Implement"Ten prohibitions" design bans：
· No fasteners that need to be blind installed (must be positioned by the guide column)
No ± 0.05mm out-of-difference assembly (design tolerance relaxed by 30%)
A medical company ignored this article,3,000 equipment reworked and reinstalled sealing rings

2. Error-proof implantation must be managed
The cost of error-proof transformation after mass production is heavy! New products must pass"Three intentional" tests：
→ Deliberately install anti-parts → The equipment should be locked and alarmed with sound and light
→ Intentional omission of processes → The system automatically intercepts the flow
Process error prevention saves 1 yuan, and post-production rework saves 100 yuan

2. Pipe landing: let the standard step into the workshop from the paper

3. Standard working hoursMust manage
"About 5 minutes" is a black hole of efficiency! useVideo analysis method is dead：
▶ Disassemble and install gears: reach out for 15 seconds + grab for 3 seconds + align for 22 seconds...
▶ Use.Slow-motion frame-by-frame optimization(If you change the guide groove to save 8 seconds)
1 second wasted× 1 million production = 278 days lost

4. Parameters must be managed to prevent fools
Workers misadjust parameters is a shame of the process! implement"Tricolor Line of Defense"：
✅ Green Zone: The parameter range (e.g. temperature 80-85°C) is →The touch screen locks automatically
✅ Yellow zone: Critical value (e.g. 86°C) →The screen flashes a warning
✅ Red zone: out-of-limit (e.g. 90°C) →Automatic shutdown of equipment
Make making mistakes harder than compliance!

3. Management changes: mass production is not the end

5. Change management must be managed
"Verbal notification to change parameters" is equivalent to laying mines! executeChange the five-step kill：

1. Fill in the "Change Application Form" →Comparison of old and new parameters is attached

2. Try to make 50 pieces →Full-size test report

3. Update the work instructions →The red pen marks the change point

4. Train operators →Sign and confirm

5. The first three batches of full inspection →The data will only be released if it meets the standard
   One step less, mass production collapse is nearone-step

6. The first article appraisal must be managed
The first item is not strictly controlled, and all batches are scrapped! establish"Three comparisons" mechanism：
Comparison drawings: use a projectorMagnify 20 times to check for glitches
· Control process: checkThe actual parameter deviates from the set value
Comparison history: comparisonThe key dimension curve of the first batch of the first batch
The first piece is a sentinel of the craft defense line

4. Pipe bottleneck: make the flow faster

7. Bottleneck breakthroughs must be managed
The welding line is stuck in the neck to the whole factory and other workers? use“Stopwatch wars”：
→ Video capturedThe worker waits for the fixture to reset for 12 seconds
→ Cylinder push →Compress to 3 seconds
Bottleneck station efficiency improvement by 1 second = 1% increase in production capacity of the whole line

8. Human-machine collaboration must be managed
Workers standing and waiting for equipment? implement“Three principles of human-machine separation”：
✅ When the equipment is running automatically, → workers operate other stations
✅ → when the device alarmsRespond within 10 seconds
✅ Manual loading bit →It is designed into a U-shape and can take into account three units
Make people more valuable than machines

5. Manage inheritance: Experience is not a personal asset

9. Knowledge precipitation must be managed
The secret taken away by the master's retirement must be kept! build"Three modernizations" knowledge base：
·Video: Take a picture of the master debugging the moldTechnique angle
·parameterization:RecordingPressure compensation values for different batches of materials
·Storytelling:write downSolve the reasoning process of weird tremors
Craft inheritance is more important than technological invention

Is your process spiraling out of control?

▢ The mass production of new products has been rampant for more than 3 months, and the yield rate is always less than 80%
▢ The same defect recurs month after month, and technicians will only "strengthen training"
▢ The process document version is confusing, and the production line uses three sets of standards at the same time

A good process supervisor is a magician – translating the design language into actionable actions on the production line