1. Analysis background introduction
This case comes from a medium-sized
chemical material manufacturer. The main products include basic chemicals (such
as acids, alkalis, solvents), special chemicals (such as high-performance
polymer materials, coating additives) and fine chemicals (such as
pharmaceutical intermediates). The company's production mode is mainly
continuous production, involving complex reaction devices, separation equipment
and fine temperature and pressure control.
Although the company has advanced equipment
and mature technology, in the actual production process, it still facesSuch as
raw material fluctuations, equipment aging, process deviation and other
problems, these factors have brought many challenges to product quality and
production stability. Therefore, the company has set up a special quality
control department to regularly summarize the production and quality
performance of the factory through the monthly quality report and express
abnormal tips in words.
2. Statement of key issues
The analysis of the root causes of
production fluctuations is complicated. In chemical production, quality
problems are usually affected by many factors, such as raw material quality
fluctuations, equipment status changes, operator behavior differences, etc. The
root cause of production fluctuations is often difficult to find through simple
statistics, which requires more complex analysis models or tool support.
However, the analysis capacity of many enterprises is limited, resulting in a
lengthy process of problem analysis, and it is difficult to take timely
measures.
Lack of comprehensive evaluation and
correlation analysis of indicators. The monthly report of production quality
usually involves multiple indicators (such as raw material utilization rate,
product qualification rate, unit energy consumption, emissions, etc.), but
there may be an inherent correlation between these indicators. For example, a
process optimization may improve the utilization rate of raw materials, but it
may also lead to an increase in the defective rate of products. When preparing
monthly reports, enterprises lack in-depth analysis of the correlation between
indicators and cannot provide global optimization suggestions.
The implementation and closed-loop
management of improvement measures are inadequate, but in the actual
improvement process, enterprises often lack effective mechanisms to track and
evaluate the implementation and results of improvement measures. This closed-loop
management ability of "finding problems and solving problems" is
insufficient, resulting in quality improvement staying on the surface, and
long-term problems are difficult to eradicate.
3. Analyze the plan
3.1 Select key data indicators.
|
Serial number
|
Name of the indicator
|
Paraphrase
|
Analysis angle
|
|
1
|
Output of qualified products
|
After quality inspection, it meets the
quality standard. The number of accurate products. This indicator measures
the output of qualified products in the factory's production process, and is
an important indicator for measuring product quality stability and production
control ability. It is divided into a pass rate, a final pass rate, etc.
Qualification rate = quantity of qualified products / total production
quantity
|
Through the high or low pass rate,
students can be evaluated.The level of quality control in the production
process. If the qualification rate is low, it may mean that the production
process is unstable, the quality of raw materials fluctuates or there is a
problem with the production equipment.
|
|
2
|
Planned product output
|
It refers to the target product output
scheduled according to the production plan or order requirements. This
indicator reflects the production targets of the production line in a
specific period of time, usually based on market demand, production capacity
and raw material supply.
|
By comparing the planned product output
with the actual product output, the implementation of the production plan can
be evaluated. If the actual output is significantly lower than the planned
output, it may mean that there are bottlenecks in the production process
(such as equipment failure, shortage of raw materials, shortage of personnel,
etc.).
|
|
3
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Actual product output
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It refers to the total amount of products
produced by the factory within a specific period of time in the actual
production process. Compared with the planned output, this figure reflects
the implementation effect and resource utilization rate of the production
process.
|
If the actual output far exceeds the
planned output, it may indicate that the load of the production line is too
large, which will lead to increased equipment wear, excessive fatigue of
personnel and other problems; and if the output is lower than the planned
output, it indicates that there may be problems in the production line that
have not been detected in time.
|
|
4
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Tips and countermeasures for abnormal
situations
|
It refers to the timely response and
corrective measures taken when abnormalities or deviations in production
quality, equipment, personnel, etc. are found during the production
process.The main purpose of this indicator is to ensure that any problems arising
in the production process can be detected in time and effectively dealt with
to ensure production quality and safety.
|
By recording and analyzing abnormal
situations, we can understand the most common fault types or quality problems
in the production process. For example, whether there are frequent equipment
failures, fluctuations in the production process, or certain raw material
quality problems. Identifying these anomalies and finding the root causes can
help reduce the occurrence of similar problems.
|
|
5
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Produce
|
It is a normal large-scale production
activity carried out after full verification of product design, technology,
equipment, resources and other aspects. The products produced at this stage
are market-oriented. The goal is to meet customer needs and ensure the
stability of production and the quality and efficiency of products.
|
Mainly for verification and adjustment,
pay more attention to experimentality, adjustment and optimization.
|
|
6
|
Trial production
|
It usually refers to the preliminary
production activities carried out to verify the feasibility of production
technology, equipment operation, product quality, etc. before the product is
officially put into production. It is usually a key link after the product
design and development stage before formal mass production.
|
It is the stage of achieving stability,
mass production and meeting market demand, focusing on efficiency, quality
and large-scale execution.
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3.2 Power BI Visualization Scheme
Description: The data of the DEMO page are
allThe simulation data is for reference only, analysis angle and Power BI
function display, and does not involve any actual business data.
4. Analysis and interpretation
Changes in production trends usually
reflect many factors such as production environment, market demand,
technological progress, and enterprise management strategies. Enterprises need
to flexibly adjust production lines.
Enterprises will reasonably arrange
production tasks, equipment use, personnel division of labor, material
scheduling, etc. according to the weekly production plan to ensure the
efficient operation of the production process.
Regularly summarize and analyze the
abnormalities in the production process, find the root cause of the problem,
improve the relevant management measures and technical means, and avoid the
recurrence of similar problems. In addition, the enterprise alsoEmployees
should be encouraged to make suggestions for improvement and form a culture of
continuous improvement to continuously improve production efficiency and
quality.
5. Application effect
Qualified product output, planned product
output, actual product output and abnormal situation prompts and
countermeasures are indispensable quality management tools in the process of
chemical production. They reflect the quality control, production efficiency
and abnormal response in the production process from different dimensions.
Through a comprehensive analysis of these indicators, enterprises can find
potential problems in time, optimize production technology, improve production
capacity and product quality, and ensure the stability and high efficiency of
production.
The feature of this case is to use BI
tools to display the flexible access of a large number of texts, which helps
factory managers quickly understand information and shorten decision-making
time.Factory managers can improve production efficiency and reduce costs
through keen insight into changes in production trends, accurate production
week breakdown, strict qualification rate control and effective abnormal
countermeasures.