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1、WENZHOU AUDIT 温州考察,June 2007,WHO人员,参与沟通的人员 Xiao Tang Clive Hall Valerie Chan Many, many people from Wenzhou plant很多温州工厂的员工.Thank everybody they talked to for their openness and co-operation对谈话人的开放心态和合作表示感谢,WHY原因,Manufacturing in LCCs is becoming more and more efficient at meeting the increasingly st
2、ringent demands of European customers. 面对欧洲客户日益严格的需求, 低成本國家的生產效率必須变得越来越好. This means that existing suppliers have to continually upgrade their operational and technical capabilities to stay in business.這意味著現有的供应商为了保持业务关系,必須不断地升级他们的运作和技术能力. This audit is to support current management to achieve this
3、goal by performing and reporting an external, top-level business process audit.这次考察的目的是通過檢驗及匯報高層次的管理，協助現有的管理層達到上述目标.,WENZHOU,is exclusively a manufacturing and logistics operation温州公司为生产制造和物流操作企业 has five different process technologies on site with one more being introduced她有5種不同的工艺技术,同時正在添入一种新的工藝技術
4、 outsources many sub-components and unpackaged end-products. 有很多外购半部件,及未包装的成品 all products are packed and labelled at Wenzhou所有的产品都在温州包装和贴标贴 currently transferring production from Shanghai to Wenzhou现在正在把上海生产的产品转移到温州,SYSTEM体系,Wenzhou currently runs a wish-based push system with few feedback mechanis
5、ms.目前温州的运作是很少有反馈机制的推动式体系. The systems there did not cross departmental boundaries effectively. 跨部门的协作功效不理想. A significant number of systems were either unknown, not implemented or there were different understandings in different departments很多系统要不欠缺、要不沒有貫徹，或者不同的部门有不同的理解.,MENTALITY心態,There is a signif
6、icant somebody elses problem mentality 将问题归结为“他人的问题”的思想比较严重(即这不是我的问题) People work hard and do exactly what is asked of them but there is little energy or enthusiasm for long term problem identification and solving.员工工作努力按要求做事,但是对长期问题的鉴定和解决缺乏活力或热情.,MANUFACTURING PROCESSES制造程序,Casting压铸 Stamping冲床 Pai
7、nting喷涂 Plastic extrusion注塑 Packaging包装,PRODUCTION生产,Piece work based difficult to combine with consistent quality products.以计件為基础很难保持产品质量的一致性 Experience based people have to rely on their own experience to know what to do. 靠经验辦事员工不得不依赖自己的经验去知道他们要做什么 In-line QC not working to objective standards. 进库
8、检验没有按照客观的标准进行,OUTSOURCING外购,Departmental systems look good 部门內部体系看上去不錯，包括： Supplier qualification 供应商资格 Supplier rating 供应商的等级 Supplier monitoring 供应商的控制追踪 Price aware 价格意识 Although some questions raised about its effectiveness.尽管有效度方面值得懷疑,LOGISTICS物流,Runs essentially five warehouses基本有个仓库，包括： Raw m
9、aterials 原材料仓库 Incoming outsourced components and products 外购配件和产品进入仓库 Semi-finished products (responsibilities unclear) 半成品仓库（责任不明确） Over production of packaged products 已包装的過量生产产品的仓库 Items for shipping 待运成品仓库,NPD新产品开发,This is essentially a copy operation from samples provided by customers. 基本上是拷贝客
10、户提供的样品 There is no design function. 没有设计功能.,HR人力资源,Suffering from a high personnel turnover rate which is bad for an organisation that runs mainly on experience 职员流动率很高，這对靠经验辨事的组织结构不利。 Functional qualification requirements of positions not known 对职位功能性的资格要求不清楚 No training plan 没有培训计划,FINANCE 财务,Indi
11、rect costs only 10% of total costs 间接成本只有总成本的10%。 Material costs some 80-85% of total product costs 材料成本大約是总产品成本的80-85%。 Includes labour in outsourced parts 包括外购产品的劳动力成本,CONCLUSION 结论,All the components of a successful, flexible production system are present. 成功的,灵活的生产体系的所有基本成分是存在的. However, they ne
12、ed to be organized to work effectively and efficiently together. 但是他们需要有效地组织在一起. This can be done by Evolution not revolution.这可以通过”演变而不是革命”来完成. Material savings of 20-30% possible. 材料节约20-30%是可能的. Unit labour costs will increase slightly but will then drop as operators become more effective. 单位劳动力成
13、本最初會稍微增加,但接下來隨著操作者效率的提高将會降低下來。. Production system becomes more flexible, quicker and more predictable. 生产系统會變得更加灵活,快速和有预见性。,SUGGESTIONS 建议,Improve information management 改进信息资料管理 Flow design processes such that: 流程-设计程序應具如下結果： ALL the information needed for a person to perform his work is available
14、when needed 每个人执行工作中，需要的所有信息资料, 必須要能方便地找到 ALL the information generated by a particular process is passed on efficiently and effectively to the next person/department performing any work on that product/service公司運作過程中，每一步中收集的所有资料要被有效的传递到下一個人员或部门. Document control people are working from the current
15、document文件档案管理 从現有的档案出發 Any changes in specifications/working methods/machines are authorised and rapidly communicated to those who need to know任何规格/工作方法/机器方面的改变，需要事先授权,變化後应迅速地与需要知道的人员进行传达. Out of date documentation is made unavailable过時的文件應保證從現場撤除.,SUGGESTIONS建议,Improve information management (cont
16、.).改进信息资料管理 Make all information transferred actionable.所有訊息资料應有實際功用. Dont collect data for the sake of it unless somebody needs it to perform their function properly, dont collect it不要为了收集资料而收集资料 除非有人需要它去执行他们的任務,否則不要收集這類资料. Wrong data is dangerous ensure the process includes some reality checks错误的资
17、料是危险的 确保工艺，包括一些真实性的检查 Codify knowledge where possible, otherwise know what people know在可能的話匯编知識, 否則得知道员工有什么知識.,SUGGESTIONS建议,Introduce feedback into the system引入反馈系统 Problems notified as soon as possible尽快通报问题 Give people the information to adjust plans as soon as any problems occur.遇到问题的时候尽快给员工信息去调节计划,
