01 The Boss’s Headache
Mr. Zhang runs a small furniture factory. Orders keep coming in, but headaches never stop:
- The workshop asks: “Which order should we do first today?”
- Workers ask: “Who’s responsible for this task? How should it be done?”
- Finance asks: “What was yesterday’s output? How many were good?”
- The warehouse complains: “We’ve run out of paint again!”
- And when a machine breaks down, delivery dates have to be pushed back…
Mr. Zhang often sighed: “Why does my factory always feel like chaos?”
02 The Old Master’s Advice
One day, an experienced old master who had worked in a big factory patted Mr. Zhang on the shoulder and said:
“Don’t panic. To run a factory smoothly, you only need 8 forms. Each form solves a key problem. Use them well, and everything falls into place.”
Mr. Zhang was doubtful, but decided to give it a try.
03 The Eight Forms Appear
1. Production Scheduling Form → What to do, and when to do it
With this form, workers finally knew: Monday was for cutting wood, Tuesday was for painting. No more random guessing.
2. Operation Card → How to do it, and who does it
The card posted at each station clearly stated: Mr. Zhang cuts, Mr. Li polishes, with detailed instructions. No more vague “experience-based” operations.
3. Daily Production Report → How did we perform yesterday
Every evening, the report showed: output, good products, defects. Now Mr. Zhang could go to bed with a clear picture.
4. Standard Hours / Time Sheet → Is efficiency high or low
Polishing was set at 30 minutes, but Worker Zhang consistently finished in 25. That showed efficiency—and his tips could be shared with others.
5. Material Requirements Planning (MRP) Form → Are materials ready
The system calculated that producing 100 sets of tables and chairs next week required specific screws and paint. The warehouse could prepare in advance, no more stoppages.
6. Equipment Inspection / Maintenance Form → Are machines reliable
The spray machine was inspected weekly. A clogged nozzle was found and cleaned in time. Before, machines often failed at critical moments—now, they ran smoothly.
7. Quality Inspection Form → Are the products good
Final inspection showed 3 scratched tabletops. Tracing back, it turned out the cutting blade hadn’t been changed. Clear responsibility, and customers felt reassured.
8. Abnormality Handling Form → Can problems be closed-loop
When the electric saw suddenly broke, workers immediately filled out the abnormality form. The repair team followed up, recorded the cause and solution. Next time, they knew how to handle it.
04 A New Atmosphere in the Factory
After three months, Mr. Zhang was surprised to find:
- Workers asked fewer questions and did more work;
- The warehouse stopped scrambling at the last minute;
- Machines broke down less often, and customers stopped chasing orders;
- Every day’s production status was crystal clear.
Mr. Zhang exclaimed: “Turns out my factory wasn’t short of people—it was short of these 8 forms!”
05 Conclusion
- Scheduling Form → Clear direction
- Operation Card → Clear responsibilities
- Daily Report → Transparent performance
- Time Sheet → Measurable efficiency
- MRP Form → Materials secured
- Inspection Form → Reliable equipment
- Quality Form → Controlled output
- Abnormality Form → Closed-loop problem solving
These 8 forms are like 8 golden assistants, helping Mr. Zhang turn his factory from chaos to smooth sailing.