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Analysis of the Necessity of 6S Management in Chemical Enterprises

2019-06-18View Original

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  Overview of Huatianmou 6S Management Expert: 6S management, which aims for \"quality and efficiency,\" has proven through years of implementation in enterprises that its principles are both correct and practical; it has also become a benchmark for determining whether a company is advanced. Due to the unique nature of their industry, chemical companies have higher requirements for 6S management. Let’s take a look at the necessity of implementing 6S management in such companies.   I. The characteristics of chemical logistics force enterprises to implement 6S management. First of all, chemical products exist in liquid, solid, and gaseous forms; therefore, in addition to transportation by road, rail, air, and water, there is also pipeline transportation, which is used specifically for transporting liquids and gases such as oil, coal, and chemical products. Pipeline transportation boasts advantages such as large capacity, low cost, safety, and low loss rates, and it will become one of the main methods for transporting chemicals in the future.   Secondly, the products handled in chemical logistics are mostly hazardous chemicals. Compared to other logistics industries, safety and environmental protection issues are more prominent in this field, which leads to: 1) The international community and our country having to classify these substances based on their hazards to the environment and living organisms, and to establish strict regulations regarding their transportation, storage, and handling.   2. **Raise the entry barriers for the hazardous materials transportation industry; the “Regulations on the Safety Management of Hazardous Chemicals” were issued, imposing strict requirements on the professional competence of personnel involved, as well as on transportation facilities and equipment.**   3. There is a great variety of chemical products, and their flammability, explosiveness, toxicity, corrosivity, and other properties mean that the equipment used for packaging, loading, unloading, and transportation must vary depending on the characteristics of these products. Such equipment is highly specialized, which requires high standards in terms of technical equipment and results in significant cost investments.   This also indicates that the operating environment for chemical logistics companies is more challenging than that of ordinary logistics companies, and they require 6S management even more than other logistics firms.   II. The necessity for chemical enterprises to implement 6S management   Given the high risks and high costs associated with chemical logistics, standardized management, well-maintained equipment, a favorable working environment, and highly skilled employees are essential to ensure safe production, provide quality services, improve operational efficiency, and thus create favorable outcomes and prospects for such enterprises. Therefore, it is even more necessary to implement 6S management in chemical logistics. Especially in the two areas of chemical product storage and transportation, where the share of occupancy costs is high and accidents are likely to occur.   Main problems faced by chemical warehousing before 6S management: 1. Poor hygiene conditions. At present, the logistics of most chemical products are handled by the producing units themselves. In warehouses for chemical raw materials and finished products, there are many substances that are toxic, harmful, corrosive, or have unpleasant odors. The characteristics of these stored substances, combined with logistical issues, lead to a lack of enthusiasm and resistance among warehouse workers. Liquid leaks, dust pollution, messy stacking, overcrowded spaces, and unclear signage are common problems.   2. The equipment is aging, and it is not equipped with complete fire protection devices. Due to the special nature of chemical products, the equipment used for storing these products or raw materials, along with the corresponding fire protection systems, is expensive. Non-specialized chemical logistics companies find it difficult to afford the costs associated with updating such equipment. Additionally, the corrosive nature of these products leads to equipment aging or thinning as a result of corrosion, which reduces storage efficiency and creates serious safety hazards.   3. The quality of personnel is low. At present, the warehouse staff in many chemical enterprises are mostly older individuals with low educational levels; they lack knowledge regarding the proper storage and handling of chemical products as well as procedures for dealing with emergencies. Coupled with a lack of attention at the management level, this results in low awareness among employees, a strong tendency to take risks, and low work enthusiasm – all of which are key factors contributing to the frequent accidents in chemical warehouses.   4. The level of informatization is not high. In many companies, warehouse management is still based on manual operations; all data related to goods entering and leaving the warehouse must be entered manually by warehouse staff. This traditional approach to warehouse management significantly hinders efficiency, as many records of goods movements are not updated in a timely manner within the system. Effective management of storage locations is also not possible in such systems, making it impossible to know the location of materials within the warehouse or its storage capacity. Workers lack guidance from the system when placing or retrieving materials. It is possible that materials may be placed in the wrong location or retrieved incorrectly. All these drawbacks severely affect management efficiency, reduce the storage capacity of corporate warehouses, increase warehouse management costs, and hinder the development of the enterprise.   Problems faced in chemical transportation before 6S management: 1. Low level of professionalism. Chemical products, especially those produced and transported by companies in the hazardous goods sector, account for a significant proportion of such shipments, and road transport, which is energy-intensive and has a low safety level, is the most common mode of transportation. Moreover, the loading and unloading equipment owned by enterprises, especially vehicles, are generally in poor condition, resulting in low transportation efficiency and poor work quality.   2. Outsourced services pose significant security risks. The transportation of hazardous chemicals is costly and requires high entry barriers; the market demand exceeds supply. Moreover, inadequate supervision systems have led to a mixed quality in the transportation industry. To control logistics costs, companies often compromise on safety measures and requirements. When outsourcing such tasks, they turn to small logistics firms or individual transporters who lack the necessary qualifications, which results in an increase in transportation accidents. Eliminating these potential hazards is the overall goal of the safety implementation phase in 6S management.   3. The modernization level of transportation enterprises is low. Most of them are small in scale, have weak risk resistance, and lack integrity. Without modern management and a shortage of talent, the management systems for areas such as qualification management, quality and safety systems, standard setting, maintenance, on-site supervision, safety training, and packaging inspection, along with their implementation, are highly inadequate. The quality of practitioners is generally low, with insufficient safety awareness and inadequate skills. There are no unified technical standard requirements for specialized equipment used in the transportation, handling, and loading/unloading of hazardous materials to ensure safety. The packaging is outdated, and modified tank trucks can be seen everywhere.

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