Thoughts and Exploration on Transformation and Upgrading of Tobacco Production Promoted by Lean Management

Zhongxin ZHANG,Tiewei QIN,Yong ZHANG

China Tobacco Hubei Industrial Co.,Ltd.,Yichang 443000,China

Responsible editor:Xiaoxue WANG Responsible proofreader:Xiaoyan WU

Tobacco industry management has undergone from extensive management to standard management,which can be concluded as standardization process,and from standard management to lean management,which can be concluded as improvement process.On August 4,2013,State Tobacco Monopoly Administration issued Suggestions on Advancing Lean Management of Tobacco Industry,proposing to comprehensively advance lean management in the industry to change precision management into lean management in order to improve industry efficiency[1],which coincides with present trend of tobacco industry development that tobacco production changes from yield-orientation to quality-orientation with increasing of inventory of tobacco materials.Nevertheless,the concept of lean management is not well understood in some tobaccoproducing regions,especially for grass-roots units[2].The research made a conclusion on lean management in a comprehensive way and explored measures for advancing transformation and updating of tobacco production in order to provide sustainable development of tobacco in tobacco-producing regions.

The Definition of Lean Management and Its Application in Tobacco Production

Lean is a method for the elimination of waste within a management process,involving less investments of labor,equipment,site,resources and time,to create more economic interests and values.As such,companies are to optimize resource allocation and increase the value of the products or services in order to maximize profit.From the current situation,it is an effective way for changing traditional management concept and model and optimizing resource allocation by advancing lean management.In the long run,it is a way to comprehensive enhance management,exploit development potential of the industry,change development mode and achieve sustainable development[3].

Lean management as an effective way for resolving three problems of the industry

State Tobacco Monopoly Administration proposed three problems,including the source of reform bonus,the source of development potential and the development targets.Specifically,reform bonus comes from optimizing of resource allocation,development potential is based on full use of resources available,and the development targets are from objective analysis on resource use rate.Hence,by lean management,companies would grasp the key chain of optimization of resource allocation,systematically detect production and management,and change traditional concept and model.

Lean management as a guarantee of highly-qualified raw materials

Highly-qualified tobaccos can never be produced from an extensive and backward management model.Hence,it is necessary to strengthen lean management under fined technology guidance,relying on keen-witted and capable employees to accomplish large-scale production and intensive management.

Lean management as an important method for implementing plan and scale controlling

The implementation of controlling plan and scale is a crucial task confronted by tobacco industry in China,which concerns existence and sustainable development of tobacco industry.Lean management allows precise information management of tobacco production and advance tobacco production step by step,avoiding blindness,so that tobacco production plan would be finished well without waste of tobacco overstock.

Lean management as an effective method for improving enterprise management

Anew concept and method enables system integration on original management system nad methods,which is conductive to comprehensively improving enterprise management.

Analysis on Problems Existing in Lean Management of Tobacco Production Currently

Confusion on lean management for some employees

Some technicists misunderstand lean management as management at a high frequency,so that they just give farmers a call frequently or urge farmers to implement related technologies.However,it is not sure that key technologies have been well accomplished.What’s more,some tobacco farmers blindly believe that lean management would increase work and resist lean management.

Microclimate in restricting lean management of tobacco production

As a part of agricultural production,field production of tobacco proceeds in natural environment,which is mainly under influence of ecological factors.In terms of climate,for example,tobacco production would be significantly affected by low temperature,hot summer,drought,rainstorm,gale and hail.What’s worse,climate change is generally hard to be predicted,let alone a long-term prediction.It is known that natural force is difficult to be predicted and can not be controlled not matter how precise a production plan or how sophisticated production technology.

Low mechanization in preventing advancement of lean management

Tobacco production in China is mainly distributed in Yunnan,Guizhou,Sichuan,Hunan and Hubei provinces,which are dominated by mountainous landform,characterized by steep slopes,varying textures and structures,uneven soil layers,and diversified soil fertility,so that large-scale mechanization is hardly conducted there.These areas are basically concluded as poverty-stricken mountainous regions where some tobaccofarmers still choose manual work.Meanwhile,some advanced production technologies can not be promoted,limited by backward supporting facility.For instance,the transplanting technology in well cellar requires highly ridging,which can not be accomplished in middle or high mountainous regions,without ridging or film machines,affecting tobacco growth in late period.

Further implementation prevented by incomplete infrastructure or poor management

On the one hand,the industry advocates planting tobacco in a large scale,which is easily to be accomplished in plains well equipped with infrastructure,such as a curing barn.In mountainous regions,however,it is hardly to be finished limited by landform as well as supporting facilities.On the other hand,in the fields dominated by tobacco planting,curing barns,cisterns,and pipe networks are constructed in large numbers,playing a significant role in tobacco curing,water supplying or field irrigation.When some facilities are transferred into villages,tobacco production would be controlled by village committee or administrative staffs,and some facilities can not be repaired timely,which would influence tobacco production accordingly.

Exploration on Tobacco Production Transformation and Upgrading by Lean Management

Lean management of tobacco gives highlights to characters of tobacco quality to improve the quality,centered by "reduction of labor and cost and improvement of quality and efficiency".

To strengthen promotion and training and to improve recognition on tobacco production

Recognition decides action.Lean management is a new management concept,which is understood as an upgrade of standardization or just GAP by workers or managers at the production line.Actually,the truth of lean management lies in management,including optimization of personnel structure,balanced production,synchronization,and guarantee system of supply chain quality,in order to reduce wastes of every chain and on-time production.Furthermore,it is important to carry out training work to popularize the core,principle,and characters of lean management among employees and promote the truth and final target of lean management among tobacco-farmers relying on tobacco schools and promotion teams.At the sametime,it is necessary to print publicity materials of concerning technology and flowchart.As for some fields,TV and broadcast can be used for the promotion.On basis of the promotion work,it is aimed to enhance related employees or farmers’ recognition on lean management for further implementation.

To optimize management mode and improve production level

Tobacco industry has proposed the work principle of ecology deciding characters which are manifested by tobacco varieties and guaranteed by technology.What’s more,lean management can be conducted in different ways as per local characters,and standardization and agricultural rules can be applied in most regions.Nevertheless,some exclusive technologies,such as transplanting technology,curing technology and control technology of diseases and insects,are diversified upon regions,which should be applied according to local conditions[4].

To optimize technology standardBased on standard production available,it is urgent to make optimization on production technology in different chains to adapt to local production and meet demands of modern tobacco development.

To optimize operation procedureOperation procedure of tobacco production should be optimized in terms of precise organization,lean procedure and sophisticated work,involving sowing,transplanting,harvesting and curing,from employee organization,procedure optimization,and precise work in order to extract the optimal work procedure and reduce cost and labor force.

To optimize access to information

It is a tradition to obtain information by experience,listening or estimation,but these can not be the only way.Hence,it is necessary to establish prediction systems,carry out research exclusively,settle fundamental information,and establish files of tobacco fields and farmers,which lays foundation for optimization of fundamental tobacco fields and construction of professional team of tobacco farmers.

To optimize examination methods

The final target of tobacco examination is to improve tobacco quality and maintain stable texture.Therefore,it is recommended to conduct lean management on basis of local standard,suitable technology,and proper management,to carry out a spot check on key technologies,reduce examination frequency in production phase,and reinforce punishment,and finally,if the result meets corresponding demands,the management would be defined qualified.

To optimize team constructionIn accordance with company’s demands,it is important to divide tobacco field in a scientific way,to explore competing for a job in tobacco fields,and to fully exploit manpower resource.Still,it is suggested to set mangers in charge of agronomic production,adjustment and quality,respectively to achieve specialized operation.Meanwhile,attention should be paid to cultivating tobacco farmers who are professional in operation and management under the principle of good faith.

To reinforce construction and maintenance of related facilities to play the role

It is important to insist on the principle of planning first,followed by construction and of adjusting measures to local conditions,and advancing as a whole at an appropriate scale.As for construction of granted tobacco infrastructure,some limitations should be ruled at management to guarantee service life.For example,a limitation contract should be signed of local government with village committee and Party branch committee to guarantee tobacco infrastructure would provide services sustainably for local farmers.What’s more,tobacco infrastructure should be highly-qualified and the infrastructure facilities at constructing should be well considered,and the maintenance capitals of tobacco infrastructure should be arranged based on coordination and communication with tobacco office and village committee to make sure a long term service life of tobacco field.

To strengthen research and promote science and technology advancement

At first,it is necessary to conduct research on hot issues,difficulties and technical bottlenecks according to tobacco fields to guarantee the role of scientific research in leading tobacco production.Secondly,the suitable technology should be optimized and well explored.For instance,some advanced technology should be integrated with local conditions.

To broaden guidance on cooperative construction to highlight service functions

Currently,tobacco-farmer cooperatives have been constructed in different tobacco-producing fields.With supports from tobacco companies,some have equipped with working field and funds,but some still develop in an initial stage,so that services are not so professional.Therefore,tobacco companies should reinforce guidance on cooperatives and improve tobacco production and organization,in order to establish healthy and professional service mechanism and provide professional employees,as well as services in different chains.

Conclusions

Lean management is a sustainable and improving systematic project[5].A comprehensive proceeding of lean management lays foundation for income-increasing and cost-saving,as well as a key method for resolving practical problems, improving weak chains, accomplishing management of leading companies, and standardization of tobacco companies[6].At present, lean management of tobacco develops at an initial stage, so that it is of necessity to carry out exploration, achieve tobacco production,optimize production procedures, to improve tobacco quality and promote sustainable, healthy, coordinated and stable development, by optimization of procedure design, settlement of resources, and cooperation of employees.

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