Research On A Product Line Improvement Of GT Company Based On Lean Production

With the impact of economic globalization and the COVID-19,from the data of negative growth in the automotive industry in 2019,it is shown that most of the automotive giants’ production and sales cannot meet the set goals,resulting in unsalable sales,resulting in overstock of inventory.At the same time,new energy has caused the rise of new forces,the short development cycle of new models and the use of various innovative elements have brought a huge impact on the traditional automobile manufacturing concept.The manufacturers of the automobile supply chain can only improve the competitiveness of the market by improving production efficiency and reducing production costs,so as to maintain the operation of the company.The competition of enterprises is becoming white-hot day by day.The survival basis of enterprises is the pursuit of cost minimization and advanced cost management methods.However,at present,the manufacturing industry has a relatively weak awareness of production cost control,the cost control method is more traditional,and the concept of cost control is also relatively backward.Lean production is an advanced and effective way of production management.It emphasizes the full use of all production resources,the maximization of benefits,the reduction of costs,the encouragement of the participation of all staff,the effective handling of problems in the production process,and the promotion of the minimum investment of resources to obtain the maximum benefits.More and more enterprises begin to realize the importance of implementing lean production,and actively implement lean production application practice in the daily production process of enterprises,as an effective means to improve the comprehensive competitiveness of manufacturing enterprises.GT Company was founded in 2011,is a wholly foreign-owned company,mainly engaged in the design and manufacture of artificial leather for automobile interior decoration.At the initial stage of the establishment of GT Company,it caught up with the golden development period of the use of PVC in the interior decoration of China’s automobile industry.Although the internal management mode is backward and there is no long-term planning in the development process,due to mastering the core manufacturing technology of the product,the product sales volume and profit are relatively high,and the development of new projects is relatively large,the problems of poor on-site environment,low manufacturing efficiency,high WIP inventory,low yield,serious waste,and low willingness of employees to improve are not paid high attention.However,with the rise of new forces of car building and the shortened development cycle of new vehicles,GT is facing the pressure of not meeting the delivery demand brought by the adjustment of customer orders.The company’s management has the determination to urgently change the current situation.In this paper,we focus on the A product line of GT Company,and conduct a comprehensive optimization study on logistics relationship layout,production line balance,total quality management and rapid mold shift,starting from the implementation of lean management of the production line.First,through on-site observation and analysis of the production line of GT Company’s product A,it was found that the major existing problems are: unreasonable distribution of logistics relations,low production line balance,low production rate and poor production management.Then,to address these issues,the production line balance,5W1 H,ECRS and other lean production theories and tools are used to formulate the corresponding optimization plan.Finally,in order to ensure the implementation effect of the improvement plan,corresponding safeguard measures have been formulated,including encouraging the participation of all staff,strengthening the development of employees and optimizing the incentive mechanism,to ensure that the A product production line achieves the development goals of improving production efficiency,improving product quality,reducing production costs and shortening the delivery cycle.With the optimization and improvement of lean production,the balance rate of the production line has increased from 69.64% to 83.18%,as well as the moving distance.It was reduced from 514 m to 311 m,and the die-change time was reduced from 1800 s to 1246 s,a reduction of 30.8% lower,effectively improving the production efficiency and market competitiveness of GT.This paper uses lean production theory and tools to solve practical problems in the production site,verify its correctness and feasibility in practice,and provide reference for the optimization and improvement of multi-variety and tiny-batch production operation mode enterprises.