Lean Production Theory Application Research In SDM

In factories around the globe, Toyota consistently raises the bar for manufacturing, product development, and process excellence, the result is an amazing business success story:steadily taking market share from price-cutting competitors,earning far more Profit than anyother automaker,and winning the praise of business leaders worldwide.Now China became manufacturing center of the world gradually,there are more and more company want to implement lean production. Fewer man-hours, less inventory, the highest quality products with fewest defects of any competing manufacturer.so that they can keep their competitive strength.SDM is a ShenZhen company, wholly owned by her mother company in Fench- Thomson. SDM face same situation with other state-owned enterprise in China.after Lean production concept introduced to SDM, many problem were found,such as operation concept,production,workmanship,quality and logistic problem.The analysis gone through production operation system,IE & workshop improvement,JIT and Value engineering.Refer to SDM current situation we feel it's necessary to change current workshop separated by process.also production line,production equipment and fixture need improvement but no big investment.all expenditure come from company special budget.cooperation departments are the mechanical operation,Process center in French,R&D center in German.This task process run as:training—case study---make action plan---Continual improvement----summary.the main research and experiment way are Gemba Kaizen.By lean production's implementation SDM's productivity improved by 24% and yield improved from 75% to 95%, through lean production inventory reduction 97%, customer return reduction from 2.6% to 0.5%,The key process is lean production concept and implementation drive. This project success in SDM due to the special lean production project team,top management commitment and good consultant Mr Andrew.Through lean production,the line layout changed,some process changed,some fixture and equipment modified,also some management principle,but not big investment.The key process are the lean production concept understanding and implementation drive.