The Execution Of Lean Production In Optimization Project Of Overhead Projector Lines

In order to enlarge its market and sales in Asia area continuously, AAA China corp. introduces and implements Lean Production, requires its production departments to eliminate waste and reduce production cost.According to the production status quo of overhead projector department, the paper uses VSM (Value Stream Mapping) technology to identify waste in current process activities. The paper also uses work measurement method to measure operation time, calculate standard working time and production pacing. According to current operations arrangement, it identifies that production line is unbalancing, operators'usage is low and some usage are only 60% or so. Last, the paper uses process analysis method to study the status of WIP and transportation in the process. It identifies that waiting time is long and takes up about 92% production time, some transportation is non-value added motions and need be eliminated.The paper uses IE and Lean tools to map out and implement one project of Lean production. First, overhead projector department improves the process flow. It uses ECRS (Eliminate, Combine, Rearrange, and Simplify) principle and 5W2H methods to reduce waiting time of WIP during the process and eliminate unnecessary transportation. It reduces about 52% waiting time. Second, it increases the average usage of operators from 76% to 88% through optimizing operations and balancing assembly lines. Then, the department optimizes the workshop layout in order to realize the improvement result of process flow fully. The department consolidates 5 assembly lines into 3 lines and improves line usage through elimination, combination, rearrangement, optimization, and operations design improvement. Some linearity assembly lines change to U-shape line and bow-shape line which are easier for materials flow. At the same time, the...