Applied Research Of Value Stream Mapping Based On Line Balance Optimization

The production process is composed of several production activities.The production activities are divided into three kinds:value-added activities, non-value-added activities and waste.To eliminate existed waste,minimizing non-value-added activities and improving the efficiency of value-added activities as the key factors,which can shorten the production cycle,catch the market opportunities,reduce inventory costs and increase profits must be considered. However the value stream mapping techniques is the effective way to realize this goal.This paper selects PT5 assembly line of a TV production manufacturer as applied research object.Firstly,the TV production line survey data has been collected and processed;secondly,a process of program map of the production line has been drawn;thirdly,the existing problems in the production line have been analyzed.On the basis of those program mentioned above,the stations of the line has been combined and simplified by using the software named Proplanner.At the same time the Bar-Chart to achieve the initial equilibrium is also been established.Furthermore, a production line optimization model which run the optimization model and optimization results has been Established with software named Xpess-mosel,As a result,the optimized tact time was 46 seconds after optimized and the balance rate of the production line is improved from 76.55%to 84.16%.Through analyzing the value stream of the product and mapping the current and future VSM,It is showed that the Products Order Lead Time has been shortened from 21.57 days to(shortened for)7.46 days,among which the production assembly line cycle time has been shortened from 9.56 days to 1.72 days;At the same time,the number of the work in process of the Production assembly line has been reduced from 4846 to 860, moreover the value-added rate of the Production assembly line has been increased from 2.33%to 0.42%.It is concluded that combining the Bar-Chart with optimization models of the production line can provide a scientific basis for the VSM analysis.