Study On The Production System Re-construction For Continental Automotive Changchun

Step on the global economic integration, the automotive industry is changing deeply and market competition is more fiercely. A huge number of automotive group are merger and united, higher integrated mode are used in assembly car; new material, new technology and new service concept are more and more used in the automotive industry. About the supply market, European enterprises, US enterprises and Japanese enterprise are stand in the dominance position in the finance and market field, and stand in the monopoly position in the technology field. About the demand market, with the center of Asia Pacific Region, Southern America, East Europe and Africa demands are increasing dramatically. For the reason of these, the production base of European and America enterprise would transfer to the emerging country and region, such as China to reduce their production cost and posit near to the demand market. This can enhance their competitive. In China, more and more automotive spare part company are controlled by European and America company, the local company seams not very strong in the competitive. So that is an important place for the European and America company to compete in emerging country.German Continental Group is a global automotive spare part supplier with more than 100 years history. It is a top 500 enterprise in the world. Some spare parts are monopoly and a lot of spare parts are stand on the leading position. Continental Automotive Changchun (CACC) is a company with whole hold by Continental Group. And new CACC is the biggest production base of Continental Group in Asia. And the company produces electronic product, sensor, and fuel rail and so on. Various series of products in China's domestic market share of large occupation.With the influence of the finical critical in 2009, all the economic especially automotive industry is damaged. All the automotive enterprise selling reduces. In order to get more profit, all the enterprise does every thing to stop reducing to enhance market competitive, CACC re-construct production system to improve the system to reduce to production cost to enhance profitability. CACC implement lean production at the beginning of company running. CACC used the production method of Just in time and Jidoka management for a long time. For the critical, the concept of improvement is enhanced. CACC improve the production system from a production line of MCPS. With the statistical of production line, we know there are 7 persons working for the MCPS production line. With the brain stream, we find the problem need to be improve as follow: It is to far of the distance from Kanban to the production line; cancel the Visual Inspection location; low temperature test not necessary; It is hard to change component while produce. With value stream mapping, we know the product leading time is 46day and the No. of Work in Process is 14000pcs. And we knew reduce inventory and eliminate waste time is important thing to do. With the analyses and calculating of production line re-construction, we calculate the Tact time is 27.5s, the most high efficient operator number is 2.9 and the most persons is 3.7. Considering with the production layout and use the one piece flow stratagem. We use electronic simulation and objective simulation, and implement this re-construction. The result is the production area is reduced by 40%, productivity increased by 250%, inventory reduced by 45%, lead time in Process reduced by 48%, cost saving is 250000RMB for this project. Implement 3 shift stratagem, 3 persons and 4 persons working stratagem, add the flexible of delivery time and produce time.The element of production system re-construction is lean manufacturing. It is not only a manufacturing method, but all so a management concept. The implementation of the production system re-construction and improvement continuously is a way of finding perfect and never stop, and this idea is good for both a enterprise and a person who using it. It is a pursuit excellence way for an enterprise or a person to enhance his competitive.