| The main purpose of this thesis is to improve Materials Handling Equipment manufacturer L's productivity, on-time delivery rate and cost advantage for providing multi-varieties and customized forklifts. The competition within domestic market is becoming fiercer and fiercer. Company L must adapt its production system to multi-varieties, small batch and customized demand.Firstly, Strategy Management theories were adopted to analyze L's strengthes and weaknesses, business profile and market trend. Lean production was then proposed to support L's corporation strategy.Secondly, based on analytic results of Value Stream Mapping, value added time and non-value added time (NVAT) in processes, 5W and fishbone chart were used to find the root causes of NVAT. To solve the problem of non-match materials, high WIP and inventory, production planning was improved for balancing JIT production. Process utilization chart was applied to identify the process bottleneck. Production resource was reassigned to remove the limitation from bottleneck.This thesis applied ABC classification to analyze demand of each variety, and then designed main production plan mode. Inventory and"make to order"strategies were adopted to respond the requirement. Based on equipment and worker utilization rates, job assignment and production scheduling and sequencing were proposed to improve material matching rate. Process flow chart was used to balance production line and remove wastes. Process layout was further improved to reduce transportation distances. For one piece flow production, other lean tools including 5S, visual management and Kanban, were applied to improve production lines. Combining statistical data in each procedure, SPC was successfully applied in small batch assembly for improving production quality.Finally, inventory optimization model for revenue maximization was also proposed. Based on sales data of each variety, forklifts were sorted into 3 types and stocked by MTS, ATO and MTO modes respectively. |
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