Study On Inventory Control In Painting Plastic Bumper Production

With the competition increasing in the field of automobile, the painting plastic bumpermanufacture enterprises surfer more and more cost down pressure from OEM. How tocontrol and reduce the inventory during the whole production procedure is a problem ofgreat importance.Based on the production process analysis to a typical painting plastic bumper plant inShanghai of YFPO group, we point out the reason for too much inventory and study theeffect on it. First is the cycle time difference between injection and painting process whichcause the WIP after injection and the inventory in painting line. Second is the finish partsafter painting.Third is the inventory of paint raw material.As the solution, introduce a way to connect injection segment and painting segment byimproving each cycle time to the same time. Suggest painting line as the core of the wholeproduction in the plant which can change the production organization from "push" to"pull-push" and reduce the inventory tremendously by shorten the lead time. RecommendCPU operation mode based on VMI to optimize the paint material inventory management.After these solution implemented, the inventory of Shanghai plant reduce.As experiencethese solution is also applied in another plant.