Sulzer (Dalian) Lean Production Design & Application

Lean Manufacturing is originated in Toyota Corporation Japan as a production management method. The core of Lean Manufacturing is to eliminate all of the wastes, establish just-in-time production system with high agility, and while pursuit the perfect target of quality, safety, and cost. It represents the tendency of modern manufacturing industry; it has been credited as the standard production management approach in the 21st century.Dalian (Sulzer) is a Swiss-owned enterprise specializing in the production pump. The company's biggest challenge is on-time delivery. As many products are not delivered on time, so we get many complaints from customers, at the same time, it affects the company's reputation and lone-term interests.Meanwhile, there are some problems in the organizational structure, field management, production organization, and production line layout and supplier management:organization structure is unreasonable; field operation is not standardized, the efficiency is not high; production line layout is compact; field management is disorder and we have not formed a long-term, strategic partnership with our suppliers. The existence of these problems greatly restricts the company's development. In order to maintain the company's competitive, Sulzer (Dalian) must make form, must carry out the lean production. Sulzer (Dalian) extensive production management has unable to meet the needs of market competition, and lean production provides it a good medicine to Sulzer (Dalian) to change the present situation.The paper combines the actual situation of Sulzer (Dalian), in view of the existing organizational structure, field management, supplier management, pump production process and other problems, using lean production theory as guidance to design the company's lean production programs. First of all, by changing the existing organizational structure to strengthen communication, enhance the ability of solving problems; secondly, in the organization of production, establish Kankan pull production to eliminate waste; in the production process, establish operation standardization to standardize the work flow and improve work efficiency; in the production line layout, by altering the production line layout to change the production logistics, make the production process more smoothly; as to the field management, implement 5S to improve the management level; finally, strengthen supplier management to achieve a win-win situation and improve the on time delivery. By implementation of these measures, the logistics, production processes, field management and other aspects of Sulzer (Dalian) have changed greatly in short term, and provide better protection for the future implementation of the lean production.