Research On Lean Production And Line Balance For Auto Transfer Switches

The core of Lean production is reducing waste of enterprise resources, obtain maximum output with minimum input. Making the most rapid response to the market demand with the highest quality and lowest-cost products is the ultimate objective. And it can realize the cellular production, enhance resilience of production, correspond to the market shift, and achieve the flexible production system by line balance. Based on studying lean manufacture, line balance and related knowledge, article put theory into practice, to analysis Auto Transfer Switch (ATS) market demand, research product structure and assembly, plan materials layout and line layout, design workbench and line architecture, analysis value stream and so on. To design production line, article use the MTM software to analyze working hours, use the orthogonal experimental design to seek the most suitable factors that would make production line more efficient, study product value stream by value stream map, simulate U-shaped line and analyzes results with EM-Plant. The production of this line can meet the customer need. Furthermore, this line has lower investment and good indicators. The main line and the sub line are independently. The main line is a U-shaped line with three stations and two operators, and its assembly balance rate can reach 96%. The sub line is just one assumed U-shaped line for reducing operator’s moving distance and line area. Through the research, feasible production line can be set up and start ATS production in factory earlier. It greatly shortens time from researched and developed to production in factory, reduces process time, manpower and investment.