Production Line Kaizen Study Based On VSM Analysis In K Company

As the increasingly fierce market competition and customer’s changingneeds, traditional mass production can’t meet the market competitionrequirements. Lean production integrates the advantages of mass production andsingle piece production, and tries to achieve multiple varieties, high-quality andlow-cost production in mass production. Cell production as a new stage of leanproduction development has been more widely adopted and successfullyimplemented by manufacturing plants of electronics industry.This paper studies cell line production process flow improvement and layoutoptimization by analyzing VSM of production line. Firstly, this paper introducescurrent status and production process flow of high performance test products, andmakes primary kaizen plan by analyzing VSM. Secondly, we propose the idea ofmoving assembly, and adjust and improve the operation sequences by analyzingproduct process flow. We redesign the working benches according to ergonomicsrules. Base on the cell line layout rules, we redesign the layout for each workstation, and work out the final layout and implement it to production line. Thirdly,we set up two-bin system and material supermarket by using kanban card tocontrol and manage the inventory on production line. At last, we evaluate thekaizen effect and summery the experience during the kaizen project.43%room was saved and14%daily output was raised from the productionline improvement. It also can be a good sample for future production cell lineoptimization.