Lean Six Sigma Method In Discrete Parts Processing Enterprises Applied Research

In the late1980s and early1990s, the excellent performance of Toyota MotorCorporation in the North American market, shocks the American auto industry. Theexperts of America MIT, studying as long as five years, called Toyota ProductionSystem as the Lean, and affirmed, Lean must be revolution of production system inmanufacturing. Afterwards, the practice of lean in lots of auto an auto parts industriesproved the Lean can improve quality, reduce cost, shorten delivery and increasecustomer satisfaction through devoting to eliminate waste continually. Almost thesame time, the Six Sigma, born in Motorola, helped Motorola, GE become excellentfrom good.Lean devotes itself to eliminate waste of process, and six sigma is aimed atreducing variation of process. The elimination of waste can reduce cost and speed upthe delivery. The reduction of variation can stabilize output of process and decreasethe loss of bad quality. So, the effective combination of them can help enterprises inquality, cost, and delivery of the three elements of competitiveness to achieveremarkable results.Currently, the domestic auto industry competition is extremely intense. The autoparts industry, not only met the requirement of the continual price reduction of thehost plant, but also coped with the reduction of profit space of upstream raw materials.The main purpose of lots of auto parts enterprises is, how to met customer needs in amore economic, more efficient way to meet customer demandThis paper takes production efficiency improvement of Ji’nan Fuqiang power limitedas the research object, using systematic problem-solving route of six sigma, and withthe help of problem-analyzing and improvement tools of Lean. This is a typical caseof application of lean six sigma.In the project period, the kinds of indicators of lean model line were significantlyimproved. For example, the average manufacturing cycle of three products reduced36%, the comprehensive production efficiency increased13%, and the WIP reduced43%, the FTT of fly wheel from80%to92.3%, the floor space of three productionlines saved400m~2, meanwhile, the lean talents were train during the practice.