Design And Implementation Of Lean Manufacturing Program In YOST Corporation

YOST is a small and medium manufacturing corporation producing photoelectricdevice. Since the corporation was built up, the business and production scale continues toexpand. However, due to increasingly competitive market, business form is constantlychanging. From2004to2007, the proportion of exported products was accounting formore than90%. This proportion decreased gradually in2008and reduced to70%in2010,which leads to a gradual development of the ODM services. In spite of demanding morediversified species, shorter delivery and increasingly stringent quality, prices have notsignificantly been raised. Therefore, it is important for the survival and sustainabledevelopment of YOST to design a reasonable lean production methods to improveproduction efficiency and quality, reduce material consumption and stocks.This thesis briefly describes the current situation of YOST’s production. It elaboratesthe production processes, logistics and inventory management, manufacturing technique,and quality control to identify the main problems in the corporation’s production processes,and discusses the reasons. On this basis, the thesis proposes that the YOST need topromote lean manufacturing, and select the pilot production line to design the program oflean manufacturing from three aspects--the production process, internal logistics andquality management, and make out its specific implementation. Through theimplementation of lean manufacturing in the production flow of the pilot production line,product yield of the pilot production line has been increased to95%from90%and theproducing unit time of the products has been reduced by15%; through implementation oflean manufacturing in the internal logistics, workshop area has been decreased by13%,and inventory has been reduced by20%; through the implementation of leanmanufacturing in total quality management, the complaint rate has also declined. If thepilot production line is the full implementation of lean manufacturing, the corporation willsave RMB220,000per month.