Lean Production Application Research On Production Efficiency Enhancement

From2006, GD Company became the global manufacturing base of GSM product. Thehysteresis production efficiency cannot fulfill the orders. This article is based on the leankaizen project of S18000outdoor base station production line, through the diagnosis of theproblems existed in S18000outdoor base station production line, worked out theimprovement objective and scheme, and realized the improvement objectives.Firstly, by production line layout analysis, confirm the aspects for improvement for thecurrent intensive type layout. Then, using work measurement mensurated the process timebefore kaizen. And using the result of work measurement drew the Value stream map.Through the result of takt time calculation combining with Value stream map analysis, foundthe key posts to be improved, configuration and final inspection, and the utilization rate ofemployees only reached79.76%, the production line is not balanced. Combining with theprocess time and the observation and analysis to WIP and transit, found the stagnancy timeoccupied70%of total process time. Through product working procedure analysis, theproblem existed in configuration and final inspection was found out.After confirming the improvement objectives and scheme, through process analysis,standard work and re-layout of production line, improved and enhanced the productionefficiency of S18000outdoor base station. By using ECRS rules and5W2H method reducedthe stagnancy time of WIP, eliminated the unnecessary transit, to reduce50%of the stagnancytime. Next, by improving and optimizing the operation, balanced production line, enhancedthe average utilization rate of employee from79.76%to84.68%. In order to fully realize theeffect of process improvement, re-designed the layout of production line by eliminating andcombination, resetting and optimization, operation designing improvement, to enhance theproduction efficiency.Through implementing lean production, the lead time of GSM S18000outdoor basestation is enhanced62.08%than before, the PCE is enhanced59.81%. Base on the personnelstructure optimization, the output of every shift of every operator is enhanced12.99%. Thislean production improvement project was a good outset and model of GD company’s leankaizen activities, and lay a good foundation for promoting lean production in GD company.