Research On The Carriage Productivity Improvement In Dongfeng Automobile Co.,Ltd

This paper focus on the present situation of low production efficiency in compartment branch of the Dongfeng Automobile Co., Ltd. With the basic theories and methods of industrial engineering, it analyzes and improves the problems which bad affect the painting, welding and assembly capacity. Effective analysis and improvement achieve the overall objective of the capacity improving and the vehicle packing supporting capacity requirements.The main researches include:The first part focuses on the status quo of the long coating beat and low coating efficiency. Ultimately making the JPH to achieve the objectives and requirements needs many efforts such as:identifying bottlenecks process-electrophoresis with work measurement, improving it with motion analysis and station merger, analyzing each station with5W1H and ECRS, identifying invalid actions to eliminate wasted time, reorganizing of the backplane, side panels and the front and rear panels of the suspension.The second part focuses the present situation of low production efficiency of the three weld line of the backplane, side panels, front and rear panels. We can identify the main reasons which restricting the beat and the bottleneck process by factor analysis of5M1E and causal analysis diagram. Then, two steps are needed to achieve improvement goals of JHP of welding production lines. The first step is the finding of welding line’s processes which need worker or workers through analysis of line balancing theory and the improvement for the job programming of welding five major processes. The second step include:analyzing causal diagram by PDCA, identifying the main reasons for restricting the welding line’s beat and verifying, developing countermeasures, implementing and verifying for each main reason.The third part makes great efforts to improve the current situation-backplane couple-uncouple ability of final assembly production line and carriage assembly capacity are insufficient. Firstly, we deal with the insufficient of backplane couple-uncouple ability. Time measurement methods based on the stopwatch is used to find the bottleneck processes.5M1E method and associated analysis method is also needed to identify the main reasons which result in the bottleneck processes. Developing appropriate countermeasures, implementing and verifying them will be followed. Then, we improve the carriage assembly capacity. Secondary analysis is done with5M1E method, associated analysis method and PDCA cycle diagram. Developing appropriate countermeasures, implementing and verifying them for the existence of problem will be followed. Finally, the overall improved effect of the company’s capacity is verified. After the improvement, the expected targets of capacity improvement are achieved.