Lean Manufacturing Design Of SGM GF6 Transmission Plant

Shanghai General Motors built a new plant in its Yantai subsidiary company, for the new six speed transmission product. The capacity of this plant is 600,000/year. In-house work content includes machining of transmission case, converter housing, valve body and channel plate, and assembly of transmission.The objective of this project is to make a layout for this new plant by applying lean manufacturing principles, and to optimize the layout to meet capacity requirement and other constraints.This thesis applies SLP theory to initiate the layout planning of new plant, then optimizes the layout in three following aspects: improve by applying lean manufacturing basic principle, eliminate bottleneck with work time study tools, and improve the stock and buffer area with simulation tools. Therefore, the area of plant and manufacturing line is reduced; the HPU (Hours per Unit) is decreased; and lean material flow and cost is reached. All these contribute to the achievement of company goal: Produce the new low cost, high technical GF6 transmission by end of 2007.