Study On Lean-Production Management Of Large Complicated Customized Product Manufacturing

With the advancement of reform and opening-up, China accelerates the pace of integration into global economy, companies face unprecedented intense competition. For further development, level of QCD (Quality, Cost, Delivery) should be enhanced constantly to satisfy customers’ needs in such a situation. Lean production is a kind of effective production and organization style after one-piece-hand-made style and mass production, which is thoroughly proved by practice and extensively used to improve the QCD of enterprises in all walks of life.Studies show current lean-production methods is not totally suitable for all kinds of manufacturing organization, some of the methods or tools are partially suitable. Also, with the increase of complication and customization of products, it becomes harder and harder to directly use lean-production principles or methods in production organization and control of large complicated customized product, for example:it is hard to identify the value stream, it is hard to test and control the fluctuation in the process of production and so on.Under the guidance of lean thinking, we have analysised the dilemma of production organization and the features in large complicated customized product manufacturing, then some changes are performed:(1)Net-working planning method is applied in the processes of large complicated customized product manufacturing to make the master plan. The product corresponding to the whole network, the assemble structure connection corresponding to the relation among the nodes of the network, the workshop produces the most necessary parts which are assigned by the net-work plan, this reflects the lean-production feature of value; Mass production is replaced by net-work flow, this reflects lean-production feature of value stream, namely, net-working value stream; The flow of value stream is driven by the net-work structure and schedule; Pull style is formed by the schedule of net-work structure.(2)Earned value mothed is applied in the large complicated customized product manufacturing, instead of WIP buffer, time buffer with the combination of probability lose is used to measure the schedule in practice, effective adjustment will generate by analyzing the degree and source of change.(3)Process-style pull is designed to pull all the production activities based on network of value, a Kanban that is more suitable for the process-style pull of large complicated customized product is designed.Then, we performed a case study on lean-production solution in TST company. Redesign is performed including plan mothed, measurement and control mothed, production-site improvement,staff training and education, and then effects are evaluated from aspects of inventory cost and inventory related cost,intensity of PD,operator number of shopfloor, which significantly improved the effectiveness.