The Application Study Of Lean Production Technology In A Motor Lighting Company Production Efficiency Improvement

In order to reduce the production cost, eradicate the production waste andimprove the production efficiency, lean production was introduced in C motor lightingcompany. It will ensure the high-quality, low-cost products and the on-time delivery.Therefore, the reaearch on the application of lean production in C motor lightingcompany will be meaningful.The problems existed in C motor lighting company are as follows:(1) The valueadded ratio is low and the production cycle is long.(2)The production system is thetraditional push system. The waiting and storage time are relative long.(3) The dieexchange time in moulding shop is as long as2hours and which results in the longwait of equipments.There are a lot of possible causes of long production cycle, and thelean production system are relatively huge. So, only the most outstanding problemswere studied with the methods of lean production. The main contents of this thesis areas follows.(1) The current situation description and the existed problems analysis. A seris ofproducts were selected as the investigated subject with PQ analysis. The current valuestream mapping was drawn to analyse the existed problems. And then the researchscheme of the thesis was drawn up.(2) The layout optimization of plant and production line. The layout of Ccompany was unreseanable for the material handling waste, waiting time and longproduction cycle. In order to acheive a stroke arragement and fluent logistic route, theglobal layout the plant was improved according to lean production idea. The detaillayout scheme of the moulding shop was designed to eliminate the redundanttranportation, reduce the WIP stock and promote the product quality. The assemblyproduction line of C company was the linear layout which has several weak pionts,such as the inelastic personnel arrangement and takt time. Therefore, the assembly linetype selection and layout were researched to enhangce the fexibility and efficiency. (3) The assembly line balancing. The management level of C company is low.The bottleneck of the assembly line was prominal and the balance ratio was just64.7%.The assembly line banlancing and workstation improvement were studied with frockimprovement, ECRS, stopwatch test, bottleneck transterring. The assembly linebalancing ratio was promoted by technics optimization and operation recobination.(4) The single minute exchage of die in moulding shop. In order to shorten the dieexchanging time in moulding shop of C company, the SMED of lean productionsystem was adopt. The iternal operation time was turned into external operation time,and the rapid relocation and rapid first examination schmes were designed to reducethe die exchanging time. And then the production batch may be cut, the WIP stockmay be reduced, and production cycle maybe shorten greatly.In this thesis, some application acheivements of lean production in C motorlighting company were acquaired. Many similar motor lighting provate enterprises areexsited in China, and the improvement methods and acheivements can be spread inother similar motor lighting company.