Research On MES-Based Lean Production Of Shop Floor

With the development of economic globalization, multi-species, small quantities and customized production model makes a sharp rise in manufacturing production costs, while lean thinking brings hope for manufacturers by eliminating waste and reducing overall production costs. However, completely artificial lean production management brought many problems, such as difficulty in Kanban management, unified paper documents, inventory management confusion, and so on. It is difficult to realize standardized operation, a stream flow, and a balanced implementation of the workshop. MES-a shop floor management information system, appears to provide a reliable technical support for lean production, they both do well in the workshop production management, and can promote interdependence and jointly improvement for production management in shop-floor level.Through literature research, field research and data collection of manufacturing information, lean production and manufacturing execution systems are studied in structure and both theoretically summed up to come up with mutually supportive place in the workshop production:production dispatching, quality management, equipment management, materials distribution and other business processes on shop-floor. In these processes, lean manufacturing tools can be used to realize lean production in workshop based on MES. In order to verify that lean production is feasible in MES, this paper carries out in-depth study of the theory and applications according to the production planning and control process, taking visual management, value stream analysis and continuous improvement as examples.Firstly, from the level of production planning, combined lean pull principles with MES push principles in shop floor, the key nodes of production are identified as the pull point and non-critical nodes are scheduled by pull production, thus a combination of push and pull is achieved in production planning.Secondly, in the production process control level, the integration of visualization tools such as Andon, electronic billboards and touch screens, with MES systems, makes dynamic management of production dispatching, distribution of materials, quality control and real-time data timely collection and feedback.Thirdly, this paper takes Value Stream Mapping as the system analytic tool, which involves a few of other lean tools and the whole process of production planning and controlling. With value stream mapping based on MES model, it is feasible to achieve real-time rendering of value stream mapping of workshop process, to discover the production process waste in time, providing data and information for continuous improvement in production, technology and management level.Finally, the paper takes a diesel engine company machine shop as an example, having value stream analysis as the main line, making requirement analysis of the workshop from quantitative (value-add activity ratio) and qualitative respectively, combined with the actual production process-oriented MES-based Lean application described. Draw the future state value stream map under the envisaged MES-based future value stream, and take it as the basis for continuous improvement.This study provides a new idea and method for lean management workshop. MES is used to achieve efficient implementation of lean production, improve the efficiency of production management, and realize real-time, visualization and lean management. This study provides reference to integration of management thought and management technology for workshops where lean manufacturing or MES is being implemented.