| LT company is a small and medium-sized technology-basedenterprise. Its main business is in designing, manufacturing anddistributing energy-storage battery. In this thesis the issues of the batterymanufacturing line improvement based on IE theory and TPS are studied.The thesis analyses customer requirements, material flow andinformation flow by introducing the method of VSM (value streammapping), and then recognizes wasted items, discovers the causes forproductivity loss and overstock of WIP (work in process) in currentproduction process. On basis of above analysis, the thesis presents theVSM diagram chart of future production process, that is, the improvedone.From the angle of lean production, a whole set of plans are workedout and has been implemented to enhance MCE (manufacturing cycleefficiency), reduce the non-value added time, overstock and laborintensity. Firstly, the thesis analyses the workshop layout and the logisticpath to adjust the layout, improve carrying methods, sharply shortenlogistics distance and reduce the handling frequency. In the end, the totalquantity of handling has been reduced67%. Secondly, the process flowof product is analyzed. The production cell of welding has beenorganized to improve operating methods, eliminate unnecessarytransportation, and thus reduce waiting time of WIP during the process.Meanwhile the balance rate of manufacturing line is improved26.8%through the optimization of the assembly line and the “one flow”production pattern is realized. Finally, through standardization of moduledesign, it has been realized to reduce the specification of electrode andbattery diaphragm etc., and thus reduce the funds occupied of inventorymore than60%. After implementing above production processimprovement plan, lead time is reduced from21days to13days, theMCE is enhanced25%of original.The thesis is not only valuable for lead-acid battery manufacturingline, but also holds reference value for the assembly line balance of otherlike enterprise. |
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