| With the manufacturing cost in China keep on increasing, the profit of labor-intensiveenterprises becomes less and less. It’s a priority task for them how to eliminate the wasteand cost down. Lean Production is regarded as one of the best manufacturing managementmethod in current industry. The core of Lean Production is to eliminate waste, pull fromthe customer, build just in time and keep on improving. The enterprise who implementLean Production can make significant benefits on lead time shorten, inventory cut-off, costdown with kinds of management methods.This thesis is studied the lean production implement in BT injection moldingcompany. According to the value stream mapping tools, choose tool box as a serie product,then find the key problems in the production by analyzing the current value streammapping based on seven wastes in Lean production. Later make the improvement plan andfuture value stream mapping. The mainly improvements is firstly to optimize theproduction logistics by re-layout the facility. Secondly reduce lead time by processanalysis. Thirdly increase the whole capacity by decreasing the bottleneck process timewith Theory of Constraint. Fourthly control the materials better by reorganizing thecompany organization and changing the purchasing ways and goods delivery times.Finally shorten the exchange time of die by using single minute exchange of die (SMED),the equipment availability has been increased.After above improvements, the tool box lead time has been shorten from55.84daysto27.76days by50.3%.The transportation distance inside has been reduced from155meters to25meters by83.87%. The WIP quantity has been reduced by78.3%. The WIPinventory in warehouse has been eliminated. The whole capacity has been increased by28.8%. The exchange time of die has been shorted63minutes by36.8%These resultsshow the Lean improvement for the tool box by value stream mapping method works well.BT company will keep on improving and find the best way of Lean Production by itself. |
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