A Research Of The On-site Diagnosis And Improvement Of The Production Line Of TZ Company Based On The Lean Production

In the early 1900s, mass production was widely used in American manufacturing industry, making America the center of the world. However, in the 1970s, owing to the Great Depression caused by oil crisis, the world gradually began to focus on Japan with rapid rise. In terms of this, America carried out a research named "International Motor Vehicle Program (IMVP)", which has summarized the Toyota Production system (Lean Production). Lean Production is a kind of production and management mode that is most suitable for the modern manufacturing. It combines both the merits of mass production and small scale production, pursuing zero stock, zero defect, zero waste, zero breakdown, zero stagnation and zero disaster. Besides, it lays emphasis on the importance of people by integrating everyone’s wisdom and creativity, then changing them into the infinite power for the development of the company. Lean Production should be applied into the transformation of Chinese manufacturing, as it can lower the cost efficiently, increase productivity and the quality of the products, ensure the quick response to the market, and enhance the enterprise’s competitiveness.TZ Company emerges complying with the era of intelligence, providing electrical products with high reliability, high performance and high values for high quality users in the line of electric power, power grid, petrifaction, steel, manufacturing and real estate. This thesis carries out a research from the perspective of M1 production line of TZ Company. At first, through the introduction of the current situation of Lean Production in manufacturing and the dilemma that TZ Company faces in the market competition, the author makes the research direction of this thesis clear and put forward the problems in diagnosing and improving the M1 production line of TZ Company in the production operations based on the Lean Production mode. Besides, the author briefly introduces the Lean Production theory and ways of improving the production line, including field management, total quality management, line balancing and PDCA. The evaluation index of Lean Production Improvement is also proposed. The author then illustrates production operations of M1 production line of TZ Company. An overall analysis of production efficiency, equilibrium rate that affects production efficiency and the situation of man-hour loss is also included in this thesis. For the production efficiency problem, Lean Production Project is carried out in Ml production line:firstly, strengthening the awareness of Lean Production among people in the management level and operating staffs of this company; secondly, setting up the relative organizations for Lean Production Project; thirdly, proposing the principles and aims for the improvement of Lean Production Project; Fourthly, improving M1 production line from the following aspects, including on-site improvement, total quality management, line balancing based on consistent improvement of PDCA; last but not the least, evaluating the improvement of Lean Production according to the evaluation index and summarizing the improvement experience.As this research is carried out based on the real enterprise production, the research results, research methods and the tactics of production line improvement are of practicing significance. At the same time, the author hopes that this research can provide reference for the same type enterprises in China and promote the mass application of Lean Production in Chinese manufacturing assembly industry, then enhancing the competitiveness of Chinese manufacturing industry.