Research On Lean Improvement Of Z Printing Plant Based On Value Stream Mapping

Over90%of the printing enterprises in our country are small and medium-sized printing enterprises (SME-printing) which contribute a lot to national economy. But the input-output ratio of them is much lower than large scale enterprises because of their backward production technology and management level. Therefore it is urgent to reduce the production cost for SME-printing. As the production methods for low cost, lean production has been introduced by many large-scale printing enterprises, but few SME-printing. Z printing plant is a small state-owned enterprise, located in the western of China. With the deepening of the national western development policy, the demand of the printing market becomes more and more large. So Z printing plant needs to lower the production costs and increase production capacity.This dissertation takes the books and periodicals printing process in Z printing as the main subject of lean improvement. It formulates relatively complete solutions on the lean improvement of books and periodicals printing through using lean thinking and lean tools. We get that the basic management of the plant is chaotic by learning and doing analysis on its basic situation, production process and production management. We also identify the problems of huge waste in production and poor production plan, which exists in this plant, by carrying out detail analysis of books and periodicals printing process using value stream mapping (VSM) analysis. According to the principle of the optimal value stream improvement, this dissertation puts forward its improvement direction. Then the dissertation formulates specific plans on the basis of above analysis. In view of the chaotic management, we put forward to carry out5S activities in the plant and design a complete introduction and implementation scheme of5S. We also design an improvement plan for the post-press processing workshop, the appliances layout optimization based on the production optimal principles, the production process optimization based on the ECRS improvement principle, the operation arrangement optimization of the quality inspection station by improving the balance of the binding cell through the joint operation analysis and5W1H technology. After the improvement in the post-press processing workshop, unnecessary processes decreased by42.5%and single material transportation distance of saddle stitching line decreased by30.4%through the improvement. We propose to establish pull-type production system to decrease the occupation of funds and space by WIP (work in process) and ameliorate the operation of production plan, and designs the pull system and KANBAN. Finally, the dissertation puts forward the safeguard measures of the lean production according to the specific condition of Z printing plant. The improvement plan in this dissertation can provide a reference for other product line improvement in this plant.