Research Of Floor Improvement Of Slideway Assembly Based On Lean Production

With the increasing competition of the manufacturing market, the going down ofdemographic dividend, and the rising of material prices, the demand for product quality,production efficiency and cost control is becoming higher and higher. Faced with the severeenvironment of domestic and international market,enterprises must be self-adjust and improveto suit the market requirements.The Precision Manufacturing Co.,Ltd of Guangdong Provinceis a professional of the metal processing enterprises,and the slideway and hinge is theirmainly product,which covers both domestic and international market,and has a greatinfluence in the industry. Due to some historical reasons,its production still belongs to crudeproduction model.For the current slideway assembly line of the company,most of themanufacturing process gives priority to the manual work,which means that the degree ofautomation and standardization is really low.In addition,because of the unreasonable facilitylayout,nonstandard operation and some the other factors in the production, it create someproblems such as a series of latency time by futher handling process,and delay feeling bysupply chain logistics jam.As a result,it leads to the production disjunction which hinderingthe improvement of the production line balancing rate.Futhermore,the working environment istoo poor to improve the employee’s production enthusiasm.It may cause the homeworkfatigue easily,and constrain the development of production efficiency in the end.Therefore,combine with the current situation of Lean Production at home and abroad,thisarticle provides some solutions for the specific problem scene, by applying the idea of LeanProduction,in order to improve the production site,reduce the cost of production,and realizethe improvement of the both effectiveness and efficiency ultimately.Here are some researchtopics in the follows:Previously, this article reviews the relevant theory and some characteristics of LeanProduction, introduces the common tools among the whole Lean Production, and expoundsthe meaning and significance of the site improvement.Secondly, the article does the description and analysis for the slideway assemblyproduction line of the case company, The Precision Manufacturing Co.,Ltd.of GuangdongProvince. It uses5S,5W1H, ECRS and a series of industrial engineering principles to analyzethe problem of site layout, such as unreasonable layout, low production balancing,unstandardized operation, poor working environment, material illegally placed, and supply not in time. At the same time, it analyses the five influenced factors in the production linerespectively by using the5M1E method.Thirdly, the paper proposes theoretical solutions through the idea of Lean Production,including the process flow optimizing, logistics optimization, and site layout optimization.For the process flow optimizing, it contains non-value-added operations eliminating, thereduction of the time in handling and waiting, and the specification of standardization work;for logistic optimization, reducing the phenomenon of the leak and wrong material, makingthe production line for the material in a timely manner, and reducing the inventory cost are allincluded inside; for the site layout optimization, it covers the removal of the waste, cuttingdown the WIP, and the enhancement of operation conditions as well as the efficiency of theproduction line.Finally, the article builds the workshop layout mathematical model based on siteconditions, and use the genetic algorithm and MATLAB to get layout program.For siteimprovement plan, uses the ED simulation software to do the simulation and verification forthe conclusion, and does the performance analysis through the comparabele of the before andafter improving simulation data. This is aiming at certifying the feasibility of improvementplan, and it shows that the plan is benefit to increase the producing efficiency, and reduceinventory and production cost.