Lean Production Research Of Aero-engine Products

In recent years, with the rapid development of science and technology, theaviation industry has become one of the most important high-tech strategic industriesin the world, and its development level has also become an important symbol of acountry’s comprehensive national strength. Rigid production of the original singlespecies and large quantities has been unable to meet the market demand in the wake ofthe fast-paced economic development and changing of market. In order to reducecosts, improve efficiency and enhance the market competitiveness of enterprises,many companies’ mode of production has changed to lean production methods ofmore variety and small batch, especially in the aviation industry.Taking AVIC South Aviation Industry (Group) Co., Ltd as example, at first thi spaper analyzed its implementation of lean production, then many problems have beenfound such as the low productivity, low customer satisfaction, low product quality,etc.After that, taking typical products for instance, various lean manufacturing tools andmeans were used to improve and enhance productivity, customer satisfaction, productquality levels and save the cost of production.This paper contains following content:1) We conducted a brief introduction of Aviation Southern Company and focusedon analyzing the processes of its implementation of lean production. We found, lowproductivity, low customer satisfaction and low product quality, three main problems.And we cited problems of three typical products, namely the too long cycle of bladealuminized, the too long period of XX8series engine test delivery and the heavy lossof chromium-plated ring scrap. According to these cases to explain the necessity ofimplementing lean production, and then we generalized the goal.2) For the low productivity mentioned above, we analyzed the reasons why theproduction cycle is too long by using value stream mapping and fishbone diagram. Asfor these reasons, we developed and implemented a plan that is using process analysis,Kanban management and other means to cut down the distance product handling,improve stability of product quality, and shorten the production cycle.3) For the low Customer Satisfaction that is proposed previously, after fieldresearch and statistical analysis of historical data, we obtained four factors, vibrationfault, oil spills failure, flame test and data acquisition failures, that affect its delivery period, then proposed14measures to shorten the troubleshooting cycle, improvetroubleshooting efficiency and shorten the delivery cycle engine. After that, thiscompany could save the costs about3.063million yuan.4) For the low level of product quality that is proposed previously, at first, weused fishbone diagram to list the possible causes of the problem, and then investigatedworkers to find the five key factors. According to these five elements, we madeimprovement plans. And finally we found the scrap loss rate reduced from44.80%to10.24%per year, and the capital of scrap loss reduced74,670yuan per year.This paper advocated conducting lean production to improve productivity,enhance customer satisfaction, improve the quality of products, save the cost ofproduction and benefit enterprise.