Research Of Lean Line Design From B Company

With the rapid progress of China automobile market in recent years, the demand of the vehicle component is increasing, the competition between automotive component suppliers is fierce. How to reduce the production cost and improve product quality has become the most important task of the automotive component suppliers. This paper briefly introduces the theory of lean production and lean production line design requirements. According to the present situation of B company lean production line design process, combine the advantages of MTM and PFMEA, this paper describes how to use MTM and PFMEA into the lean production line design analysis.First of all, in the lean production line design stage, following the definition of the MTM standard operating time, engineer separate the basic operation groups which is only operated by one operator independently and cannot split to multi operators reasonably. Then these actions with its operating conditions are divided to the basic action elements and transfer to MTM code group, summary all value from the code of the corresponding basic elements action to get the operation time. An operation flow chart is created following the operation sequence for the whole production line. Then according to the result of MTM analysis, optimize the operation content for each operator and operation flow, to reach the balance of operator workload. Production line design should be update following new optimized operation flow solution, and a process flow chart is defined.Secondly, according to the product design functions and requirements, base on the process flow chart, engineer analyzes all potential risks from the operation or process to realize the functions and requirements of products in production line. Engineer determines the failure or the root cause of the failure severity rate, occurrence rate, and calculates and analyzes the Risk of Priority Number base on these three rates. Improvement actions must be developed according to the RPN from high to low for the related failure mode to control risk in the acceptable scope. Finally the improvement actions from PFMEA analysis result must be updated to the lean production line design. The purpose is to eliminate or control the potential failure occurrence probability, reducing the potential waste from mass production.The MTM method and the PFMEA tool used in this paper is general skill, it can provide a reference for other similar enterprises.