Research Of Lean Production In Tite Company

H Company is a German company, with a history of 140 years. The vision is “ To be a global leader in brands and technologies. ” So far, it is the global leader in consumer market and industrial market, with leading brands such as Persil, Schwarzkopf and Loctite which are very famous. H Company has three business sections, home care, beauty care and adhesive technologies. To outperform in the fierce market competition is the purpose of this study. Tite Company is a manufacturing site of Adhesive Technologies, H company in China, and for Tite, to keep the competitive advantage, we need to reduce costs on the basis of good quality, and improve the management competency so as to improve the level of customer service.How to achieve this, first in this thesis, it introduces the theory and mindset of lean production, with lean improvement methods and techniques, including Seven Wastes, 5 S, Visual Management, One Piece Flow, Line Balance, SMED and the application of MES system, as well as continuous improvement, demonstrated the necessity and feasibility of Lean Production.Secondly, make analysis on the current operation situation of Tite Company from two aspects, the external environment and internal management. Deep dive on the existing problems in the production management, mainly from five aspects: 1. the material piled up in disorder and blocked the path. 2. The layout of production workshop is not reasonable which bring much waste in production. 3. Production equipment are outdated, and less automation, while more manual operation in the packaging process, which led to low efficiency. 4. High complexity of products and technologies, and most are small package, multi batch, and long change time. 5. Uneven task time, low line balance rate caused too much waiting time and WIP.According to the existing problems, applying the theory of lean production, a lean improvement scheme was customized, and implemented in four phases. Phase I, Systematic training, the trainees include the site management team and production staff. Phase II, 5 S activities roll out. Phase III, Lean activities implementation, and pilot plant establishment, then get learning from it, and find the suitable improvement plan of lean production in other production line. The improvement plan include visual management, one piece flow, SMED, line balance and MES which brings data transparency and flow, working process paperless, and keeps an eye on the spot, and in the end help management team on decision making and improvement. Phase IV, lean production roll out in the whole site.Finally, the summary was made based on the current stage, refers to FTE saving, productivity and capacity enhancement, processing cost saving, WIP reduction and space saving, with a result of customer service improved, and MES launched bring benefits to working efficiency and information transparency, and quality control etc.. Afterwards, the strategy of continuous improvement is raised, focusing on the fully involvement of the staff with their competence enhanced, and leading the company in the lean way and outperform in the intense market competition. This paper has significant of practical work, is advantageous to the theory of lean production in H company other factory or even other enterprise application finally, solutions have been made on the improvement of the implementation stage summary, mainly from the human to save, the improvement of productivity and production capacity, manufacturing cost savings, wip and space saving, etc in the accounting, and through the improvement of productivity and production capacity, make the customer on time delivery rate has improved, improved customer service levels. At the same time introduces the MES to Tite company launched production operation efficiency and transparency of information, the benefits of quality control, etc., puts forward the strategy of continuous improvement, focus on the total involvement to the staff’s professional quality is higher and higher, make the enterprise in lean way more walk more wide, in an impregnable position in the intense market competition. This paper has great meaning of putting Lean Production theory into practice, and in favor of providing guidance on lean production roll out in other plants of H company and even in other enterprises.