Optimization Study On Manufacturing System Of Project 308 In DP Company

With highly development of China auto industry, the market is facing intense competition. In order for a big market-share and high earnings, foreign-capital enterprise, state-owned enterprises (SOE) and private enterprises all adopt advanced technology and equipment import world leading level management, elimination of waste, cost saving and productivity improvement to adapt to market demand. Lean Production is one of the hot advanced management practices.DP company is a United States listing wholly owned subsidiary company, with over 120 years history and provide different kinds of wire harness products and service to big auto-makers around world.308 project is a program that DP Yantai Branch provide whole wire harness to new generation small car in SAIC GM with annual demand of 300 thousand sets.In this essay, we will learn the history of Toyota production system and background of Lean Production for a deep comprehend of relevant theory and utilities. With reference of success experience of Toyota lean production, combine practical situation of 308 project in DP Yantai Branch with lean production theory, analyze manufacturing situation to find the waste and improve opportunities during project process, with working hours analysis and layout optimization or other industry engineering tools to find bottle-neck working position during current production and make system optimization for the visible and invisible waste points during process design. Eliminate waste in 308 wire harness production process, eliminate non value added action or process to achieve the improvement on position balance and layout optimization for labor efficiency improvement and project manufacturing cost decreasing of DP Yantai Branch.Enterprise culture is one of key affecting factors to implement lean production, and The innovation point on this essay is improvement lean production utility with analysis and optimization on process and layout improvement on material delivery, it’s the first time to implement some tools of lean and IE in the wire harness manufacturing process of project 308 in DP Yantai Branch and summarize a series of management rules in practical process to set up lean culture. A series of management activities was held for a new comprehend of lean production from production line operator to top management staffs, all these theories finally shaped the specific Excellence culture of DP Company, focus on customer, teamwork, continuous innovation and improvement.All the research in this essay is with high practicability and also with high reference value especially for labor-intensive automotive components companies.