| The purpose of the below research is to investigate the production flow of the GW company’s automotive product range and to find out the way to optimize the production process by improving the production efficiency, reducing the work in process inventory level and increasing the production capacity.By using the value stream mapping(VSM) to evaluate the production status, we can see the major influence of the production capacity is the length of process time, and the key factors affecting the slow production process are as below:1) Unreasonable production flow setting2) Long production idle time3) Low level of production standardization, low production balancing efficiencyThrough the line balancing, lean production study, we redesign the production line setting to optimize the working process, introducing the flow line production setting way in some of the assembly areas to save production idle time, as well adopting the MOD method to standardize the working instruction to the operators and ensure the most efficient working standard to be taken.The result shows, after executing the improvement actions, production leadtime was reduced to 1.56 days from the previous 3.77 days, there was a 58.6% up in production leadtime improvement; through the production flow redesign and the application of MOD method standardization in production line, the capability balancing was greatly improved, and the production efficiency increased up to 34.5% reaching 70.18% from 52.16%; after the production flow was optimized, the on-line average stock level decreased to 2,662 pcs from 7,265 pcs, showing a 63% change in improvement.The mentioned standardization working process and corrective action plan would be taken as the continuous improvement program in practice and would be promoted to the other working processes to further improve the production efficiency in the factory as a whole solution as we start to benefit now from the improvement actions. |
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