Application And Study Of Lean Production Model Used In Heavy Diesel Process In Y Company

Currently, lean production is the best method of producing organization system in industry, and successfully used in many well-known foreign companies, such as Boeing, GE Company, South Korea's Samsung Corporation and British Rolls-Royce. From these companies, it's easy to see the lean management can bring tremendous benefits. Lean manufacturing has proven to be an effective management tool.However, low labor productivity, quality issues outstanding, high production costs, extensive management, waste serious and long lead time issues are common in SOEs of China. It's a short time since domestic enterprises introducing lean management model, and there is almost no achievement. If the lean production can be successfully applied in SOEs of China, which will enhance the reform of SOEs to upgrade the competitiveness of the market provides an important safeguard. Actually, after introducing lean manufacturing, the achievements of Y Company enhance the confidence of promoting lean production model to SOEs.Though Y Company as a domestic industry leader, productivity, quality, cost, delivery, advanced engine compared to foreign companies are still large gaps. In 2011, Y Company began the introduction of lean manufacturing, after four years development of lean manufacturing, it has made some achievements. The paper take the lean manufacturing of fifth engine factory of Y Company as a object, elaborated the method used in lean manufacturing plant to promote the process and achievements for other SOEs as reference in the process of implementing lean.The paper studies on the following aspects:To improve the production of S models machining production line, according to the line balance theory, uses the Eliminate, Combine, Rearrange, Simplify( ECRS) method. The implementation method: by adding tooling to eliminate waiting time of clamping, tool integration through the merger process step by step process content recombinant balance beat, by optimizing the tool feed speed shorten the processing time, and ultimately improve line balance rate from 61.7% to 86.4%, the production capacity 16 units / day up to 32 units / day, and achieved remarkable results.According to the utilization rate theory, the use of Total Productive Maintenance(TPM) and time management methods, help to make the machining line equipment failures improving. The implementation method: Through the implementation of equipment inspection and maintenance of the reference work, the establishment of the equipment running status billboards, to develop equipment maintenance standard OPerating instructions and maintenance standard time, and finally to the equipment failure rate of the production line fell 67% utilization rate improved 6.2%, effective obvious.The SMED(sixty seconds Instant retooling) theory and method makes the machining wire loss product changeover time reduced. The implementation method: Plato analyzed by retooling existing in the process waste, improved by routing, for improved modeling tools to develop standard operating methods change type, so that the production line changeover times reduced by 32.6%.