Increase Capacity Of Passenger Car Axle Based On Lean Production Methods

With the rapid development of China’s economy and rising demand of domestic markets, the insufficient of production capacity is one of the most principle contradiction for all vehicle companies in China. However, China has the advantage of long-term demographic dividend and favorable policy, are facing all-round challenges of rising labor costs, appreciation of the RMB and increasing deterioration of environment. Therefore, the mass production and extensive management is obviously not suitable for China due to lack of resources, low-quality product competition and high management cost. The transform of production mode is the inevitable trend of historical development. lean production provides an excellent choice for vehicle company of China to improve efficiency and control cost. Through focusing on the problem that the capacity of company assembly line can’t meet the demand of new project, this thesis studies typical method of the use of lean production, analyzes and solves all kinds of efficiency loss and waste in the production and manufacturing process. In the end, significant benefits have been achieved in the capacity of assembly line production.Firstly, this thesis introduces the background of lean production and the current developing situation of manufacturing sector, then elaborated the practical significance of lean production mode and its implementation method. Theory introduction of these methods and tools pave the way for the application research below.This thesis lead the former production capacity analysis of the assembly line by using dynamics analysis, line balance and other tools. Furthermore, OEE(Overall Equipment Efficiency) is a tool to indentify and affirm various factors influencing the efficiency in the manufacturing process, such as line loss, mass loss and so on.In the last improve phrase, this thesis rearranges the action sequence between every positions through performance standard method, updates distribution of production, improving the original balance rate from 69% to 81% to solve the balancing problem of the assembly line. Then aiming at the problem of OEE’s insufficient meeting the capacity demand, this thesis puts forward using rapid changing line method, site layout and visual management to reduce line loss. Then complete the study of using PFMEA to improve process qualified rate and eliminate waste, reduce cost and improve OEE from 88% to 95%.Based on all kinds of improvement in the production process, the annual production capacity of the final assembly line is increased from original 200,000 to 310,000. Lean production not only has a positive impact on the scene of the management and economic benefits, but also has reference significance to other related enterprises.