Application And Research Of Lean Production In Process Of Gear In Reducer

Gear is one of the core parts of gear motor. Single variety and mass production is applied in the production process of gear. With the more fierce competition in the market of reducer and more extensive scope of application, the varieties and the accuracy requirement of gear increase continually. The original production mode cannot adapt to the requirement of competition in the market. Lean production should be applied in the production process of gear to realize multi-varieties and small batch production and provide the best quality products to customers with lower cost, higher efficiency and shorter delivery time.Based on the study of many literatures about lean production at home and abroad, this thesis introduces the origin, the basic principle and the goal of lean production. Meanwhile, the value-adding system is summarized according to the characteristic of reducer enterprise in this thesis. Then, take a real example that lean production is applied in production process of gear. To look for problems of current situation and points those need to be improved, value stream mapping is applied in the process. According to plan of improvement from value stream mapping, some tools of lean production are practiced including 5S, pull system, TPM, SMED and continuous improvement.After implement of lean production in the production process of gear, the level of management on site is improved. The situation of man, machine, material, material and environment is changed better than before. Moreover, the lean operation ability such as level of process control and performance of operation is promoted. The improvements are as followed: the output can meet the demand of customer, the lead time has been shorten from 28 days to 11 days, the cost of stock has reduced 30% than before, the reject rate has reduced from 10% to 3% and the rate of delivery in time has achieved to 100%. The satisfaction of customer is higher than before because that the multi-varieties and small batch production is realized. Finally, through the implement of continuous improvement, everyone in the production process of gear can join the practice of lean production actively and keep enthusiasm for continuous improvement persistently. Thus, the solid foundation of “people” can be built in enterprise to achieve the target of a long-term strategy.Lean production applied in production process of gear has collected much practical experience. The experience can be used when lean production is implemented in the processes of other parts in reducer include pin shaft, worm, worm wheel and output shaft. So that, the whole machining of enterprise can realizes the lean production finally.