Study On The JIT Production Control Scheme Of ZF-FAWER Tianjin Plant

The background of this paper is the ZF-FAWER Chassis Technology(Changchun)company plans to build a new plant in Tianjin for the new project of FAW-VW,the purpose of this paper is to design a JIT control process with the relevant theory in order to meet the request of both internal customer and external customer,the point of this paper is that the traditional JIT control process focus on the process design,but with the development of the auto,the FAW-VW pay more attention to the lean management and scientific management of the manufacture process and the inventory,so in order to meet the new requirement of customer,the new plant in Tianjin needs to apply the information technology in its JIT control process,the technology should be combined with the process,the process provides the JIT solution,and the technology supports the automation to fix the solution,reduce the waste and eliminate the disturb of the environment.The procedure of this paper: The first step is do the analysis for the early research of the new project and the initial layout of the new plant to get the project plan and the plant layout,production mode,manufacture process,the production and the delivery of the new project needs the support by JIT process.The second step is to recognize the three probably problem in new plant JIT process,including the material control,the process of production and delivery,the information tracing,and do the comprehensive analysis for problem's reason,including the emergency time for production and delivery,too many kinds of the product and the material,the disordered management for the warehouse,the insufficient apply of the information technology,actually,the first three points are the process design reasons,and the last point is the technology apply reason.The third step is to collect the demand from the internal side and the external side based on the problems and the reasons,the external demands include the new plant should do the production,create the buffer and do the delivery according to the signal from the different positon in customer assembly line,and also should promise the information tracing,the internal demands include the order recognition,the flexibility of the engineering change,the process control for production and delivery,the product information tracing,the accordance between the material flow and the information flow,the disaster recovery plan for the information system,all the mentioned demands are requested by each business department based on its duty in the JIT process.The forth step is design the control process according to the lean production and the JIT management theories,including the 5S theory,the flex production theory,the KAN BAN theory,the visualization management theory and the PLC control,at the meantime,in order to promise the process could be executed without the environment disturb,the process also apply the information technology to fix it,and finally design a JIT control process meeting the requirements from external and internal customers.The fifth step is to provide the guarantee measures for the JIT production control from organization side,technology side and the regulation side,the organization side provides the JIT process organization structure,and defines the department duty and the position duty for each JIT production activity,the technology side provides the information system in JIT process,defines the information flow,designs the logical algorithm for the interface between the core system,the regulation side provides the disaster recovery plan for each emergency issue in JIT process,and also defines the daily regulation,including the regular meeting,the emergency issue simulation regulation,the JIT problem escalation process,ensure the JIT control process from the emergency issue handle side and the emergency issue prevent side.The outcome of this paper is the high automation JIT control scheme for ZF-FAWER Tianjin plant,this scheme combines the information technology and the business process design,and also meets the JIT requirements from external and internal customers,and also provides a new way for JIT process study.