Research On Applying Lean Production To Optimize Production Line Balance

Currently,some manufacturing enterprises of China still in the lower end of the value chain,and face the main problem of high production cost and low production efficiency.Take G Company as example: low effective capacity,high inventory of work-in-process and low removal efficiency are all existed in G Company.Among all the reasons,logistics not smooth,removal workload too heavy and production line not balance are the key reasons.The production efficiency is seriously influenced by the reasons above,and leads to delay and appears defective products,increases the production cost.This thesis integrates lean production theory and production line balance theory,combined with practice of enterprise,then raise “Three Steps Method”to solve the production line problems mentioned above: First step,according to the removal situation among the machines,the size and shape of workshop space,applying SLP principle to design the production line layout,in order to reduce the removal times,shorten the removal distance and reduce invalid removal.Second step,find the longer time expending work station based on standard time bar chart of cotton dress production line,use “5W1H”and “ECRS”to adjust the job contents and workers,remove the bottleneck,in order to make the operation time of all processes beginning to converge.Third step,optimize the production management from performance appraisal,5S management and standard operation,cultivate the operation habits of workers,maintain the improvement achievement.Through analyze,research and summarize the production line balance optimization method,this thesis succeed to apply the lean production theory to production balance improvement,and obtains favorable effect.Meanwhile,this thesis points out the problems during researching,so has reference significance for production balance improvement of enterprises in the same industry.After optimization,the production balance efficiency has risen by 18%,daily maximum capacity has risen by 147 pcs / day,and direct economical benefit is 3822 Yuan/day.After the optimization of production line balance,the production environment improved,the worker quality enhanced,and also achieves obvious indirect economic benefits.