Research On Efficiency Of Circular Saw Assembly Line Based On Lean Production

With the current increasingly severe international economic situation,increasing market competition,China's human cost advantage weakening than before,manufacturing industry in China has encountered further development bottlenecks and even for labor-intensive enterprises.Lean production is a revolutionary production management and its core idea is to reduce waste.Although more and more companies begin to implement the lean production,however in the actual implementation process,it still relies on subjective experience judgement,or mechanically forming.It does not form a systematic operation process,so the improving effect of the production line is not obvious.Therefore,how to apply the ideas and methods of the lean production,improve the production line in a systematic way is an urgent problem.S company is the world's leading manufacturers of power tools and accessories,and most of its production lines are manual assembly lines.The orders number change periodically.In busy season,it often lacks of production capacity and needs to recruit contractors.And the increasing of manual labor coat,leads to a dramatic increase of the outer pack cost.In addition,in order to reduce the plant leased area,the factories are merged,and it leads to the layout problems.This paper taking the S company saw assembly line as the research object,based on related theories and methods of lean production,it uses DMAIC improvement model to improve the production line which systematically solves the problems of insufficient production capacity in busy season of S company and the unreasonable layout.The whole improvement process is divided into five stages: Define,Measure,Analysis,Improve and Control.The whole improving processes will become more processing and staging,and make the improvement process more systematic and logical.The main contents include:(1)The stage of “Define”,by analyzing the gap between the target demand of the circular saw assembly line and the current status of the production line,it is concluded that the current production capacity of the circular saw assembly line is lower than the theoretical level,and the layout is unreasonable,6S management level need to be improved.(2)The stage of “Measure”,collect the basic data of the production line through measuring,it builds the basis of quantitative improvement.According to this,ensure the optimizing target: improving the efficiency to 6.5 pieces/person/hour or above,improving the balance rate of the production line,reducing the bottleneck of working time,optimizing production line layout,improving the management level of 6S.(3)The stage of “analysis”,use the method of 5W1 H and ECRS to have the operation process analysis,looking for the improving point of the operation process.Apply MTM method for analysis of concrete actions.By shortening the distance of material taken by staff,improving the degree of control of materials,to reduce production waste and work efficiency and then get a preliminary solution.(4)The stage of “improve”,according to the root causes of the analysis stage and the basic solution of the specific implementation measures,it redistricts production processing,allocates the staff,improves the optimization of the layout of 6S,puts forward specific improvement plan.Finally,using ED simulation software and physical simulation of assembly line improvement to simulate,it verifies the rationality and maneuverability.(5)The stage of “control”,based on lean production people-oriented thinking,through formulating work instructions and related standards,strengthening the staff training,it will make the improving results be sustained and continue to optimize the improvement.Through the above work,the study provides a more systematic solution,with a strong practical operation.The methods and steps used in this paper are more convenient and practical,easy to master.It can be applied for more enterprises,and produce significant improvement effect.