Optimization And Improvement Of Logistics And Layout In CT Factory Based On Lean Thinking

With the rapid development of commercial vehicle industry,the scale of production and the ability of research and production are improving a lot.The competition in the auto parts industry is becoming more and more intense.So how to reduce the cost and improve the productivity has become one of the most important issues for every manufacturing enterprise.CT factory is one of the commercial vehicle and auto parts manufacturing enterprises.With the gradual increase of production capacity,in order to take account of low production cost and normal operation at the same time,CT factory is required to plan the factory logistics system in the limited plant area,and improve the utilization ratio of the space.For the automobile manufacturing industry,the internal logistics management is very important.As an important part of supply chain management,internal logistics is an important guarantee for material flow,storage and packaging in the factory.Layout is the basis of logistics,good design can make the route and feeding time shorter.Lean thinking,as the most advanced production concept,the core thinking is to eliminate waste.This paper will use lean thinking to solve the problems about production logistics and layout,to reduce unnecessary waste.Not only ensures the continuous flow of production,make the production plan completion of quality and quantity,but also effectively reduces production cost and improve the material flow rate.This paper introduces CT factory internal logistics presentation and analysis the status from four aspects,including value stream,line feeding process,layout and the line feeding route.The problems existing in the internal logistics of CT factory are analyzed by noodle map,fish bone map and value flow chart,to find the waste in the process and layout.Then we set up an improvement team and make a plan to solve the problems existing in the factory,such as insufficient capacity of the line side warehouse,long feeding cycle and high error rate.In view of the problems about the layout of CT plant,the whole factory is divided into 23 operation units by using the Systematic Layout Planning method(SLP),and sorted the 23 units by logistics intensity.We set up a C parts market to reduce the pressure of distribution and improve the efficiency of internal logistics.Then drawn the comprehensive correlation graph according to the intensity of logistics,calculate the ranking of comprehensive proximity,and draw the position graph according to the list.Finally,according to the actual situation of the CT factory,the final layout of the warehouse and workshop is drawn.In view of the problems about internal logistics process,I get the standard time of each movement and the standard time of the whole cycle through video and stopwatch.The whole logistics time is shortened by improving the bottleneck and optimizing the process.By comparing each production line’s materials,finished products,air box,the KANBAN Cards’ number and scan time in case of 45min,60min and 90min,this paper finally chose different cycle different time,and achieve the high efficiency and high utilization rate.After studying the logistics of the plant,the feeding car is optimized to increase the capacity to 86,which not only satisfied the cuirrent demand,but also satisfied the capacity requirement in the future for a long time due to the increase of production capacity.Finally,we put forward a continuous improvement direction for the factory,which will continue to optimize and improve.