Research OEE Improvement In Machining Workshop Of W Company

China’s high speed rail cause get a rapidly progress after 21 st century.Compare western countries,we achieved “corner overtaking” already become world leader in high speed rail industry.China even become rules maker in quite a few aspects in this industry.China’s high speed rail get great leap forward development in past 20 years.China keep the world first in total mileage of high speed rail from 2014.Meanwhile,High speed rail industry in china mainland become flourishing.More and more world leader brand in High speed rail industry set up and invest new factory in China.To be honest,these manufacturing factory select quite high starting points at the beginning.They also have strong competence in China market.For example,W company in Qingdao I worked in previous.This company implement Lean when they set up.W company has a basic foundation of Lean production after several years’ operating.There are still seriously imbalance not only between sales order and capacity but also the requirement of continue improve.This company is facing the major problem How to finish order on time in a limited factory area.W company designed and implemented several lean concurrent projects in order to improve the performance of deliver cycle and capacity.The improvement of OEE in machining workshop is one of projects,After a thorough analysis to historical data,we found many points should be improved.such as extensive production plan,machining quantity over need,too long time in process;WIP is too large,unreasonable workshop layout caused material routing abnormal,error in using material&drawing show 5s still big improve space,cleaning machine not good caused equipment fault and reduction of speed,defective of process and fixture caused product transition time lost.We made and implemented one by one to improve the problems after we find the root cause according to 5 why methods.The 5S management in machining workshop is strengthened,especially visual management.The operation of the workshop is kept in a normal state,and the abnormal condition is very easy to find out.Through the improvement of the implementation of the equipment cleaning plan,the failure rate of the equipment was reduced by 42%,and the loss caused by equipment failure was reduced by 40%.We take actions to optimized machining workshop layout to reduce material transport routing,avoid transportation waste,add working area for welding,gluing and forming,painting workshop.such as updated process,training multi skilled workers,add shaping process after bending,washing,polishing process.The products quality performance get progress,the pass rate of CNC from 91.5% to 93.5%,the loss of quality reduced 75% by optimize tooling and fixture in machining workshop.We optimized production plan get following results: the WIP in machining workshop reduced 70%,the product changeover time reduced to 50%,production cycle time from 11 days to 5 days.All those actions for improve OEE of machining workshop get a good result raised the data from 50% to more than 65%.The implement of machining workshop OEE improve project verified the scientificity and applicability of Lean production which based on TPS.Of course,different company different characters,we can not copy this kind of management methods and management tools.This article can help manufacturing industry especially small and medium size enterprises in machining process control.All these reference can be intuitive reflected through the comparison between the result before and after improvement.