Design And Application Of Lean Production Line In Bogie Assembly Factory

Lean production mode is a new way of production born in Japanese Toyota Motor Corporation following a lot of production mode,which aims at completely eliminating all waste within the enterprise and improving production efficiency.By keeping reducing production cost,improving products quality and realizing zero waste and inventory,all invalid labor and waste can be eliminated.Along with the rising of company capacity,In the face of the rapid growth of orders,the factory run well below capacity with limited production space.In order to solve these problems,optimize operation process speed to meet customer demand and the competitiveness of enterprises,lean production is introduced to improve the original production management mode,and make quick response to the changing environment,so as to maintain the advantage in the competition.This paper focuses on how the bogie assembly factory achieve timely delivery,reduced waste and production cost,improved quality and core competitiveness through lean production.Firstly,this paper reviews the theory of the lean production.Based on the situation of processing and assembling of products,this paper analyzes the entire production line.The analyzing mainly focus on the character of products,the pattern of manufacturing,process arrangement,logistics distribution,project management,quality management and foundation management.To establish the production pattern of work position system,and take account of three-level management elements,optimizing the content,forming the standards of main thinking way of solidification and extending,this research combines the physical truth of bogie assembling workshop to apply the theories and tools of lean production.And the scheme of work position distribution and balance of production line,process arrangement of production line and work position shifting,K3-ERP system data,rules of logistics distribution,quality management of production line,5S and visualizing has been designed and verified successfully.As a result,the curing management mechanism has been found,the basic management has been rammed and the working atmosphere of workers has been improved.Finally,the production pattern of work position system has been established in the bogie assembly factory,and the transformation and upgrading of manufacturing realized.This article hopes to initiate the introduction of lean production method in other assembling shop or factory and to make contribution to the research of the related fields.