Research On Application Of Lean Production In BS Changzhou Facility,Drier Workshop

Lean manufacturing is an advanced production methodology.It is appraised as the best production organization and management system in the industrial community.Lean production aims at waste elimination at each step and at each process,continuous improvement of product quality,lead time reduction,cost down,operation efficiency and customer satisfaction.With the ever increasing market competition and diversified customer needs,it is the inevitable choice of enterprises to introduce lean philosophy and implement lean production to promote the enterprises' whole competitiveness.Firstly,this thesis analyzes the current status,problems and deficiencies of BS drier workshop.The problems are: internal production lead time too long;production efficiency too low;excessive inventory;a lot quality issues.Secondly,the actual lean production practice of the drier workshop is elaborated.With the launch of 5S campaign as well as improvement proposal reward policy and employee skill upgrading,the workshop builds a solid foundation of lean production.Guided by lean philosophy,the workshop layout is re-designed to ensure smooth logistic flow and reduce cross handling and roundabout.The sub-components pressing process is consisted of four individual processes,which leads to redundant WIP inventory at each process.It is replaced by U shape and one piece flow line.This helps shorten internal lead time and reduce WIP inventory.The stations at the final assembly line have imbalanced workload.With ECRS,bottleneck process troubleshooting,automation process upgrading,the production efficiency of the final assembly line improves tremendously.Besides lean production implementation at phase I,error proof system is also upgraded and Andon information system is set up.Finally,the achievements of lean production are summarized and phase II plans are put forward.