BJA Assemly Line Improvement Based On "One Piece Flow" Model

Since automotive industry in China is getting booming in 21 st century,the marketing competition becomes more and stronger with globalization.It is a critical task for each automobile manufacturing enterprise that how to occupy a favorable position in the fierce competition in China’s auto market.The inevitable choice is to improve our traditional production way,to increase manufacturing efficiency and to reduce production cost through the lean production way.For each automobile enterprise,how to find the suitable own enterprise’s lean production method is worth us to discuss and research.In view of this,this thesis focuses on the ramp up issues of the assembly shop of BJA,which is an automobile manufacturing enterprise.Firstly,we select the Trim 4 production line as the research object,and make a comprehensive analysis of restriction factors that affect the production capacity.When the production capacity requirement need to increase from 35 JPH to 40 JPH,a variety of bottleneck station will appeared,then we analyze the bottleneck stations and pre-assembly stations by the analysis methods such as MTM,Snap and Line balancing wall.After we finished the analysis process,we can defined the waste during the assembly process and find process is not balancing between the production main line and pre-assembly line.Secondly,based on the characteristics with “Just In Time” and “Automation” of "One Piece Flow" concept in lean production management,we design and implement the “Shopping Cart" system optimization concept through optimize the process lay out,improve the logistic delivery methods and integrate the pre-assembly area.We try to realize the U-shaped layout between the production main line and the pre-assembly area by implement the “Shopping Cart” plan,,then solve the bottleneck stations issues systematically.At the end,the comparisons of production data of implement the “Shopping Cart” concept before and after that demonstrate its advantage and feasibility.Besides,we try to make the “Shopping Cart” concept standardization and generalization in the company,hoping “Shopping Cart” concept reflect a greater role in lean production management,and provide the new ideas for lean production management of the automobile manufacturing enterprise.