Research On Process Optimization Of Product Design And Manufacturing Of Y Company Based On Lean Thinking

Y company is a key enterprise in high-end equipment manufacturing industry.It has been committed to producing the high-end CNC machine tools.On the basis of providing core products such as vertical and large gantry maching centers,it has provided a large number of efficient processing solutions for customers in aviation,automobile and ship industries at home and abroad.However,with the improvement of people's living standards and income,customers are gradually showing high demands and personalized needs.This has led to a continuous decline in the sales volume of Y's standard model machine tools and the number of orders for custom machine tools has increased dramatically.The company's R&D center is under greater pressure due the product differentiation.Therefore the enterprise should pay more attention to fast,affordable,high quality design and manufacture products.In general,Y company mainly has the following two types of problems:(1)The product design stage of VMC machine tool has the problem of high cost and long time.There are three reasons why the design process is costly and time consuming.(1)In the market research stage,technicians indirectly contact with customers and lack understanding of the real needs of customers.The technicians only makes function additions on the standard machine according to the customer's requirements.But they did not remove the functional parts that the customer did not need.This causes the final product's production cost is too high.(2)In the design process,there is a lack of problem record,lack of management and accumulation of previous technical assets,resulting in a large number of repetitive work by technical personnel;(3)After technical and working drawing design,the sample production system is carried out,and no simulation experiment is carried out.If the product fails,the prototype will be rectified and tested simultaneously,which increases the design cost of the prototype parts.(2)There are two reasons why the design process is costly and time consuming.There are two reasons for the low efficiency and insufficient capacity of the assembly line.(1)The station division of VMC assembly line is not clear,the distribution is discrete,and the assignment time of each station is not balanced.(2)Production site management is confusing,lack of standard work instruction documents,unreasonable design of tools and tooling,confusion and versatility.In view of the above two shortcomings,this paper optimize the design and production process of Y company products based lean thingking:(1)From the perspective of lean design,we optimize and improve the product design process of Y company.Firstly,Y company product development design model was established by the IDEF0 functional modeling method.Secondly,ASME table is used to analyze and improve the model.Finally,after the improvement,the time of total design process was shortened from 119 days to 81 days,the value-added step was shortened from 103 days to 75 days,and the non-value added step was shortened from 16 days to 6 days;(2)From the perspective of lean production,based on the field data obtained from the job measurement,the mathematical model of the balance problem of the first and second class VMC assembly line is established by using the method of 0-1 integer programming,and the model is optimized by LINGO11.0 software to obtain the improved optimal operation.And after the final improvement,the assembly line's balance rate reached reached 93.91% and 89.26%,respectively,which was 33.64% and 28.99% higher than before the balance.Through the research on VMC product design process and VMC assembly line of Y company,this paper provides a practical and feasible improvement case for precision machine tool manufacturing enterprises.And we hope that it can provide a reference for the application of lean thinking in similar large-scale equipment manufacturing industries.