Research On Capacity Improvement Of F Automobile Co.,Ltd.painting Workshop Based On Lean Production

With the increasingly competitive environment,China's auto industry is facing unprecedented challenges.How to be recognized by the market and bringing considerable profit is the pursuit of every enterprise.The promotion of lean production has helped the automobile manufacturing industry to achieve the change of management mode,the improvement of production efficiency,the optimization of waste problem and the optimization of manufacturing cost,so it has become the production management mode implemented by many enterprises.The capacity improvement of the painting shop is a typical case of the lean production concept which is promoted in the factory.This article analyzes the production status of the painting shop of F automobile limited,and by the actual measurement of the field,it is concluded that the UBS manual stop problem of PVC section and the takt time problem of painting section are the core problems affecting capacity improvement.By using the cycle balancing of lean production,the 14 positions of UBS single line manual operation are analyzed,and the problem of 6 positions which is surpassed takt time is analyzed deeply.Use the four principles of ECRS and combine the other lean production methods including error prevention,5S,man-machine engineering to analyze and formulate the measures for each problem.Finally,the problem was eliminated by realizing the target of all UBS positions takt time.Using the PDCA cycle and 5W1 H method of lean production and combining fishbone diagram to find the key factors which influence takt time.Measures such as optimizing the positioning pin procedure,eliminating the cleaning procedure conflict and activating PUSHOUT function are formulated.The takt time of painting section was optimized from 118 s to 93 s,the production capacity of is improved,and the overtime problem was eliminated.Using PDCA cycle and 5 w1 h methods of lean production,through the fishbone diagram to find the paint beat will effective,develop the optimal locating pin procedures to eliminate the specific measures,such as cleaning that PUSHOUT conflict activation function implements the paint the beat from the beginning of 118 s to optimize the design of the 93 s beat,improve the paint production,eliminate the paint beat timeout problems.Finally,the measures are solidified and implemented into standardized operation cards and process regulations.By using the application of lean production theory and method,the core problems of capacity improvement in painting workshop is eliminated,and the actual capacity is improved from 58.5JPH(Job Per Hour)to 62 JPH.The planned production capacity target of F automobile co.,LTD.has been achieved,and it improved production efficiency,and provided favorable support for the company's talent cultivation and lean system establishment.