Lean Application For The A Company Transmission Product Automation Line

Entering the year 2010,Germany USA and China on behalf of manufacturing level to motivate the industrial revolution,the global manufacturing is facing the upgradation.Automotive industry is the country level manufacturing and China also show the big market share.Most of Automotive company move the business strategy in China.A Company is an automotive tired 1 supplier ranked as Fortune 500 with many years of automotive experience and technology,especially in automotive transmission control system.In 2017,Great Wall Moto and A company developed the new generation engine platform as a solution for gearbox controllers.The new Great Wall transmission controller production line is fully automatic assembling testing production line and sensor production line is fully automation operator free.When new transmission sensor line launched,the company’s existing lean management methods can not apply for Great Wall transmission line.How to make lean production became one question,A Company look for a new lean application to improve the equipment efficiency and reduce the production operation cost.A company Great Wall production line has been optimized process flow and the production cycle.Implement the production JIDOKA reporting system,5S visual management,TPM system,and POKA YOKA management;The fully automation production line carries out safety and lean design,less change over time for transmission sensor.The JIDOKA reporting system are self-trigger with the intercommunication with automation PLC system.Production equipment trigger the alarm and JIDOKA auto send message to employees for one completed loop.Production maintenance system drill wide scope to reduce machine downtime,using WeChat to share lessons learn and teach each other.New idea is to improve capability of all staffs by share real practice;visual production system design to real-time dynamic display via internet display,POKA YOKA management also makes innovative attempts on the machine.Finally,the summary and comparison are made between fully automation and U cell line,the evaluation and KPI are reached to class A in the automotive industry.Finally,the further improvement direction and insufficiency of this thesis are summarized.