Research Of Lean Production Application On An Assembly Workshop In A Port Machinery Manufacturer

This research is about one of the leading manufacturer among the market,the company undertakes more higher pressure with the global competition in the world during these few years.The costumers request higher product quality,the cost raised rapidly,shorter delivery time and these factors cause the profit of this company is decreased for some years,that is the reason the company was determined to start a Lean improving on one of important workshop and facing the whole factory extension if it is successful.The research is based on this background.Based on the theory of industrial engineering,the on-site improvement process of a general assembly workshop of the company was studied by using the knowledge and methods related to lean production,through investigation and systematic analysis.In the process analysis of products,the process flow is redesigned by using ECRS method.The knowledge of human factors engineering is integrated into layout design and station design.Standard operation instructions were made to ensure the quality of production.Apply 5S and visual management in lean VI design.Through the improvement of system,whole and standardization,we succeeded in realizing the improvement on three major indicators of QCD,shortening the overall production time of products,simplifying unnecessary operation processes and procedures,improving efficiency and reducing production costs.The results of this research are not only reflected in the digital indicators,but also have certain social benefits,creating a QSHE(quality,safety,health,environment)has been comprehensively improved production workshop environment,promoting the occupational health and sustainable development of workshop workers.After the improvement,the visual production status has promoted the level of safe and civilized production,and created a positive and good corporate image.Base on the characteristics of port machinery and equipment manufacturing industry,this research specified steps for the overall lean improvement of workshop,which are implemented step by step.It explores and validates a set of lean improvement processes and steps suitable for port machinery and equipmentmanufacturing industry.It is a useful exploration and summary of how the theory of industrial engineering and lean production can be more effectively landed in Chinese equipment manufacturing enterprises.It has certain significance for the application and promotion of lean improvement in the same type of enterprises.