Research On Production Process Improvement Of A Company Based On Value Stream Map Technology

With the continuous growth of economic in China,the labor cost,supplier chain cost and material cost are continuous increased in local industry.The cost increase are more serious in Eastern cities where the economic is more advanced.In the mean time,huge amount of local company are appeared and joined the competition.Also there are lot of companies from southeast of Asia such as Malaysia,Indonesia,Vietnam,India whose manufacturing cost and labor cost are much lower than China.Obviously we can image that the competition in industry will be more and more serious than the past.In this case the manufacturing plant in China have to continuously improve themselves to reduce the production cost in order to survive in the market.Lean manufacturing is an effective and useful tool for shop floor management.It can eliminate the waste during production to reduce production cost.The article was started at the instruction of back ground and situation of company.Then it introduced the internal and external research status of lean manufacturing and value stream map after deep study and research.After that,it take the example of A company and introduced the organization and manufacturing process of current products.After finished the VSM of current situation using lean manufacturing methodology,it was found that there were lot of problems in our production such as too much WIP,long and useless working steps,too much setup time,too much rework,unreasonable layout and material flow,low manufacturing efficiency,bottle neck at certain workstation.As the head of industry engineering department,the author coordinated the recourses of relevant department and started the lean project based on VSM analysis.The problem were finally solved by improvement of machining process,improvement of fixture and clamps,improvement of pre-setup procedure in machining department,break down and do time study on polishing after harden step,re-layout,FIFO and milk.As the result,the manufacturing problems and production KPI are successfully improved.After the improvement based on VSM analyze,the value added ratio was increased by 15.4%,WIP reduced by 41.5%,line balance rate increased by 23.2%.The other KPI such as capacity of bottle neck,production cost and rework rate are also got improved.