Lean Production Research Of UE Company New Production Line-PFMEA And Value Stream Analysis

In the current market,the development of the automotive industry has entered a stage of steady growth.Auto parts companies that have been born around automakers are also increasing.How to use less investment to get quality qualified products is the focus of this harsh competition."Reducing costs and improving efficiency" has become the most considered issue for all companies at this stage.This paper takes UE's new production line as the research object,and conducts lean research through PFMEA(Process Failure Mode And Effect Analysis)and value stream analysis.Firstly,the production line layout and process flow are briefly introduced,the failure modes of each station are collected,and the inter-departmental functional teams are established to obtain the corresponding failure impact results.Based on the fuzzy hierarchy theory modeling,the evaluation expert constructs the judgment matrix according to the three influencing factors,namely the occurrence(O),the severity(S)and the detection(D),and performs consistency test,then calculate the weights of the evaluation indicators and the participating experts,get the final weight vector of the expert and each indicator,and establish a fuzzy evaluation matrix based on the five evaluation levels,calculate the final fuzzy comprehensive evaluation conclusion level value for each failure mode,for the failure mode ranking of each station with a grade value greater than 3,focus on the failure mode with high conclusion grade value,so as to facilitate the second-line debugging and the later maintenance of the whole line sort of production,and also greatly improve the defect detection efficiency.Finally,according to the production status of production line,the value flow diagram is drawn from the two aspects of logistics and information flow to the bottleneck station,and the value of the target production line and the non-value added time are analyzed.Analysis the results of the bottleneck station combined with PFMEA,make reasonable improvement measures for the failure mode with the highest failure rating level,adjust the takt time,and increase the value-added ratio.The comprehensive analysis shows that the non-value added time(UT)in the running station is reduced from the original 120s to 75s,the non-value added time(UT)in the test station is reduced from the original 125s to 87s,the non-value added time(UT)in the assembly station is reduced from the original 120s to 68s,the value-added ratio increased from 14.2%before the improvement to 17.74%,and the improvement effect was obvious.