Research On BCM Product Process Optimization Of Value Stream Analysis In A Company

BCM is the core component of the brake control system applied to high-speed rail vehicle,which is widely used in CRH3 high-speed EMU because of its high integration,compact structure and easy disassembly and assembly.As running distances and uptime increasing,BCM products need to do overhaul,during which the parts easy to aging and wear will be replaced,and its functionality need to be verified again to ensure the safety and stability.The complex overhaul process has gradually led to the extension of the BCM lead time,so shortening BCM lead time is an effective way to improve the production management level of A company,reduce operating costs and ensure high-speed rail transport capacity improvement.Firstly,the paper introduces the development background of A company and the purpose and significance of choosing BCM as the research object,expounds the main problems that company A is facing at present.This is followed by a theoretical description of lean production and lean tools to be used in BCM production process optimization,also a description of the main problems in the BCM production process and the identification of improvement objectives and main methods.Secondly,the BCM products and production process are introduced,through the value stream analysis,the current value stream map of BCM is drawn to find out the imbalance of overhaul demand in the production process,the lead time of the wire harness box is too long,the capacity of key processes is insufficient and the lack of effective control of the field inventory.Then use leveling production,standardized work,TAKT time planning and pull production to study the problems,to work out improvement measures.Finally,verify the implementations of the improvement measures,sum up the improvement results,then the problem of overhaul demand imbalance solved,wire harness box lead time reduced from 10 days to 5-7 days,BCM assembly efficiency increased 29%,the total process time reduced 36%,BCM lead time decreased from 46 days to 22 days.Based on above achievements,the future value stream design is carried out to complete future value stream mapping,which points out the direction for the further improvement of BCM production process.The research applies value stream analysis and other lean tools to the improvement of BCM production process,provides an application example of systematic investigation of complex processes through value stream analysis,and provides reference for the popularization of lean improvement in enterprises.