Lean Production Application In Heat Exchanger Production Process Optimization

As the continuously progress of globalization of the supply chain,manufacturing industry is facing increasing pressure from the global competitive,how to achieve business transformation to adapt to the rapid development and changes in market demand has become a key question.Therefore,the promotion of lean production system in our country becomes so exceptionally necessary.This paper use AL brazed plate heat exchanger production workshop as the background,the main purpose of apply lean production is to reduce production lead time,meet customer various delivery requirements,while reducing the company's operating costs and boost profits.Its main contents are as follows:First,production system analysis use process analysis,work measurement and VSM analysis on overall process for deep dive in the process work elements to identify the 7 waste in the production process.Second,improve the production process within the cell.Using the combined principle of ECRS and 5W1 H for process flow analyze,identify and eliminates waiting,inventory and transportation waste by establish single piece flow which help to achieve WIP reduction and production lead times shorten.Third,improve the production process between cells.By establish the Kanban pull system,effectively eliminating the overproduction,waiting and inventory waste between production processes.Fourth,improve the whole workshop process in big picture.Through re-layout,effectively reducing the overall internal material transportation process and improve space utilization.After the implementation of lean production program,the heat exchanger manufacturing workshop achieved the result of 79% total lead time reduction and almost double the ITO which is a great kick off for driving lean transformation in AL as well as a solid foundation for promotion lean production in whole company scale.