Research On A Company’s D Plant Paint Shop Sealing Line Production Capacity Improvement

With the rapidly information development,there has more and more requirements on various product models,customized categories and self-selected functions with shorter life cycle and delivery time.Manufactures has bigger and bigger pressure on lower price and cost.They need solutions to increase production capacity with lowest cost.IE theory and methods already successfully applied in many kinds of companies to increase their capacity.Especially Toyota Motor Corporation in Japan after the World War Ⅱ through the creative application of lean Production way comprehensively improved and optimized the production process,material planning,logistics supply system design,workshop layout design in a system way,it can maximize reducing all kinds of waste in the production process and increase UPH.It has been approved that it works.Through IE and lean management tools to increase Paint shop sealing line capacity is the target.First,we need to know the current situation and problem in the sealing line which is blocking us to reach 40 UPH through IE program analysis;Then we could use the Stop Watch to make time study of each station and calculate the current production cycle time and line Capacity,line balancing rate.The purpose is to identify bottlenecks,which are the blocks of the capacity and production efficiency increase.Second,analysis all bottleneck stations’ time content and operation processes,using the"5W1H" questioning method to analysis the bottleneck problems,such as the waste of non-value activities,waiting time,too much brushing glue,repair glue,etc.Third,use the ECRS principle to improve the bottleneck stations and reduce operation time,including the following improvement scheme:Fourth,for too much time on gluing and brushing,we are going to improve the gluing process and sealant parameter,nozzle size and structure to eliminate all unnecessary brushing to increase operation efficiency;Fifth,re-allocation work contents with ECRS principle after eliminating waste,separate current work into small pieces and balance to neighbors.It achieved hourly output 40 units.Sealing line capacity increasing is the objective and focus.The paper had systematically carried out layout/headcount/process/tool study,which used capacity improvement related work-study,line balancing methods.It approved the IE methods’ effectiveness and systematic.It can be the reference of other lines and shops for their production capacity improvement.