Research On Manufacturing Process Optimization Of F Company ADC20 Products Based On Lean Production

With the rapid development of the social economy,the market demand for high-tech products also tends to diversify,the customer’s requirements for product quality are constantly increasing and delivery lead times are constantly shortening.As a high-tech innovative company,Company F is mainly engaged in the design,development and manufacturing of intelligent driving systems and components such as radar sensors,vision cameras and domain controllers.At present,the manufacturing process of Company F has problems such as low productivity and insufficient production capacity,so it is necessary to optimize the manufacturing process of its products in order to reduce costs and increase efficiency and improve the competitiveness of the enterprise.This thesis takes the ADC20 series of products from company F as the object of study and systematically investigates its manufacturing process using a combination of site investigation,value stream mapping theory and linear programming.Firstly,the value stream diagram was used to analyze its product production process and it was found that the existing production process had problems such as long bottleneck process time,unreasonable production line layout and low level of inventory management.Secondly,through the production line balance analysis of ADC20 product,the study concluded that the existing production line is inefficient,the cycle time of each process varies greatly,the production line balance loss rate is high,and the monthly maximum capacity is low to meet the market demand and other problems.For the bottleneck process shown in the value stream diagram,the 5W1 H and ECRS methods were used to improve the operational flow of the bottleneck process,reducing the time from 80 s to 46.93 s and the distance travelled from 260 cm to 105cm;for the production layout and site problems,the supermarket pull system was introduced to reduce the work-in-process inventory on the production line,while the5 S method was used to optimize the tools and personnel on the production site.For the inventory management problem,the ABC classification method was used to classify the inventory,implement targeted management strategies and enhance the flow of information between departments.For the production line balancing problem,the thesis constructs a mathematical model for the ADC20 production line balancing problem based on 0-1 integer programming,and uses LINGO18.0 to find the minimum number of workstations and the shortest production cycle,and compares the production line balancing rate and the production line balancing loss rate as well as the smoothing index before and after optimization.Through the study of the manufacturing process of F’s ADC20 series products,this thesis provides F with implementable methods and suggestions,and also hopes to help manufacturers of similar products in applying lean thinking.There are 31 figures,24 tables and 75 references in this thesis.