The Synthetic Improvement Research Base On One Stream Production System Of TPS Of Truck Plant Weld Assembling Workshop

The synthetic improvement research based on one stream production system of TPS of weld assembling workshop, is a actual combat task to manage and improve the old workshop in modern ways by using the idea, manner and tool of TPS management. In this article, at first I introduced the TPS management idea, the theory base and technical system of TPS, the two props of TPS----punctuality and automation, one stream production organization of TPS, continual improvement idea, basic improvement tool and its application. I expounded the whole process of synthetic improvement using TPS thought and method in weld assembling workshop .I clarified the economic and social effect of production synthetic improvement based on one stream clear for weld assembling workshop. Weld assembling workshop's synthetic improvement plan was confirmed by explaining the general status explanations and analyzing the existing major problems in the weld assembling workshop implementinghistrogram standard work note and standard work combination schedule , emphatically resolve the problems of changing employee's concept ,improving equipment layout ,optimizing one stream production process ways in the workshop and optimizing staff. We used the and arranged every post's time consume in detail ,made the column graph ,the employees can see and understand that there are time waste and wait in every post . And everyone come to know that the shortage of substance flow staff restrict the implement the target and lead to waiting in the main productive line. Then this ensures the staff optimizing and post adjusting smoothly. In this improvement, we adjusted 88 persons and lowered employee cost 6,6000 Yuan per month. 79,200 Yuan can be saved a year. The personnel resource optimization of everyone having something to do, everything can be done came true actually. We used TPS standard work combination schedule and standard work note, and used IE about the simulating method of equipment layout improvement to improve the equipment layout several times. This improvement reduced more than 53,000 meters of staff moving distance with weight, reduced more than 47,000 seconds of moving time waste. At the same time reduced 38 cross substance flow, lowered 85 percent quality defect caused by conveying in substance flow, for example bump and scratch .The consume of assistant material and staff saved by lowering reworking is up to 50,000 to 70,000 Yuan statistically approximately .60,000 Yuan can be saved every year. To the most important, one stream productive mode of 180 seconds tempo is fulfilled actually .The rate of workshop equipment using goes up 18.5 percent. The productive ability of the line goes up 21 percent. In addition, the workshop balance and punctual production ability are strengthened greatly. The productive line and assembling line are organized in same tempo, WIP and inventory are lowered .WIP are reduced 31,000.the contract occupying fund is up to 1850,000yuan every month .The equipment layout improvement in weld workshop effect the whole factory .It offered a decisive condition to later coating workshop, inner decoration workshop and general assembling workshop to set up a new production organizing mode. And it build up confidence and offered successful experience for the truck work to build a new productive mode and advance TPS overall. We improved substance flow mode and the management of production in the field seriously. We canceled 9 rental transportation vehicles (7 trucks and 2 forklift) instead of 5 vehicles .We canceled 396 transportation work. 1460,000 Yuan are saved per month. 17520,000 Yuan are saved a year. The work area is reduced 478 square meters in the workshop field. The substance flow road was getting through. This made employee worksafely .The area was used to develop the elemental skill training in order to improve the employee's skill and specialty. This offered a powerful safeguard for the workshop to carry out the standard work. The improvement of weld workshop fulfilled all series vehicle 180 seconds tempo productive organization without extra investment. This can reduce cost 31440,000 Yuan a year and the occupying fund 2200,000 Yuan. It creates the condition for coating workshop, inner decoration workshop and general assembling workshop. No doubt this improvement is very successful. It is well known that FAW have studied Japanese TPS three times from later 1970s, for example JIT (just in time). In the early 1990s, FAW Transmission Co. adopted JIT productive mode to practice the operate of one person to multi-machine and one stream productive optimization in improvement constantly line and green work site. But the effect is too little .So many staff of FAW lost confidence to TPS. So did some domestic related trade. The success of this article's project research is powerful support for FAW and those related manufactures that want to adopt and spread TPS method and concept. The success of this research tells us that enterprise manager and operator must manage scientifically, study and operate new methods, new tools, new concepts carefully, stick up, go on step by step, esteem the science management. They can make success without invest or little invest, even though the old enterprise.