Design And Simulation Of G Company’s Pull Manufacturing System Based On Lean Production

As market competition intensifies, the manufacturing industry is facing a severe testtask，such as orders change frequently, shorter delivery time and other problems. It is veryimportant to effectively organize production to ensure high-speed and smooth. However, thetraditional mass production methods are no longer suitable for today’s market which meansdiversification, individual needs. Lean production has played a pivotal role in the process ofmanufacturing enterprises. It is an effective measure to introduction lean production toachieve business growth and improve product competitiveness. G company is one of theworld’s leading apparel manufacturer, which headquartered in Hong Kong. It is a typicalgarment manufacturing enterprises, whose customers include TOMMY, POLO, CK, JACKJEANS and other long international and domestic brands. In recent years, as the companydeveloping, management found there is a huge pressure on delivery, manufacturing efficiencyand t inventory reduction. They hope that through the use of lean production methods andtools to optimize existing production systems, in order to maintain the company’s competitiveadvantage.Based on the analysis of G company production system in the production plan,production process, the problems existing in the production control, etc, this paper putforward using lean production tools to optimize the manufacturing system. According to theactual situation of G company manufacturing system, combined with the lean productiontheory framework; A pull manufacturing system which including balanced production, kanbanmanagement and one piece flow was designed. Using arena simulation software to analyzethe simulation modeling for the pull manufacturing system to verify the mode of pullmanufacturing is feasible and effective for G company. Finally, process analyzer was used tooptimize G company’s allocation of resources in each processing units.