Small Compressor Workshop Layout Design With Lean Concept

Lean production target to eliminate all kinds of waste. JIT and Kanban are the main aspects of Lean Production. And Lean production raise its requirements for facility design, including: Assembly layout like"liver system", mix production on single line, U type manufacturing line, simple material moving method, one piece flow, Kanban etc..This thesis use SLP method, start from product-quantity and process analysis, decides what production unit needed and how much area each unit need, then calculate the material flow amount among these units, decides the location of these units according to material flow amount and other aspects of their relationship as well as the restriction. As for assembly line design, start with Takt time of customer demand and process study, calculate how many work stations each line need, then use W.B.Helgeson-D.P.Birnie method balance the assembly lines. Make sure each line are well balanced and the load coefficient of two line are 91% and 89% respectively, also the pre-assembly and main assembly are synchronized, each line has the high flexibility.Kanban, as the material transfer control method, is a main tool of Lean Production. The thesis designed two Kanban systems based on the company operation requirement. One is withdrawal Kanban, used for pull material from warehouse, the other one is direct Kanban for self making parts. Then decide where to put the material storage controlled by Kanban, this is part of the facility design. Lean production concepts are implemented in each step of the facility design.Finally, check the results of the facility design from two aspects of lean, they are shop-floor area needed for assembly each product and turn rate. The results show that this facility design is very good.