The Lean Production Practice In Single Use Intra-Vein Catheter Manufacturing Process

In order to continuously reduce production cost, improve company competitive competency, improve the market competition strength and profit margin, AC company implemented lean production to continuously improve the manufacturing process.This paper studied the manufacturing process of single use intra-vein catheter of AC company. By mapping and analysis of current state value stream, the paper finished the future state value stream, and worked out an improvement plan. The paper is focused on two improvement projects, which are setting up the molding component supermarket, and line balancing of assembly line.In the study of molding component supermarket, the MRP controlled molding component push system is replaced by a supermarket based pull system. By implementing Kanban, the WIP of molding component was dropped from 40 days to 7 days. At the same time, to optimize the supermarket system, reduce the cost increment from more frequent mold change over, the paper also studied the injection mold quick change over.In current state value stream, the assembly line is not balanced. The line balance rate was only 75.9%, and the idle rate of operators was 27.2%. There was a lot of waste on the line capacity and operator capacity. By using the line balance methodology and using ECRS principles, the assembly processes was re-organized, which shortened the manufacturing process, and reduced direct labor headcount.The lean implementation practice reduced the lead time of single use intra-vein catheter by 45%, reduced WIP quantity and WIP days by 50%, reduced total change over time by 12%, and improved the value adding rate from 10% to 18.24% by implementing the molding component supermarket and final assembly line balance. The study has gained very good direct cost saving at the same time.Upon completion of this project, the lean production practice gained primary success in the company, which increased the employee's confidence on lean production implementation and made a good foundation for full scale lean implementation.