The Lean Project Implement Of The Precious Optical Manufacturing In The TMC Company

TMC is a joint-venture enterprise, the main product is LCD enhance film and optical lens used in projector TV(PTV). The paper is focus on the conversion of the production mode in projector optical lens workshop. Latest year, especially from 2004, as the marketing demand of PTV descended, it impacted the TMC, a main vendor, seriously. In order to reduce the manufacturing cost, face up to the challenge of competition and the market, we decide to implement the lean production mode in manufacturing and logistic department first of all.The paper stand by the lean anticipation, based on several latest managing theory such as the lean manufacturing and IE. we collect the current production date of PTV workshop, draw the current value stream map(VSM), then identify the no valuable added items and the items need to improve by means of valuable analysis technique., then we draw the future value stream map i.e. the improved map. Basic on that, we implement a series of lean production blueprint. Firstly, we optimize the working procedure flow of PTV workshop, making use of the principle ECRS(Eliminate, Combine, Rearrange, Simple) and the technique of 5W2H. simplify the operating step, eliminate no value added conveying, then reduce the remaining time of WIP. Much no valued added operation has been cancelled by means of the procedure flow improvement. For example, the total operating time drop to 60.4% than previous. Secondly, we analyze the logistic path in workshop and improve the layout. Eliminate and Combine the production line, improve the operating design, the new method replaced the solid transportation as a plane one.so eliminate the flection of production line and transportation radically. on the other hand, tighten the equipment layout. By that, the production areas has decrease to 40% than before improvement, Which would be a steady basic to implement the lean thinking of the lowest WIP and no value added transportation. Thirdly, optimize operations and balance the assembly lines, which ensure the line balancing rate increase from 77.7% to 88.3%. Finally, we implement the KanBan pull system, which makes the object of"one flow"into reality.