The Study Of Production Process Optimization In Shanghai Yileng Carrier

Production process optimization is one of the important objectives of manufacturer production continuous improvement. Corporation may increase production efficiency, reduce waste, decrease inventory, increase production capability in great extent, and thereby increase market variation adaptability, enhance corporation competitive strength through production process optimization. Production process importance to corporation is obvious, it not only determine the invested size of fix assets in the initial stage of corporation foundation, but also greatly influence the operation cost of manpower, physical resource etc., and production efficiency, product quality and so on. This thesis analyzed current situation of its production line process and its future optimization issues completely, incorporating with practical situation of centrifugal production line in Shanghai Yileng Carrier.This thesis briefly analyzed facility layout character of commercial air-conditioning—centrifugal chiller, first beginning with the reason of centrifugal production line process optimization of Shanghai Yileng Carrier. Then found out centrifugal production line process issues of Shanghai Yileng Carrier, i.e. production line facility layout issues, job study issues, production capability bottleneck issues and just in time production issues with separately profound analyses, through production capability comparison between Shanghai Yileng Carrier and its main competitor—Trane China.In the aspect of production line facility layout, on the one hand replace unreasonable double U shape workstation layout with single U shape layout, hence reducing on line product transport distance by 25%. On the other hand, increase manufacturing flexibility of double compressor centrifugal production line, enabling to build single compressor centrifugal chiller, whereby reduce waste of leaving fix assets unused, and establish solid physical foundation for production capability improvement of those bottle-neck workstation.In the aspect of job study, carry out optimization measure i.e. elimination, combination (leak test workstation), rearrangement (hydraulic test workstation) for those key bottleneck workstation, with the application of 5W1H (Why, What, Who, Where, When, How) job study measure and production line renovation technology—ECRS (Elimination, Combination, Rearrangement, Simplification). In the mean time, establish fundamental bases for the objective implementation of those production waste elimination, corporate cost audit and cost reduction etc. through job hour ration recertification for each workstation.In the analyses of production capability bottleneck issues, set objective for those several bottleneck workstation, base on the market forecast of centrifugal chiller. Then, find out root cause of bottleneck and put forward pertinent improvement proposal i.e. add tube expanding workstation and vacuum workstation, split refrigerant reclaim job from performance test workstation, replace those low efficiency fixtures and instrument in the performance test workstation, with analyses of outstanding issues of bottleneck workstation item by item, applying optimized production technique and production line balance technique.In the analyses of just in time production issues, analyze several cases that causing waste, with the concept that time saving is basic of just in time production, beginning with the introduction of just in time production. In the mean time, put forward various proposal i.e. parts defect elimination, production flexibility between different workstation, flexible job worker practice, employee multi-skill training and employee respect etc. base on the practical situation in Shanghai Yileng Carrier, so that attain production process synchronization and implement just in time production authentically.We trustfully believe, Shanghai Yileng Carrier can increase production capability & competency and finally retain and develop its leading status in the commercial air conditioning area, only by production line process optimization and continuous ACE improvement.