The Research Of Application About Lean Production On The Outsourcing Workshop

Nowadays economy has developed fiercely in the world,the market competition and market revolution change more quickly,the value of consumer has structurally taken place,variety and characteristic has turned out.This situation decide the modern enterprise has to adopt an accommodative way to decrease cost of the product,it reply to the market environment effectively,quickly have a reaction, master the customer's need in time and availably produce and provide products which makes customer's satisfied.Outsource workshop is the window of international cooperation of the company, directly participating in producing an aviation product.In recent years,business of outsource grow quickly along with the extending realm and scale,the old method of production can't adapt to the demand of outsource.The confliction between the customer and the producing ability become outstanding day by day.These conflictions mainly reflect at the following aspects:firstly,Plan Economy system last in a long period of time,adopting large quantity stile of production result in the long period of production,overstock products can't meet the customer;secondly,the large production and unbalanced production become many production bottlenecks, low use of asset,the products don't have the competitive ability;Third,under the influence of Plan Economy,people pay attention to more mission and sales income, they don't pay attention to the period,quality,cost and consign etc.there is not motive which keeps on an improvement.Ⅰ.The purpose of topic researches:A.Promote the staff occupation manners.Promoting the person's quality educate an excellent community which understand management,improvement, having manners for the enterprise.B.Decrease the product cost.Lean production is able to reduce free time. homework to cut over time,stock,inferior product,time on designing a product. producing period,and thus decrease the cost of the product effectively.C.Shorten the production period of product.Adopt 6S management,production synchronize,production well balanced,production gentle and just in time production etc,which shorten producing period of production.D.Increase the quality of the product.Adopt 6 Xi Ge Ma managements to strengthen the quality of product.E.Increase the satisfaction of the delivery.Effectively shorten the production period of the product,product the thing that make the customer satisfied and providing a high-quality after-sales service,then promoting satisfaction of delivery.Outsource department is the window of international cooperation of company, asking for help of the starting of the EU cooperation item and making the Lean Production of outsource department from learning conception to practical.Well combining the actual circumstance.Employing the person who is concern about the customer,period,quality,cost and delivery,the lean production is driving by the five management,adopting the experimental unit in advance and gradually enters propulsive of strategy,namely from point to line,again from line to aspect,finally becoming a system.The point is namely using the experimental unit as a beginning, from studying,practicing,investigating,summary the experience of lean production;then remit the points into line,extension the scope of experimental unit, gradually pushing forward of other work segment;in the end building a kind of valid improvement mechanism to drive the whole work department to lean production.Ⅱ.The present management condition carried out by outsourcing workshop.A.Analysis the staffActively participating in the factory various consciousnesses which improve an activity not strongly;executing system badly;unbalanced technical ability between the staff;the technical workers have the bad comprehensive ability;new technical workers have bad skills.B.Analysis the cost of productThick process using machine to clip razor blade;The knife has bad usage,the old razor blade have no reasonable making use of again;choosing knives not scientific;Parts that need to repair didn't handle in time;the Producing plan don't complete;The period of the spare parts processes are very long.The factory and the office district waste electricity seriouslyC.Analysis the quality of the productsPersonnel problem;spare parts transformed;The knife has bad quality;The equipments broke down.Analysis the product's deliveryDelay the date of the delivery,which make the customer unsatisfied.D.Analysis the period of the productionSome pieces of parts have a very long period;Equipments utilized lowly;the efficiency of producing spare parts;the work packs checked a long period;Parts that need to repair didn't handle in time.E.Analysis the management problems of the outsourceTechnical works are partial young and the ability to comprehend the craft document isn't deeply.The crafts idealized too much,without jointed the practice; Product parts usually depend on the spare parts quality to promise the quality,and seldom add to craft document,not forming knowledge management;Producing plan uncompleted;Parts that need to repair didn't handle in time;he batch management doesn't arrive;The equipments utilization is low;Producing unbalanced; The producing spot management have no preface,6S management implementation is not workable,the tool that goes a management is not giving back and influence the period of the spare parts.Technical workers don't have passion to work.Ⅲ.Establishing available project to improve lean productionOutsource department improve itself from the public opinion,the training and the statistics of present condition,making a target and implement,finally carry on an effect valuation,walked through a more completed stage propulsion process.In this process,backlog in great quantities precious experiences has already become and applicable lean production mode.A.Making a goal,measuring the present conditionLean production must improved from measurement as a beginning,learning how to measure that let us know what level we are in currently,comparing with the nations and the domestic line,then we can find out a margin.The target of our lean production is to contract this margin and surpass them.But shortening the margin need to work out a series existing problems,this process carries out gradually,must pass every goal.Therefore measurement is also one of the most difficult problems that the bad management company.In outsource department management system producing spots usually pay more attention to the mission of completion, and less concern of the important target,such as production period,producing level, the cost of knife consumption etc.,and all of these facts have a closed relationship with the outsource departments,thus also reflected the execution not enough.B.Under the instruction of the teacher in lean production,wreath form piece work part individually the measurement of the production level from the following ways such as,quality,cost,period,delivery these five aspects.Pass present condition covariance,discovered a true circumstance:the average production period has 50 days,the production period of the advanced wreath department parts should be within 10 days;The ratio between month production and month delivery is 3.99,this target reflected the product ability on line;The knife consumption has annually take up 15%of the sale cost;Discarding an article rate, reporting rate and returning rate isl.10%,1.64%,7.60%respectively.C.Setting up a target according to the present conditionThe enactment of target in the whole lean production activity plays a very important role,all improvements should surrounded by the target to carry out. Because at the beginning of the improved stage,the improvement space is opposite bigger,generally can attain nearly 50%,therefore improving the range of the enactment should be higher.In the meantime,the target enactment can also reflect the governor improving decision.As a foundation to investigate the quality,cost,delivery,period,the work department set a stage target for the machine,namely:Production period shortens 40%and decline till 18 days;Cost two targets lower 25%respectively,the month production number and the month to delivery number decline to 2.75;The knife consumption rate decline to 8%;Discarding article rate,reporting rate and returning rate decline to 25%respectively,attain 0.9%,1.23%,5.7%;delivery the target 100%.Having an improvement target,the work department can accord to the data to compare,discovering a margin,analysis the reason,improving the implement.When the target which need to improve has a stable period,then setting up a new high target,IE improve continuously under driving.D.Setting up a team,improving the implement.Lean Production improved with team mode to open an exhibition.At the beginning,the work department established the work team,drawing up the improvement target of work department from the quality,cost,period,delivery etc. To improve themselves,and building a team that is responsible for leading a long the whole production process.As lean revolution developed deeply,work department investigates the current condition as a foundation,finding out each kind of key problem,further to analysis the target,setting up the team respectively including technical worker and master,which became a pyramid organization,which implement lean revolution.Under the arrangement of workshop,the work segment is surrounded by the quality,cost,delivery,period etc.Pass from one segment to other team.As the analysis of the target,establishing a team,Such as the craft team,turn over improvement team,examination improvement team,equipments improvement team.The improvement mission is from basic level improvement team to complete of.Justly because of the target from the top to the bottom,improvement team also surround all levels target to set up,therefore can promise contribution of the whole target on every basic aspect,thus promising efficiency improvement.Ⅳ.Improving the implements about targetsAfter all levels improvement team setting up,each grass-roots team adopt various methods and aims,guiding the whole staff to participate a lean revolution.Building up rational suggestion process,which let each employee speak out the problem that affected their work.The work department governor's resolve these problems.Bring the lean revolution into the daily investigation routine, the second line managers and the first line workers at least finish one project a month. Main pay attention to the project that is done by the workers,at the meantime put in the investigation routine at the meantime.Till now:The work department totally completes the lean revolution projects item at 196,involving production,technique,quality,cost,6 S management...etc., totally participating 281 people,among them the first line worker has 155 workers, the second line has 126 governors and personal improvement item at most up to 16.Expand the experimental unit,remit the points into line. According to implement of the outsource workshop,the work department are learning about wreath production mode to improve lean production.At the beginning of this year,the workshop established three experimental units again,and each experimental unit has finished the target of this year.The whole year,the leaders and the lean masters come to the spot to instruct.The three experimental steam finish the whole project,establish lean target,analysis the collecting data etc. Some suggestions concerning to the work department one lean productionAccording to the general way of Company,we have already walked through the principle and experimental extension.We are under the stage of large producing soldier article production.In this year,we are planning to expand all factories which build up a set of standard lean revolution system.In the meantime,wreath parts department will continue at the instruction of the master,push lean engineering to a deeply extent,in order to provide more experiences and effective improvements...