Production Process Improvement Of The RLPB Products Based On Value Stream Mapping

RD company main business is researching, developing, manufacturing and distributing high Power Amplifier (hereinafter PA) in the mobile communication equipment.Taking the lean production process of the RLPB products as a typical case, the author analyses customer requirements, products logistics, main suppliers and information flow by introducing the method of value stream mapping (hereinafter VSM), and then recognizes wasted items and items need to be improved in current production process. On basis of above analysis, the author draws the VSM diagram chart of future production process, that is, the improved one.From the angle of lean production, the author works out and has implemented a whole set of plans to improve lean production by using lean production and industrial engineering (hereinafter IE) tools comprehensively. Firstly, the author analyses the process flow of product, and uses ECRS (Eliminate, Combine Rearrange, simplify) principle and 5W2H methods to simplify steps of operation, improve operating methods, eliminate unnecessary transportation, and thus reduce waiting time of WIP during the process. Through improving various process flow, massive non-value added motions are eliminated and the operating time has shorten for 22.2%.Secondly, the logistic path is analyzed, the workshop layout has been improved. After above improvement, the entire production region reduces 33.3%, and total logistic path shortens for 68%. Meanwhile the workshop's assembly production line has been balanced transformed ,and the number of operators reduced from original 24 to 16. On the basis of above improvement, the Kanban system is applied and the"one flow"production pattern is realized.Through implementating production process improvement plan, the indexs of the RLPB's lean production are enhanced. For example, Lead Time is reduced from 40 days to 29 days, the MCE( Manufacturing Cycle Efficiency) is enhanced 21.4% of original, and First Time Through and the quality stability are highly boosted.