Lean Manufacturing Study Of Cap Painting Workshop

Together with increasing competition of automotive industry and higher function & quality expectation from final customer, lower-price-strategy, at the cost of bad quality, to win the market share cannot achieve good result any more. Instead, to deliver high quality product with lower internal production cost to obtain more margin become a major method to reinforce the competence of company and enrich its market value.As one member of automotive parts suppliers, CAP Company also faces the above problems. After conquering those difficulties encountering at the beginning of initiation, CAP have established a certain scale of the company, but at the same time, the bottle neck, such as waste and management inefficiency, appears and become obstacles for company's further development. The new program obtained, delivering painted instrument panel to a foreign company, becomes the opportunity to solve these problems. New product requirement, new customer requirement and new management method need CAP to improve itself, thus the company plan to apply lean manufacturing system in painting workshop to find a development way, fitting for itself and then implement it in the whole company.Considering present Chinese market condition and taking several typical lean manufacturing methods and tools, which are used in a wide scope and the efficiency to improve the production capacity have been proved by many samples, as reference, this thesis tries to summarize a principle to optimize internal process and eliminate waste of the company, which could fit for present condition of the company and be applied internally to improve the management level and core competence. This thesis start from value stream analysis, analyze the whole production process to find the break point of improvement and is conducted by final customer's desire and lean methodology and assisted by many lean production tools. Finally use an actual sample to test the principle summarized, find out the points need improved and feedback to make a circle of continuous improvement.In total, study of lean process based on value stream analysis is a method, which considers the whole production process and finds problem to solve it. By this way, all the root causes will be revealed and avoid those unilateral mistakes if the research is only focus on some specific work stations. As a simple method to improve production process, it also could be taken as reference in many places of automotive industry.