Lean Production Management In The Electronics Manufacturing Services (ems) Companies

Facing the current financial crisis, the international economy met the challenge of more customized product demand and lower market demand, EMS (electronic manufacturing service) industry suffered serious attack and impact. Lean manufacturing is one of the initiatives that many major businesses have been trying to adopt in order to remain competitive in an increasingly global market. The focus of the approach is on cost reduction by eliminating non-value-added activities and continuous improvement.Lean manufacturing adopts lean theory and method to eliminate all non-value-added during operating activities. It initiates appropriate automation to improve the flexibility of production system, emphasizes team spirit and continues improvement, carries on JIT (Just in Time) based on customer orientation to achieve high profit and keep low cost. Lean production is composed of JIT, pull production– Kanban, appropriate automation, balanced production, 5S and multi-skilled operators to form overall first floor improvement system.This thesis's background is based on the current EMS (electronic manufacturing service) industries'flourishing development. To enhance their competitions in market, purchase the good way of reducing high inventory, high manufacturing cost and improving production efficiency. Implementing the lean production will be the most important task at these enterprises. The subject of this thesis focuses on the typical EMS company– production management of A Electronic Company. Through studying and analyzing production process and mode of EMS lean manufacturing, this thesis tries to pursue inventory reduction and production cost control as a takeoff depending on theory and method of lean production, find and remove non-value-added and waste activities, resource and processes. On the base of carrying out the value flow studied, the thesis analyzes the current status, find the key problems and make the effective solutions by scientific management knowledge. And design the detailed solution and improvement plan, and describe the future status. Make measurement performance and objectives and system to monitor lean production for realizing the final goal of the high efficiency with lower cost. Applying electric– Kanban system to realize pull JIT system and reduce high inventory, reduce the various wastes and non-value added activities caused by materials handling to succeed in the integration between material flow, information flow and cash flow. The studied result of this thesis shows how to apply lean management tools and methods to solve the current important problems of EMS enterprises (such as low production efficiency, low capacity utilization rate, high manufacturing cost, high inventory and delivery issues, etc.), and how to have the strong competition with the high efficiency with low cost in the market. It is very valuable for EMS industries'operation.This thesis is divided into the five parts, the first part is illustrating the background, subject, objectives and content of the thesis. The second part is setting forth the relative theory, tools and methods of lean manufacturing management. The third part is studying and analyzing the current EMS enterprises'lean production system. Apply the value stream mapping theory to analyze the current status, find the important problems which need to be solved urgently and the kinds of waste in production and bring out the effective solutions and actions based on scientific management knowledge, and conduct to implement improvement actions. The forth part is studying on how to use electric– Kanban system to reduce high inventory and the wastes happened in material handling to realize JIT production mode The fifth part is focusing on improving the effective working time and cut down the all wastes during product manufacturing process to carry out the high efficiency with low cost in operation. Create and complete the measurement system for keep lean production system running smoothly and make sure the enterprise developing continuously to meet customer demand .The final part is summarizing the success and study result and spread the lean production to the similar EMS enterprises.