| Aiming at the characteristics of the customization design with multi-varieties and small-batch environment , how to short lead time ,eliminate waste in production process and reduction on cost basing on MRP(SAP) system and JIT thinking , which is a hot issue topic.The paper analyse the problem of waste on copper wire in motor production process . The cost of copper wire is nearly 25% of motor materials . Also do some research on improvement of SAP master data , BOM engineering , master production plan , tools& jig , supply chain management . Got the outstanding performance on waste reduction of copper wire , quality improvement and shorting lead time .The content and achievement of paper as following :Firstly , analyse the waste of copper wire on winding coils production .which focus on : 1) waste for unreasonable designing on material master data and engineering BOM. 2)waste for coils overproduction .3)waste for changeover so often. 4)waste for unreasonable logistic process such as missing parts , unreasonable purchasing solution and quality problem, etc..Secondly, Aiming at these problems , do some improvement action on engineering data designing , production plan , tools & jig and supply chain management , detail as following :1)Set customization engineering on material master data and BOM for copper wire .2)Run MRP in separated step , discriminate different production process for purchase plan and production plan to short lead time for delivery on time.3)Eliminate the waste for winding coils overproduction basing POKO-YOKE & SMED.4)Optimization on supply chain management , improvement on copper wire availability and reduce inventory of copper wire .5)Simulation program apply for select optimization solution on purchasing copper wire to reduce waste .The research conclusion is accepted, already taken into production practice to get good performance ,save economic value more than 1 million RMB directly . At same time , which is good experience to share with similar manufacturing . |
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