Production Process Improvement Of QPZY Product Based On Value Stream Mapping

Value Stream Mapping Analysis is an effective tool for identifying waste. Using this tool effectively can identify the existing production process waste. Combining IE principles with methods in the improvement of waste areas can achieve the purpose of eliminating waste.B company is a manufacturer of large state-owned auto parts company. It is the largest parts supplier for SGMW.Co., Ltd. Its main products are QPZY, HPZY, CQ, ZDQ, YB, CL and so on. For the QPZY with streamlined production occupy 75% or more in the finished products, the QPZY was chose as the object of the production process.In this thesis, IE theories as the basis, the Value Stream Mapping as research tool, the QPZY product as the research object, proposed and implemented a complete lean manufacturing improvement program to settle down the problems identified in production process. The research includes: First, the product family was selected. Collecting materials about the current product throughout the production process flow and information flow. Identifing the delivery method,the path, and the relevant waste, drawing a " Status Value Stream Map" based on the overall analysis of the production line then. Second, drawing the "Future Value Stream Map" combined the design criteria of future value map with the overall analysis of the production line. Third, the production process of QPZY improvement plan was developed and implemented in terms of production line layout, logistics, route, line balance rate for the waste. IE techniques were used. Such as the 5W2H question technology, ECRS principle, ect. Fourth, the implementation of the evaluation and analysis.Results of the program implementation show that several major production indicators have improved. Reduction in station operations, from the original 12 stations to 10 stations now; Reduction in station operators, from the original 21 manpower 17 manpower now; Increase in line balance rate, from the original 77.04% to 90.20% now; Shorten in the delivery cycle, from original 3.06 days to 1.03 days now.In addition, productive area was reduced by 36.08%; Material handling distance was shorten by 70% approximately.