Research On Efficiency Improvement And Lean-oriented Production Mode In LCD Monitor Assembly Plant

The LCD(Liquid Crystal Display) Monitor assembly plantof F group C company is one of the top three assembly plantin the world which is a mainly responsible for LCD OEM.The plant produces in flow line.The terminal customer’s demand change constantly to diversification, which cause that LCD Monitor production alsograduallydevelop in the direction of more varieties and smaller batch.In the production model of flow line theproduction efficiency is declining and theprofits is gradually reduced.Faced with such pressing situation, improve the production efficiency of the plant is an urgent problem to be solved.In the problem analysis phase,the value stream mapping is drawn;Through the analysis, the key problem affects the efficiency of the plant is that theUPPH(units per person hour)of assembly section is low.After analysis, Cell production will be implemented.Then Analytic hierarchy process methodand fuzzy comprehensive evaluation method are used to find which is most usefull of the there patterns which contains Roof cell production mode, Rabbit type cell production mode and Partitional cell production mode.In the problem solving phase, start Partitionalcell production with OEE and Line Balance to optimize the plant efficiency.First the present situation of the assembly line is analyzed.Then optimize the assembly line process to determine the cell location number with the optimization principle of Cell production;According to the actual situation of work posture, using the OEE method to study sitting posture, standing posture and mixed posture operation;According to the knowledge of human factors and the actual product situation the worktable is designed and the design about efficiency improvement was accepted;In the materialarrangementdesigning phase,follow the arrangementprinciples,and with the connecting value analysis method find out priority arrangement of materials,after thatmake the materials arranged. And then caculate the number of cells which can meet the customer demand.Finally,with OEE method finding out that feedingcan’t meet the demand of assembly line.Through designing new material feeding,the working efficiency is promoted,and the problem is solved.At last,DEA(Data Envelopment Analysis) methodwhich contains C2 R model and C2GS2 model is used to validate and appraise the improvement, confirm the improvement is effective, and it has reached the expected objective.