Research On Lean Production Help JP Company Improve Capacity Of A Project

Lean Thinking and Lean Production are created by Toyota after World War II.According to the information shown in1990, compare to the same capacity of massproduction system, Toyota just need half of the labor force, half of manufacturing space andhalf of capital investment, less time for developing and research and shorter manufacturingcycle even though their products are highly diversified with low volume. Nowadays, theelectronic manufacturing industry can get less and less profit via its manufacturing service,the whole manufacturing industry in the world recognize the fact that Lean Production canhave more outputs with less inputs,they try to study and follow the Lean Production ofToyota. The companies from Japan to US and from Brazil to Hong Kong China, they arerewarded via implementing Lean Production system. The manufacturing industry in China notonly got the opportunity that China entered WTO, but also faced the challenge of integrationof world economy. Can they lower down manufacturing cost then survive in the red sea?It is such an urgent question for the low-profit earning manufacturing service company how tofulfill customer demand precisely with less labor force, less manufacturing space, less capitalinvestment, shorter manufacturing cycle and less quality defects.This paper listed EMS provider---JP company as an example. Highlighted thebottle-neck problem in their manufacturing area, then applying the core principles of LeanManufacturing to analyze the root cause of the problem and how to improve it. The ECRS(Eliminate, Combine, Rearrange, and Simplify) and5W2H technology were used to combinethe work procedures and reduced waiting time of WIP and eliminate waste. Via analysis of thechangeover process and using the concurrent job method, shortened product changeover leadtime and set up standard changeover process for A product by optimizing internal and externalwork, reduced the uncertainty in the changeover process. This case gives a very good exampleof successful application of Lean Thinking in manufacturing company.