Research On Lean Production Implementation Of HF Dyeing Company Based On Value Stream Mapping

With the development of economic globalization and the promotion of Internet, diversification demand for products is growing. Quality, price and delivery requirements have been important competitive factors. Manufacturing industry is at stake with opportunities and threats. Nowadays, as one of the manufacturing industry, dyeing industry still has many problems in production management, product delivery period and other aspects. Facing the global competition environment, dyeing enterprises must introduce lean production methods to change the status quo.It has been proved by domestic and foreign cases, that lean production is an advanced management mode applicable to modern manufacturing enterprises. However, in the field of dyeing production, there are few researches on lean production. Based on the theory of value stream, this paper focused on a specific dyeing enterprise, explored specific ways to implement lean production, and provided reference for other dyeing enterprises on their lean production implementation.After depth study on the theory of lean production and value stream mapping, this paper took Z dyeing sub-factory of HF dyeing limited company as the research object, and analyzed the value stream of specific dyeing product (here means polyester/cotton blended product simply called product X)through on-the-spot investigation, depth interview and other research methods. After that, an improvement scheme was presented to implement lean production. This study mainly focused on exploring concrete ways to improve product X’s value stream, and proposed an improvement scheme having some intended effects. Firstly, based on on-the-ground research, this paper elaborated the actual production situation of Z dyeing sub-factory, made present value stream map of product X, and found five wastes by analyzing the map. Then the main reason of wastes was discussed and determining takt time, achieving pull production, balancing production and other plan was present to improve the value stream of product X. The improvement scheme helped eliminate the wastes of overproduction, unnecessary inventory, waiting, transportation and unnecessary motion in Z dyeing sub-factory. Finally, product delivery cycle would be shortened by 68.59% and WIP inventory was reduced to 44,000 meters.