The Research Of Cell Manufacturing In BH Factory Based On Lean Thinking

This thesis introduces the basic circumstance of BH company, a small size manufactory, and deeply analyzed the characteristics of the company’s sales market, the mode of the customer procurement, the mode of the supply chain, the production pattern and method. At the same time, the analysis of practical problems in current batch production mode is carried out. Based on the lean thinking, the complete data of a main product in full process, which including purchasing, production and delivery, is recorded and analyzed. By identification of process which can create value for the customer or not, the VSM(Value Stream Mapping) can help us to recognize the effectiveness of the whole process, and show us where is the waste, how to eliminate the waste, at the same time it give us the root cause of operation problem and low effectiveness.Based lean thinking, the batch production method and the production of process layout are considered as the two main cause of the problem. By further comparing the difference between the batch production method and lean production method, and the difference between the process layout and products layout, BH company decide to take the corrective solution including lean manufactory, one piece flow process, supplier chain integration and products layout.In the practice, a deeper analysis is raised to how to carry out lean manufactory process based on the customer’s demand. The method includes U type cell production unit, pull production system, one piece flow process and products layout. And some tools as Heiunka, JIT, Jidoka, Kaisen, Paka-joka are taken according to the properties of the company, to maintain the new production system running smoothly, effectively, and low cost.The small size company in China take wrong ideas and methods during their trying to practice lean manufactory, such as much excessive reliance on tools, pursuit of short term benefits…But in the end, the improvement target can’t be achieved since these tools are rigid, separate, isolated and not suitable to the company. Before using the lean manufactory tools, the company should identify his real process, and find out the valued process, and none valued process. Based on it, the tools are modified and take into practice systematically, well-organized, and with clear purpose. It is a critical point to get success.