Production Process Optimization In KB Company Based On Lean Thinking

With the continuous development of market economy, the competition among enterprises becomes more and more fierce. Modern enterprise has pursued the goal to capture the market quickly by improving their core competitiveness and adapting to the changing market. Although KB Company is the industry leader, she also feel great pressure as other manufacturing companies, while other competitors are catching up, customers are shorten lead times increasingly and constant price or lower price requirements. Therefore, it’s urgent and prior task for KB Company management to improve internal production processes, implement lean production management.The selected research subject of this article is to research to optimize the production process in KB Company. The researched value object is CCBII product. Research purpose is to assist enterprise to seek production operations breakthrough to have process improvement, cost reduction and efficiency enhancement, to assist enterprises to improve their competitiveness in the increasing fierce market competition. In this paper, the value stream mapping was used for determining the value of the object. Research team observed in the workshop as per the outline of its actual production processes, asked for data record, draw the current value stream mapping, analyze the value added and non-value added step among the value flow process, look for improvement, draw a future value stream mapping, define value stream improvement plan, e.g. layout optimization, logistics optimization, equipment optimization, implement quick change(SMED) and Kanban management etc., discuss improvement plan, simulate the planned process, and eventually establish the standardized operation process based on lean thinking, shorten the delivery cycle from 38.3 days to 18 days. At the same time, this optimization project improved the production line balancing rate, reduced walking distance by nearly 50%, reduced the number of direct labors, decreased 1st quality failure rate from 5.04% to 1%, saved the production area, increased productivity, reduced the WIP inventory and so on.This paper described a study of lean thinking as the core of the production process optimization, analysis, implementation process, which has the common features and universality as in regular improvements, it meets the development requirements of modern enterprise to develop lean management, and it is the solid foundation for enterprise to achieve long-term development. Meanwhile, the paper also incorporated KB Company their own characteristics, learned and applied, made the appropriate modifications, finally achieved substantial improvement. I hope this article could be helpful for those who want to seek and explore the production process optimization companies to bring some help and have some significance.