Research On Lean Production Improvement In Autoliv Nantong Company

After the World War II, Toyota’s engineers developed a new production system which named lean production. Lean production is a revolutionary change of existing way of mass production, and it combines the advantages of mass production and single piece production, realize the production with small bath, high quality, low cost and short lead time. This kind of production system well fulfilled the Japanese market with different varieties and small batches, then lean production extended to whole Japan, which make the Japan’s economic take-off. Now, more and more enterprises begin to adopt the lean production all over the world, successfully implement of lean production will help the company survive in the competition, and those who cannot fast adapt will weed out by the market competition.Autoliv Nantong factory is an airbag manufacturer, as a member of the auto mobile components supplier, due to the upstream vehicle manufacturers take the lead in implementation of the lean production and the market continues to grow, make the Nantong plant faces increasing pressure: shorter lead time requirements, order changes to small batches and more varieties, delivery frequency speed up gradually and continuous cost reduction. And in another hand, due to the automobile market downturn, from the customer’s cost reduction requirement getting higher and higher. As an airbag manufacturers, we deliver high quality. Product quality is directly related to the survival of passengers in a car accident, requirements for the quality of the products is zero defects.This article is to research Autoliv Nantong company on lean production improvement, based on the analysis of the achievements of factory implementation of lean production at present stage, and the existing problems together with the causes of the problem, based on the proposed improvement program, help the effective implementation of lean production. Firstly this article introduces the research background and advantages of lean production, comprehensive described the development history of lean production both domestic and abroad, and show the present situation of the lean production research and application, and further expounds the related concepts of lean production. Secondly, this article introduces the Nantong factory products and production mode, then analysis the present situation of lean production implementation, show the progress of factory lean production achievements currently, analyzes the existing problems during implement of lean production. Based on the analysis and according to the mother company’s existing lean production system, and combined with the target condition which need to be achieved, to develop an improved lean production system for Nantong factory. The main purpose for this improvement is to clear the Nantong factory with the goal of lean production implementation, which is the most optimal cost according to the number of customer demand and supply for 100% qualified products, in order to achieve this goal, the company need achieve zero defect products, strictly according to the customers’ demand, have excellent team at all levels. Then the company improve the Lean production system to five basic foundations and three pillars, the five basic foundations and three pillars as follow, teamwork, 5 s, standardization, eliminate waste, total productive maintenance, just-in-time production, employee participation, quality first. Again according to the set of the five basic foundations and three pillar setting effect evaluation system, divided into annual performance indicators and self-assessment of two partsThrough the implementation of the lean production system of the five basic foundations and three pillars and effect evaluation system, it can help us systematically achieve the three main objectives, and realize our ultimate goal: to use the most optimal cost according to the customer demand and supply 100% qualified products.