Research And Application Of Lean Production In HG Company

With the quick increase of customized requirements, the production mode of large quantity of each lot becomes less and less. Especially with the increasing labor price, there is no advantage of labor cost compared with other countries even including some developed countries in Europe or America. The competitiveness focuses on not only manufacturing cost, but also production flexibility and quick speed of response to customers. Lean production is a kind of revolutionary manufacturing mode which is a good tool for continuous improvement, cost reduction, customer response speeding. HG company is suitable for implementing lean production according to its product series and quantity.In this article, it analyzes and investigates problems of TINGO product in HG company from production layout, production flexibility and in-house material flow, with the use of Lean production theory, such as flow production, SMED as well as the use of study method of lean production combined with IE, expert discussion and comparison technique. In this article, it introduces the study background and the status in domestic and abroad, then it introduces theories and methods of Lean production, such as JIT, flow production, SMED, TQM, TPM and so on. It analyzes the present lean production status of HG company, especially focusing on production layout, production flexibility and in-house material flow. Based on the problems found above, it provides methods for improving and solving these problems making use of lean production theory and IE-related knowledge. In the stage of implementation of Lean production for TINGO in HG, it provides improvement on: 1) U line to replace L line assembly layout, 2) uses SMED to increase production flexibility, 3) and also it gives proposal for in-house material flow improvement. Afterwards, it summarizes the results after improvement, where WIP decreases 35%, production efficiency increases 2.4%. Then it also predicts the result of on-going improvement actions of in-house material flow, material spiders to decrease 40%. Finally, it gives improvement direction for future.This article shows good improvement results with the use of lean production and IE technology on improvement of flow production and production flexibility, which can be a good example and referred by other companies for implementing lean production. Our enterprises should select suitable lean production implementation strategy according to itself status.