Production Ramp-Up Management And Bottleneck Solution Of BBAC Assembly Line

As an important joint venture of China’s fifth largest auto group – BAIC Group, the development of Beijing Benz Automotive Co., Ltd has become an important part of the group’s business capacity growth. With the fierce competition in luxury car market segment, only relying on brand advantages is not a way of long-term development. Therefore, BBAC has realized the gap between our major competitors in current HPV(hours per vehicle), and is focusing on production process rebalancing, efficient line side logistics solutions, and sorting organization that adapt to the multi collinear production to enhance the efficiency, in the aim of enhancing competitiveness in the industry.This paper addressesthe information that to identify the factors which cause volume loss during production ramp up, combining industrial engineering theory and methods to analyze the correlation and impact among the various factors; therefore, understanding the dynamic correlation between an operation and the system, so as to accurately identify the major contradiction when solving production ramp up bottle necks and act appropriately to the situation.Production line of BBAC(Beijing Benz Automotive Cooperation) MRA1 Assembly Shop Trim 1 has been selected as the research object to study how to apply the ideas and methods of modern industrial engineering theory and to manageproduction ramp up and to continuously improve bottleneck issues in multi-model mixed production line based on industrial engineering(IE) theory and methodology. The relationship between the process planning and the line side logistics, as well as the sorting organization of multi-model mixed line production during ramp up stage is also the research point. Based on combining theoretical research with practice, a variety of chart analysis methods-- waterfall chart, line chart, histogram and production line rebalance analysis methods-- balance wall, working hour analysis theory and tools are adopted in this paper. How to link the process planning and line side logistic solution with multi model mixed line production sorting organization effective to get a set of bottleneck solutions and achieve lean management, in order to achieve the goal of competitive HPV(hours per vehicle) through systematic, process oriented solution round the key subject of efficiency improvement. The theories and methods, such as Top up, Shopping Cart that addressed in this paper embody the innovation and development of the IE theory usage in the field of automobile production. Therefore, the theories and methods discussed in this paper have a reference value in the process of production efficiency improvement.