Application Research Of Lean Production In TY Company

Since implementation of reform and opening-up policies,a rapid development has been achieved in Chinese economy and a considerable progress seen in China manufacturing industry.However,when comparing with western developed countries,some gaps still exist in various aspects.As an important part of China manufacturing industry,textile industry is featured labor-intensive and conforms to the basic realities of our populous country.So,during the past years,textile industry developed fast and became an important part in national revenue of our country.However,along with industrial structure adjustment carried out in China and due to changes in local and foreign economy situation,Chinese textile enterprises have suffered great impact and quite a number of problems and crisis have been revealed.In front of such a situation,textile enterprises must carry out reform and transformation in order to drive the past prosperous and glorious business into the future.The company business operation method introduced in this paper is similar to that in family businesses-a rather arbitrary management mode is adopted and collective wisdom gets no way to play a full role.Since financial crisis in 2008,problems in management and production put the textile dyeing and finishing company with existing various internal and external problems into great trouble for a time.Facing a situation like this,the leader of the company decided to introduce Lean Production concept into the company.In order to ensure a successful Lean Production reform,the author of this paper and the leader of the company studied Lean Production theory,analyzed the company's overall existing production /operation status and problems.It was found that problems of different levels were present in the company's workshop layout,production process and production site management.Toward these problems and company current status,we further carried out reform necessity and feasibility analysis.Finally,we proposed a set of Lean Production optimization steps based on Lean Production theory.The first step is systematic training,including LP concept training for all personnel and LP training for front-line workers.LP concept training for all personnel focuses on LP theory introduction with the purposes of staff mobilization and forming an atmosphere of All People with One Mind for the LP reform of the company;LP training for front-line workers focuses on cultivating front-line workers with LP skills and habits based on LP theory and thus forming a sound basis for subsequent LP renovation activities.The second step is evaluation of company production capacity,with which the company's production capacity can be confirmed for orders received before production starts so that late delivery caused by insufficient production capacity can be avoided and the company image and reputation in market can be improved.The third step is establishing a rational production layout.This step was proposed specifically for the unreasonably distributed production sites in the textile dyeing and finishing company and aiming to eliminate wastes,such as waiting – a time waste caused by unreasonably distributed production layout.The fourth step is implementation of standardized operation and standardization of production process in order to realize on-time production and increase production efficiency.The last step is implementation of 6s production,with which detailed rules have been established for each step of LP production,therefore LP production reform becomes further detailed and definite and can be carried out more smoothly in the company.After a period of LP reform movement in the company,the overall situation has been evidently improved.Afterwards,we carried out quantified improvement assessment for the company.LP reform assessment was carried out in aspects of production delivery rate,warehouse stock and product percent of pass.Moreover,we performed assessment for the company culture change and employee occupational quality improvement.In general,the LP reform can be regarded as a successful try and having reached the expected targets.However,just as emphasized in LP theory,there is not “the best”,but always a better result can be achieved in our future work.LP is an endless reforming process,so it's deemed that TY company will not be always smooth on its road for LP reform and some crooked roads have been passed during its advance in LP reforming process.Although the company on its way for LP reform has made some successes,some old and newly-occurred problems still need to be solved quickly and more improvement is required in the company in coming days.