Based On The Lean Concept, Z Company Assembly Line Layout Optimization Research

The concept of lean production originated in 1985, from the Massachusetts Institute of Technology(MIT) proposed research project called "International Motor Vehicle Program". Before it appeared, it is summarized as ―Toyota Production System‖(TPS) in Japan.In a narrow band of actual cases, the concept of production line layout is about how to place the production equipment and facilities. General speaking, the line layout design is a more systematic method to utilize the production essential elements men, machines, materials and methods(4M) and promote it to be more productive and effective.Lean Production is a practical science. The Toyota developed plenty of action principles and tools during long time implementing. these mature specific approaches would guide the enterprises production process avoiding the waste, streamlining operations, reducing costs, improving quality and optimizing results of operations.However, in actual practice, many enterprises do not pre-plan the layout of the production system. On the contrary, they directly invest production elements into factory so that resulting in a lot of waste and run the factory costly. This phenomenon is very common in China. In order to illustrate the significant of production line layout optimization in factories through pre-planning. This dissertation will systematically research the current circumstance of Company Z’s layout, meanwhile, it will discuss how to optimize the layout of assembly line in Company Z combined with the principles of lean production and lean logistics benchmark model.In this thesis, it will systematically discuss Z Company assembly line layout optimization method: Two fundamental references- Lean principles and lean logistics benchmarking model; One basis – the current situation of Z layout; Eight steps- the representative products selection, Product Quantity(PQ) analysis and Product Process Route(PR)analysis, process list, seven layout designs selection and optimization, kitting design, distribution design, storage design, the standard work of operation and logistic.With the purpose of ensure the effectiveness of the new assembly line, the author will provide the standard problem solving advices and hope it could be a helpful guide for those manufactory companies.