Research On Production Process Optimization Of H Enterprise Based On Value Stream Map Method

Lean production has been regarded as the most advanced production way from its birth till now.It aims at optimizing process and eliminating non-value added operations,and improving production efficiency at last.As a special tool in all lean tools,Value Stream Map(VSM)is an important and efficient way for process optimization.VSM describes current process by using vivid figures.It can help to find wastes in process and analyze them,so we can get a more efficient value stream future map.As continuous improvement goes on,production way will be optimized and efficiency will be improved.In the end,all the improvement activities will bring stronger competitiveness.H corporation is a chemical enterprise focus on producing adhesive.It holds a high reputation in the adhesive industry for its advanced technologies and world class quality.Thus H corporation owns a high market percentage.But when it comes to production process,there is still a long way to realize lean production for H corporation.This thesis mainly talks about AF series’ production process improvement by using VSM as the primary method.Firstly,we use current VSM to describe and analyze the process of AF series.We can easily find the problems or wastes as below:more WIP,lower OEE,longer changeover time.Then find the reason of these problems.Warehouse operators prepare raw materials a shift earlier and current layout limitation cause the more WIP problem.TPM activities cannot be implemented in an efficient way cause lower OEE.Current changeover process still needs to be improved because of longer changeover time.After analyzing the reason of those problems,we assess the possibility to improve them,design KAIZEN goals and draw future VSM.With the guidance of future VSM,we can design process improvement plan.Firstly,eliminate 8 hours WIP between nozzle assembly station and filling station by using one piece flow method.Secondly,optimize warehouse material preparation process by using one batch flow concept.We can realize pull production way between warehouse and mixing workshop.Thirdly,reduce downtime by using TPM based on MES.TPM activities can be implemented on MES.We need to link TPM with MES PO at first.Fourthly,add more available time by analyzing and optimizing current changeover process.By designing and carrying out all improvement plans,we can reduce WIP in worksite,reduce changeover time and breakdown time and improve OEE in the end.The thesis innovative points are as below.On the one hand,according to the characteristics of chemical industry,we come up with the concept of one batch flow.It can realize pull production way between mixing workshop and warehouse,so we can reduce WIP and ensure smooth material flow.On the other hand,we design TPM based on MES.TPM is contact with PO release,so operators must do TPM activity before PO start.Thus we can prevent machine breakdown in advance,and improve OEE at last.