Container Production Efficiency Promotion Research Based On TPS

Container as the major large cargo holder helps greatly to build the combined transportation system all over the world through these decades of years’ development.With the increase of container transportation,container manufacturing industry flourishes booming explosion.CIMC as one of the main container manufactures produce half containers of the whole market.The world economy develops very quickly since year 2008.In China,with the quick economy development,the increasing model also changed and upgraded.To achieve the upgrading,CIMC start to carry out TPS which is called ONE since year 2008.TJCC,as one of the main production factory of CIMC group took part in this ONE upgrading reform.The key of manufacturing company is product efficiency.The continuous increase of product efficiency can increase company’s core competitiveness which can reduce cost pressure.This topic based on the research of the container assembly line.We measure the assembly line production rhythm so as to get the base datum of assembly line balancing rate and manpower hour per unit.With the help of TPS theory and IE,we do research about the line balancing so as to improve the product efficiency.There are three line balancing problems to be solved in this research:1.Analysis the work station layout to get the minim assembly line production rhythm.Measure the working rhythm to find the bottleneck station.Using TOC to get the better Design of Assembly Line in the Overall Production,through work man-hour analysis and take measures to reduce the product rhythm of bottleneck station.2.To find the highest main assembly line balance rate.Taking the condition of operation sequence,fixture and equipment,workers into consideration,we tried to get the highest main assembly line balance rate through flow process analysis,operation analysis,work motion analysis and AMT.Eliminate the ineffective operation,barely operations,reduce production hours and operating personnel.3.Based on the production line characteristics,we use heuristic algorithm to find the best work station layout and propose the innovation technique scheme about two 20’ containers synchronous moving,gives the technological transformation plan of the existing production line.Through the first two steps of improvement,The total assembly line single-shift production capacity increase of 15.7%,line balance increased from 73.2% to 82.4%,according to the layout of the workplace given in question 3(the assembly line needs to be modified),The line balance can be increased to 89.9%,the number of operators can be reduced by 20.5%,and the number of stations can be reduced by 33%.This will give some reference for the analysis and improvement for discontinuous rhythm assembly line.