Practical Application Of Lean Production In Low Frequency Workshop Of Z Company

With the deepening of the process of world economic integration and the rapid and steady development of modern science and technology,the internationalization framework of market economy is becoming more and more perfect,which makes the competitive pressure of traditional manufacturing industry increasingly severe.In order to seize the international market share,manufacturing enterprises all over the world have accelerated to optimize their own management mode and production technology,to enhance the competitiveness of enterprises in the industry,in order to adapt to the fierce market competition environment.Z company is one of the top 100 electronic components in China,which mainly focuses on the development,manufacturing and marketing of electronic components,and has certain product R & D capabilities and independent innovation advantages.At present,Z company mainly carries out production and manufacturing activities with assembly line,so the line balance rate of assembly line is particularly critical to the company's production efficiency,which will directly affect the company's market competitiveness.According to the field investigation in Z company,it is found that the production mode of its magnetic components assembly line is still manual workshop production,the automation degree of the production line is relatively low,the process schedule is not scientific,and the operation of the staff is difficult to standardize;the assembly line is piecewise linear layout,and the corresponding workstations are arranged on both sides in turn.The division of each area of the workshop is not clear,the production line is not changed in time,invalid handling of the long distance and frequent unplanned shutdown,all of which will reduce the production efficiency of the workshop.Therefore,according to the actual situation of the workshop,this paper adopts the management concept of lean production and the optimization tool of industrial engineering,and makes an improvement plan for every practical problem in order to achieve the purpose of optimizing the production efficiency as a whole.Its specific optimization work:(1)Use 6S management thought to clean up the workshop,formulate the standard of material placement,formulate scientific personnel distribution material route and forklift scheduling route,improve the working environment of the workshop,and through training,improve the overall quality of employees,reduce the machine unplanned failure rate;(2)By using process analysis method to analyze the whole production line in detail,and optimize the line pattern of the existing production line,and the two piecewise assembly lines are integrated into the U line which conforms to the single flow production,and the production process is preliminarily adjusted and rearranged to eliminate the waste of handling between workstations,while slowing down the accumulation of in-process products,and gradually forming the production mode of single-piece flow.(3)The stopwatch is used to measure the operation time of each process,find out the bottleneck position and abnormal position of the whole production line,then use video recording equipment to collect video data for the key position of the assembly line,and professional IE analysis software is used to analyze the collected video data in detail,and the corresponding operation program diagram is drawn up,so as to analyze the waiting time of bottleneck workstations and abnormal workstations and the machine vacancy time,and import the automatic instrument,and to simplify,merge,cancel and rearrange each workstation with the ECRS principle,and further optimize the sequence of production process,make operators,products and production machines scientifically combine,improve the scientific structure of the process,reduce the vacancy rate of personnel and machines,and reduce the intensity of the work of employees.Finally,the ED simulation technology is used to simulate the production efficiency of the assembly line of the production workshop under the optimization scheme,and the assembly line balancing rate is chosen as the evaluation index.Finally,the simulation results confirm the feasibility and applicability of the above optimization scheme.