The Improved Research On An Electric Heater Die Casting Components Production Workshop

Combining the practice in an electric heater components die-casting workshop with the comprehensive use of related knowledge of lean production,industrial engineering and system engineering,a systematic analysis on this workshop is made.Based on the analysis above,the improvement projects are identified,the improvements schemes of the improvement projects are proposed and carried out.The main contents of this paper are as follows:1.Systematic analysis on shop floor problems and identify improvement projects.With the comprehensive use of the related knowledge of lean production and industrial engineering,the analysis on production capacity,WIP and production cycle time and changeover process of die-casting machine on the related process are made.Three improvement projects are identified,including workshop layout improvement,shop floor management improvement and die-casting machine changeover process improvement.2.Workshop layout improvement.Through the statistics and analysis of the data of WIP,cycle time and takt time in the process of drilling,tapping,repair burrs,blowing aluminum scraps and degreasing oil,several problems are existed in the processes above.Namely,the handling distance of WIP is too tong,the number of WIP is over excessive,the production is imbalanced and the circle time is too much.The process-based methods are used to optimize layout the improvement.Then,with the application of the analytic hierarchy process(AHP)to make a systematic evaluation of the three schemes of workshop layout improvement,the optimal one is selected.Finally,the selected optimal scheme is implemented in the workshop.3.Shop floor management improvement.The shop floor is messy and production planning is not implemented timely in this workshop.The 5S inprovement on the shop floor combined with lean production thoughts is implemented.According to the problem that the production plan is not implemented timely in this work shop,the Production Kanban management system is introduced into this workshop.4.Die-casting machine changeover improvement.Since the orders of this workshop are multi-variety and small-batch and the die-casting machine changeover is frequent and it costs too much time each time,the SMED theory of lean production and method of ECRS are comprehensively used to optimize the changeover process of die-casting machine.5.Summarize improvement results and analyze the deficiency in the improvements and put forward the ideas and directions of following research.