Research On Lean Of Assembly Line Of J Company Based On TRIZ

Due to the timeliness of market product demand and the competitive pressure of market share,the production line must be balanced and stable under the mass production mode,and the production mode should be adjusted and changed in time.As a listed manufacturing enterprise,J Company has a big gap between the original balance of assembly line and the idea of one flow of lean production.Moreover,due to the lack of production capacity caused by the imbalance of assembly line,the product defect rate is high,and there is a great gap between the original balance of assembly line and the idea of one flow of lean production.Because of the serious waste of space and resources,it is difficult to realize the requirement of Lean,and the enterprise can not respond to the demand of customers quickly,so that the enterprise is at the disadvantage of the industry and lack of market competitiveness.In this paper,the assembly line of BCK-EPC17-0670 B high frequency transformer made by J Company is taken as the research object.Firstly,the assembly line is divided into assembly section and packaging section respectively.The production status of assembly line is summarized by drawing process flow chart and data analysis of man-hour.It is found that the basic management level is low,the production of assembly line is not balanced,and the production process is not perfect.A series of problems,such as high product defect rate.Secondly,the assembly line is improved by combining lean production idea,IE technology and TRIZ theory.The contents are as follows:(1)Use Lean 6S activities to promote staff literacy and optimize workshop space and environment.(2)Use operational analysis,ECRS principles and TRIZ principles to optimize each process.Simplify the operation of the process through operation analysis to reduce time waste,improve the coordination between people and equipment;through the ECRS principle and TRIZ principle,the corresponding improvement and optimization of winding,peeling,dispensing test and other processes,so that the assembly line More balanced and reasonable,draw improved process flow chart,improve the summary table and improve the working hour statistics table,and calculate the improved assembly line balance.The result is that the balance rate is increased from 75.69% to 91.54%.From the original 44.09% to 93.14%.The balance of the production line is excellent.(3)Using the method of combining IE questioning technology with TRIZ theory,the paper analyzes and improves the problem of bad products,evaluates the scheme with the method of TOPSIS,and adds the split and amalgamation between the process and the working procedure.The original assembly line assembly section 26 processes are reduced to 22 processes,the operation process is optimized,and the cost is saved.(4)Based on the idea of reducing production waste in lean production,the waste of wooden box board and the problem of dealing with stagnant materials in workshop are improved.By means of self-made wooden box board,material return,processing consumption and so on,the cost of the company is saved.Finally,through the proposed improvement measures,combined with the ED simulation software,the model simulation of the production line was carried out,and the improved product yield improvement effect was evaluated and analyzed.The results show that the production capacity has improved significantly after the improvement,and the TRIZ-based assembly line lean improvement method is effective and feasible.