Study On Improvement Of Automotive Light Production Based On Value Stream Analysis

Magna Donnelly(Shanghai)Automotive Technology Co.Ltd.(M company for short)is a subsidiary of Canadian corporation “Magna International”,which design and produce the rear view mirror lights and various kinds of auxiliary lighting products independently.With the development of the demand of personalization,the yield and varieties of production increase.Thus,the traditional mass production mode has been unable to meet the needs.The production process is filled with a large amount of waste,low personnel efficiency,quality accidents and a series of problems,which need to be solved by the lean,low-cost and high-quality production mode.In this thesis,M company is taken as the research object.By means of the analysis of the value flow of H fog lamp and E turn signal production line and modern lean production management theory and common tools,lamp production line is optimized.Firstly,based on the theory of “production line balance”,optimize the layout of the site,make rational use of space,balance the rhythm between the various processes and achieve a balanced and efficient production.Secondly,based on the “SMED” theory,by means of converting the internal operation time to external operating time,shortening the time of internal mold changing,establishing the standard of mold changing operation and the table of common flaws of the vibration welding,improve the efficiency of the mold changing,reduce the time cost and enhance the product competitiveness.Finally,through the application of “error proofing”,improve the technological process of lamp production line,therefore reduce customer complaint and the loss of waste production and improve product quality largely.Through the application of above methods,the production balance-rate of H fog lamp production line increased by nearly 20% and the total mold changing time of the vibration friction weld of E turn signal is shortened by 47.7%.After the error proofing technology is applied to the lamp production line,the Mazda series of lamp products achieved 0ppm within one year and the company saved the loss of nearly 200 thousands yuan.This thesis exemplifies the effectiveness of the lean production theory and tools used in the production process of M company,which can guide the production management of other light enterprises and improve the production efficiency and economic benefit.