Research On Improvement Of Lean Production In KS Piston Company

With the world economic downturn and weak shipping market,the shipbuilding industry orders fell sharply,the shipbuilding market has entered the bottom,the market downturn and excess capacity,making this bottom is a long cycle.Due to the decrease in orders,shipping and shipping supporting enterprises are under great pressure.In order to reduce the cost,improve the on-time delivery rate and quality control level,many enterprises began to implement lean production.Lean production enables enterprises to find waste and quality problems in production,so that enterprises can take measures to reduce waste,improve the quality of raw materials and products,thus reducing the cost of products,improving production efficiency and on-time delivery rate.In this thesis,starting from the actual situation and combining the management concept and method of lean production,aiming at the delivery delay,quality problem of raw materials,high cost of raw materials,material management and other problems of K factory,targeted analysis was made from the production process and procurement status quo,and improvement measures were put forward.Analyzing value stream mapping is to find out the bottleneck of production.Through the Single Minute Exchange of Dies(SMED)technology,improve the product conversion speed,and production fast response to the market.Applying ECRS principles is to improve production process.FIFO method should be used to replace inventory between processes,and push-pull production method should be designed to replace push production.Through the improvement of supplier quality management,establishing a win-win relationship to reduce the cost of raw materials,ensure the quality and continuity of supply,reduce the risk of supply.Use ABC classification to manage material inventory,reduce material purchase and inventory cost.The application of ABC classification system for material inventory management is to reduce material purchasing costs and inventory costs.Material management will be improved by developing material management process,application of heavy goods shelf,RFID technology.Delivery on time and quality control will be improved by support improvement measures of TPM implement,layered process audit.The improvement has achieved significant results such as the improvement of on-time delivery rate,cost reduction and scrap rate reduction.Through these improvement measures,the on-time delivery rate of products is improved,the production cost of products is reduced,and the quality of raw materials is improved.Analyze and summarize the improvement process and results to achieve continuous production improvement.