| With the increasingly fierce market competition,domestic manufacturing enterprises are under increasing pressure to survive,and problems such as long production cycles and serious waste have gradually been exposed with the development of the enterprises themselves.In order to deal with these problems effectively,enterprises need to improve efficiency and reduce costs through transformation,and improve the ability of response to customer demand.Lean production can provide scientific guidance for enterprises in such situations,and help them gradually adapt to the diversified market demand by putting the idea of eliminating all waste as the core.As the research object of this paper,Company X is an earlier state-owned enterprise whose main products are pistons,oil pumps and gears.The current development of the company is limited by the low level of on-site management and backward production mode.It is urgent to introduce lean management concepts to help the company get out of the trouble and regain its dominant position in the industry.In order to reduce the hidden waste in all aspects of production,shorten the production cycle and enhance the competitiveness of enterprises,this paper seeks to improve the workshop layout,production line balance and production mode based on the idea of lean production.First of all,it is found that the company has problems such as long logistics routes,unbalanced process time and production mode not meeting the market demand through the value stream analysis and actual investigation of the production status in Company X.According to these problems,this paper puts forward three corresponding solutions.The first part is the optimization of the workshop layout.The SLP method is used to optimize the existing layout of the machining workshop,and two alternative layout schemes without deductible items are formed through the area-free tile map.Flexsim simulation and analytic hierarchy process are used to carry out comprehensive analysis of the combination of quantitative and qualitative to layout schemes,and the optimal layout is obtained.The second part is the optimization of the production line balance.Analyze the process program of the machining production line,and identify the location of the bottleneck station and the existing problems of the production line.Improve the bottleneck positions through process reorganization,promote the increase in the balance rate of the production line,and implement the U-shaped layout of the production line to realize one-man-multi-machine,and improve the flexibility of the production line.With the help of Flexsim software,the equipment processing load and personnel utilization of the production line before and after optimization are compared to verify the effectiveness of the improvement measures.At the same time,the production ratio reciprocal method is used to study and optimize the production sequence of the machining production line,so as to realize balanced production and lay the foundation for the introduction of pull production.The last part is the establishment of pull production.Continuous flow and material supermarket are set up between processes.Pull production of machining workshop is realized through Kanban management.Finally,the future value stream map of Company X is formed.Through the system layout planning of the machining workshop,option 2 is selected as the final layout form.Compared with before optimization,the logistics distance of machining workshop after layout optimization is shorter,which reduces the waste of transportation.By improving the bottleneck positions and implementing the U-shaped layout of the production line,the balance rate of the machining production line has been increased to 91.7%,reaching the qualified level,and the utilization rate of equipment and personnel has also been improved.The establishment of pull production further enhances the customer response ability of the enterprise,shortens the overall production cycle by 1.19 days,and the improvement effect is remarkable. |
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