Research On Lean Improvement For Q Production Line Of Z Company Based On Value Stream Analysis

Today,manufacturing industries of China is now facing more and more pressure from the environment of a new round of global technological innovation and manufacturing transformation.How to achieve lower cost,shorter lead time and higher quality at the same time becomes the major challenge for manufacturing companies.Lean production as advanced production management tool indicates the direction for most manufacturing companies.Z company is a large state-owned company,who is producing the product for both domestic and American and European market.Z company is now facing the issues of low productivity,long manufacturing lead time and unstable quality level.In order to solve the issues Zcompany expect to improve the Q production line and to better satisfy customer’s demand by introducing lean thinking theory and applying lean production tools.Started from current production status and applied lean value stream principle this article selected product family with high prioritized need of improvement and found the problems in whole manufacturing process based on observation and recording in the process flow.Whereafter,current value stream mapping was drawn by using the technique of value stream analysis.Wastes and improvement opportunities were identified by analyzing current material and information flow and then future value stream mapping was drawn combined with customer’s need.At last kaizen action list was developed and kaizen activities were completed by applying lean production tools and methods.Shopfloor management was improved on the basis of improvements of awareness of employees,5S and visual management.Cycle time for each operation was reduced by applying standard operation.Setup time was reduced by applying SMED.Transportation distance was reduced by applying layout planning.In the end WIP quantity and manufacturing lead time were reduced sharply by creating the continuous flow and first in first out.Through introducing lean thinking in to the production system and lean improvement labor hour was reduced by 10%,WIP quantity will be reduced by 24%,shopfloor space will be saved by 30%and manufacturing lead time will be reduced by 40%,which is big cost and lead timereduction and huge improvement for customer satisfaction for the company.