A Research On Production Process Improvement For T Factory Based On Lean Thinking

With the growth of domestic passenger car market slowing down,especially in the external environment where raw material prices and labor costs rise,the manufacturing cost of car parts enterprises rises sharply and the gross profit margin keeps falling.In order to ensure the enterprise profit,they began to turn to internal improvement in terms of quality and efficiency.This thesis takes T plant as the sample,to study the method to reduce wastes and shorten manufacturing cycle time in the production process based on lean thinking.There are four processes in T factory,which contains stamping,welding,coating and assembling.The main problems are high inventory in process,long production cycle time.The value stream map(VSM)is a good tool to solve the problems which can show all excess activities and identify the waste in the site processes from an overall point of view.Firstly,we clarify the purpose and significance,summarize the lean production concepts and the value stream map application samples.Secondly,we analyze the typical production process,and draw the current value stream map.And then we analyze the physical flow,the information stream,production processes and cycle time,and then study the direction of improvement and make the future state map.Ultimately,we design an overall plan to reduce the thriftless activities and decrease the cycle time which includes establishing pull system,promoting Single Minute Exchange of Die for stamping,automatic production upgrading,standardizing the standardization of operation,improving the assembly line balance rate,applying the automated guided transport vehicle(AGV)to achieve less humanized distribution.Through the implementation of the measures,T factory achieves the goal of WIP inventory reduction,labor saving and less production cycle time.