Research On The Optimization Of Production Processes In Company D Based On Value Stream Mapping

Manufacturing is the largest industry in our country.As a country with a large population,China needs independent,independent,tenacious and innovative manufacturing industries,whether to meet the strong desire of hundreds of millions of people for a better life or to realize the great rejuvenation of the Chinese nation.Under the influence of a series of complex environments,such as the Sino-US trade war in 2018,the novel coronavirus epidemic in 2019,and the Russia-Ukraine conflict in 2022,China’s manufacturing industry is facing a harsher global survival environment.However,a series of crises not only bring challenges to China’s manufacturing industry,but also bring opportunities to Chinese manufacturing enterprises."Industrial 4.0 era" arises at the historic moment,platform type enterprise,network organization,open innovation,mass customization,the socialization of production,such as behavior will become more common,interactive information between suppliers and consumers will be more and more close,the role of small and medium enterprises will become more prominent,responses to changing market demand will be more and more important...These changes require enterprises to reduce costs and waste as much as possible while adapting to customer needs.Lean production is a production system that has been proved in many industries to effectively eliminate waste and reduce costs to improve the competitiveness of enterprises.This paper takes D company’s production process as the research object,uses value stream map analysis technology to carry out lean improvement,and puts forward suggestions for improvement implementation.Firstly,the status quo of lean production and value stream research was summarized.Based on the value stream related theories,the value stream status map was drawn to analyze the problems and causes of D company’s product line,and it was found that the current production layout and production process resulted in a large number of WIP accumulation.High packaging cost and rework rate of bottleneck process;The purchasing cycle of raw materials is long.Then,according to the existing problems,lean production related theories were used to improve :(1)unit production and supermarket pull system were introduced to improve wip accumulation according to the kanban principle,and wip inventory was reduced by 60% compared with before improvement.(2)Use 5W1 H questioning method,ECRS principle and other tools to improve the bottleneck process,reduce the operation time from 364 s to 234 s,130s,and greatly reduce the rework rate.(3)Use ABC classification and inventory information to improve the problems of long procurement cycle and chaotic inventory management,shorten the ordering cycle and reduce the financial pressure.(4)Established a continuous improvement and improvement incentive mechanism,and continuously optimized and improved the review process for the future implementation of PDCA.Finally,on the basis of the above work,the future state chart of value process is drawn,the improvement situation is clearly introduced,and the improvement effect is evaluated.It is expected to save more than 900,000 yuan annually,and the improvement effect is obvious.