I. Project background

The company is a high-tech home intelligent product manufacturer integrating R&D, production and integration. The company was established in 2002 and covers an area of 23,000 square meters with more than 300 employees. We are committed to the development of smart home and office supplies. The leading products are: wall switch, power splitter, wireless remote control, lightning protection, multi-function socket, USB charger, meter and energy-saving products. The company has a standardized injection mold production workshop, SMT placement workshop, DIP plug-in workshop, and assembly workshop. At every stage of production, we strictly follow the system to ensure quality. Most products have received international safety certificates including: TUV/GS ITS/GS, KAMA, CE, ULC-tick and many more. In addition, we have a strong R&D team. The company's home intelligence field has been 10 years old, and has considerable technical data and practical experience, because of the continuous improvement in service level, product quality and preferential prices, our company has been with the United States and most countries in Southeast Asia. Established a mature trade relationship.

2. Customer needs

What problems did the customer encounter:

1. Universal old-fashioned aircraft line design, most of the stations are old-fashioned, and the material stacking materials are loaded in a variety of ways; the tooling return line is too long, the flexibility is poor; the space utilization rate is not high;

2. The flow of people, logistics, and detours lead to a large number of incidental operations without added value. The 5S on-site is poor, and there are too many WIP products on site;

3. The material distribution method is a typical one-time large-volume delivery method. Once an abnormality occurs in a material, it will cause batch errors.

4. There are a large number of incidental work with no added value during the operation.

Lean production line analysis:

1. Designing the layout and quantity of lean production lines according to TT;

2. The line body meets the requirements of flexibility and expandability, and can be continuously upgraded to meet the production needs of different products and different processes;

3. The lean production line equipment is modularized, and the lean production line can be assembled freely to improve the efficiency and longevity of the equipment;

4. According to PQPQ (order quantity, process path), classify the line body.

5, for the foreign trade orders response speed, local station optimization, semi-automatic advancement.

Lean production line benefits:

The production balance rate has been greatly improved;

The space utilization rate of the site is saved and the floor space is reduced;

Optimize the 5S site for easy management and the overall look of the company;

The first mention is flexible, can be quickly switched, and quickly respond to the market;

Reduce personnel and achieve provincialization.

3. Project improvement

Before improvement

 

After improvement