I. Project background

The company is a factory specializing in the production of starter machines. It has been in production for more than 20 years. The company has more than 300 types of starter products, with a monthly sales volume of 30,000 units. The starters are exported to overseas markets, including Europe, America and In the Middle East and other places, xx Co., Ltd. adheres to the business philosophy of “integrity, professionalism, and win-win”, insists on customer first, quality first, customer service by technology, adheres to technological progress, continuous innovation, and constantly surpasses, has become a car and motorcycle accessories. A company with strength and scale in the industry.

2. Customer needs

What problems did the customer encounter:

1. The material carrying method is varied; the tooling return line is too long and the flexibility is poor; the production line is more traditional; 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. Information transmission depends on information, information records are written, and information is lagging;

4. 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.

5. 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.

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


Improved

Assembly line body