一.Project background

Founded in 1984 and listed on the main board of Hong Kong Stock Exchange on June 15, 2007, it is the first domestic optical enterprise listed in Hong Kong Red chip. The group has more than 20000 employees and more than 17 billion yuan of assets. The company has been focusing on the field of optical products for a long time. For more than 30 years, it has been focusing on optical components and integrating the upstream and downstream. It is the largest comprehensive optical product manufacturer in China.

The company is one of the few optical enterprises in China that can comprehensively apply optical, mechanical, electrical and computing technologies to product development and large-scale production. It is engaged in special coating technology, optical aspheric technology, auto focus / zoom technology, chalcogenide glass material development and application technology, embedded software technology, 3D scanning imaging technology, 3D ultra precision vibration measurement technology, trace element analysis and detection technology. The research and application of core optoelectronic technology, such as ultra-high pixel module manufacturing technology, is at the leading level in the domestic industry.

The company's main products include three categories: first, optical parts, mainly including glass / plastic lenses, plane mirrors and various lenses; second, photoelectric products, mainly including mobile camera modules and other photoelectric modules; third, optical instruments, mainly including microscope, intelligent equipment, measuring instruments and analysis instruments.   

The company's products are mainly used in mobile phones, cars, cameras and other consumer electronics fields. Among them, the market share of vehicle mounted optical lens ranks first in the world for many consecutive years, and the market share of mobile camera lens and mobile camera module ranks first in China and second in the world. The vehicle mounted optical lens has entered the luxury vehicle fields such as Mercedes Benz, BMW, Audi, Lexus, etc., and the camera module of mobile phone has entered most famous domestic and foreign mobile phone manufacturers, including Samsung, Huawei, Lenovo, Xiaomi, etc.; about 30% of the company's leading products are exported to internationally famous customers, and the product grade belongs to the domestic leading level, some of which have reached the international advanced level, and have developed into Photoelectric enterprises with strong international competitiveness.

The company ranked 498 on the fortune China top 500 list for the first time in 2016 and 458 on the fortune China top 500 list again in 2017. In 2015, its sales exceeded 10 billion yuan for the first time and reached 14.3 billion yuan in 2016. In 2017, the company's sales exceeded 20 billion yuan for the first time, reaching 22.4 billion yuan, an increase of more than 59% over the same period of last year, and its profits reached 2.9 billion yuan, an increase of more than 129% over the same period of last year.

The development of the company has been recognized by all levels of government departments. The company has successively won the honors and titles of Ningbo mayor quality award, Zhejiang Provincial Key Enterprise Research Institute, Ningbo industrial leading enterprise, the first batch of "three pilot enterprises" in Zhejiang Province, the deep integration demonstration enterprise of two modernizations in Zhejiang Province, and the first batch of comprehensive management innovation demonstration enterprise in Zhejiang Province. In 2016, the company also won one respectively. The project of national development and Reform Commission and Ministry of industry and information technology was approved, and won the honorary title of the second batch of manufacturing single champion demonstration enterprises of Ministry of industry and information technology in 2017.

二.Customer demand   

What problems did the customer encounter?：   

1. There are various ways to carry materials; the return line of tooling is too long and the flexibility is poor; the production line is more traditional; the space utilization rate is not high；   

2. People flow, logistics intersection and detour lead to a large number of ancillary operations without added value, 5S poor on-site, and too many WIP products on site.；   

3. Information transmission depends on roar, information recording depends on writing, and information lags behind；   

4. Information transmission depends on roar, information recording depends on writing, and information lags behind；   

5. In the process of operation, there are a large number of non value-added side jobs.   

Lean production line analysis：   

1、Design lean production line layout and quantity according to TT；  

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

3、The lean production line is modular, and the lean production line can be assembled freely to improve the efficiency and service life of the equipment.；  

4、Classify the line body according to pqpqpq (order quantity, process path).  

Lean production line efficiency：  
 
Production balance rate is greatly improved；  

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

the 5S site is optimized to facilitate the management and the overall face of the company;

the flexibility of the first step is great, which can be switched quickly to deal with the market quickly;

the number of personnel is reduced to realize the provincial humanization.

三.Project improvement   

Before improvement    

Improved
skills requirement
Technical requirements for 1.2m worktable:
1. The main body is made of European standard 40 * 2.0 aluminum profile + standard connector.
2. The table top is made of 18mm density board + 2mm anti-static.
3. The storage platform is made of 1.5mm cold-rolled steel plate with white paint sprayed on the surface.
4. The accessories include double energy-saving lamps with cover / process Kanban / bull row / wooden drawer.
Technical requirements for 1.5m worktable:
1. The main body is made of European standard 40 * 2.0 aluminum profile + standard connector.
2. The table top is made of 18mm density board + 2mm anti-static.
3. The storage platform is made of 1.5mm cold-rolled steel plate with white paint sprayed on the surface.
4. The accessories include double energy-saving lamps with cover / process Kanban / bull row / wooden drawer.
MX mobile car technical requirements:
1. The main body is made of European standard 40 * 2.0 aluminum profile + standard connector.
2. The table top is made of 18mm density board + 2mm anti-static.
3. 4-inch silent caster is used at the bottom.
Technical requirements for packaging workbench:
1. The main body is made of European standard 40 * 2.0 aluminum profile + standard connector.
2. The table top is made of 18mm density board + 2mm anti-static.
3. The accessories are double support with cover for energy saving / bull row / wooden drawer.
Technical requirements for drying rack 1:
1. The main body is made of European standard 40 * 2.0 aluminum profile + standard connector.
2. The table top is made of 18mm density board + 2mm anti-static.
3. The door panel and surrounding panel are made of 4mm silver white aluminum plastic plate.
4. 4-inch silent caster is used at the bottom.
Technical requirements for drying rack 2:
1. The main body is made of European standard 40 * 2.0 aluminum profile + standard connector.
2. The table top is made of 18mm density board + 2mm anti-static.
3. 4-inch silent caster is used at the bottom.
Technical requirements for trolley:
1. The main body is made of European standard 30 * 2.0 aluminum profile + standard connector.
2. The table top is made of 18mm density board + 2mm anti-static.
3. 4-inch silent caster is used at the bottom.
Technical requirements for inspected packing table:
1. The main body is made of European standard 40 * 2.0 aluminum profile + standard connector.
2. The table top is made of 18mm density board + 2mm anti-static.
3. 4-inch silent caster is used at the bottom.
Technical requirements for complete machine turnover car:
1. The main body is made of European standard 30 * 2.0 aluminum profile + standard connector.
2. The table top is made of 18mm density board + 2mm anti-static.
3. 4-inch silent caster is used at the bottom.
Technical requirements of turnover car 1:
1. The main body is made of European standard 30 * 2.0 aluminum profile + standard connector.
2. The table top is made of 18mm density board + 2mm anti-static.
3. 4-inch silent caster is used at the bottom.
Technical requirements for turnover car 2:
1. The main body is made of European standard 30 * 2.0 aluminum profile + standard connector.
2. The table top is made of 18mm density board + 2mm anti-static.
3. 4-inch silent caster is used at the bottom.
Technical requirements for corner table:
1. The main body is made of European standard 40 * 2.0 aluminum profile + standard connector.
2. The table top is made of 18mm density board + 2mm anti-static.