基于价值流视域下的AIP公司生产流程改善研究
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摘要
以提高企业运作效率为核心,选取AIP公司轮胎生产线的优化作为本次研究案例,首先,通过绘制现状价值流图,达到生产线的现状可视化,分析工艺布局与物流和信息流的活动,找出当前生产模式中存在的增值与非增值环节;其次,运用精益思想和工业工程的方法,对生产流程进行分析与改善,引入看板拉动式和连续式生产等方法,以节拍平衡方式进行生产,压缩非增值时间、消除信息阻碍、减少作业人员和在制品库存等,使生产周期及产能得到有效改善;再次,采取工序重组、流程优化等改善手法,对生产流程进行精简,并绘制未来价值流图作为重点改善方向,从而实现生产线的再设计;最后,通过价值流图的前后对比发现:企业产能、设备利用率及生产周期改善显著,在提高产品质量的同时有效地降低了生产成本。实践证明,价值流图分析技术是提高企业生产效率的有效方法,是企业实施精益生产的有力工具,值得广大企业借鉴与推广。
With improving the enterprise operational efficiency as the core, this paper takes tire production line optimization in AIP company as the study case. Firstly, through drawing the current value stream map, the present production line is visualized,and through analyzing the layout and the activities of the logistics and information flow, the value-added and non-value-added links in the production mode are identified; Secondly, by using lean thinking and method of industrial engineering, the production process is analyzed and improved; with the introduction of pull production and continuous production, production on beat balance is aimed to reduce non-value added time, eliminate information block, reduce workers and work-in-process inventory, etc., thus improve the production cycle and capacity. Thirdly, process restructuring and optimization are adopted to improve technique,streamline the production process, and draw the future value stream map so as to redesign the production line. Finally, through a comparison between the previous and present value stream maps, it is pointed out that enterprise production capacity, equipment utilization and production cycle are improved greatly while the production cost is reduced effectively. Its application has proved that value stream map analysis is an effective way to improve the efficiency of enterprise production, and it can serve as a powerful tool for enterprises to implement lean manufacturing. Therefore, it is worthwhile to promote its application.
With improving the enterprise operational efficiency as the core, this paper takes tire production line optimization in AIP company as the study case. Firstly, through drawing the current value stream map, the present production line is visualized,and through analyzing the layout and the activities of the logistics and information flow, the value-added and non-value-added links in the production mode are identified; Secondly, by using lean thinking and method of industrial engineering, the production process is analyzed and improved; with the introduction of pull production and continuous production, production on beat balance is aimed to reduce non-value added time, eliminate information block, reduce workers and work-in-process inventory, etc., thus improve the production cycle and capacity. Thirdly, process restructuring and optimization are adopted to improve technique,streamline the production process, and draw the future value stream map so as to redesign the production line. Finally, through a comparison between the previous and present value stream maps, it is pointed out that enterprise production capacity, equipment utilization and production cycle are improved greatly while the production cost is reduced effectively. Its application has proved that value stream map analysis is an effective way to improve the efficiency of enterprise production, and it can serve as a powerful tool for enterprises to implement lean manufacturing. Therefore, it is worthwhile to promote its application.
引文
[1]刘义乐,李红广,梁斌.价值流分析在精益维修中的应用[J].国防技术基础,2013,(1):54-57.
[2]Tomasz Sobczyk,Tomasz Koch.A method for measuring operational and financial performance of a production value stream[J].IFIP Advances in Information and Communication Technology,2013,257(1):151-163.
[3]徐光银.应用价值流的差速器壳生产线的精益生产改造[J].汽车工艺与材料,2011,28(4):41-44.
[4]Abdulmalek FA,Rajgopal J.Analyzing the benefits of lean manufacturing and value stream mapping via simulation:A process sector casestudy[J].International Journal of Production Economics,2013,107(1):223-236.
[5]缪周,徐克林,李振飞.基于价值流图的生产线再设计:案例研究[J].工业工程,2009,12(5):115-119.
[6]李文杰,徐克林.基于价值流图析的精益生产研究[J].机电设备,2014,(1):41-44.
[7]杨雷,张晓鹏.空调生产中的价值流分析及其改善[J].工业工程与管理,2009,(1):90-96.
[8]倪稷子,阚树林,沈军.基于价值流图技术的锁体生产系统优化[J].工业工程,2011,14(4):139-144.
[9]卓浩.精益思想重塑价值流[J].企业管理,2014,(6):112-114.
[10]谢庆红.基于价值流图析的复杂产品装配优化研究[J].2013,18(4):117-121.
[2]Tomasz Sobczyk,Tomasz Koch.A method for measuring operational and financial performance of a production value stream[J].IFIP Advances in Information and Communication Technology,2013,257(1):151-163.
[3]徐光银.应用价值流的差速器壳生产线的精益生产改造[J].汽车工艺与材料,2011,28(4):41-44.
[4]Abdulmalek FA,Rajgopal J.Analyzing the benefits of lean manufacturing and value stream mapping via simulation:A process sector casestudy[J].International Journal of Production Economics,2013,107(1):223-236.
[5]缪周,徐克林,李振飞.基于价值流图的生产线再设计:案例研究[J].工业工程,2009,12(5):115-119.
[6]李文杰,徐克林.基于价值流图析的精益生产研究[J].机电设备,2014,(1):41-44.
[7]杨雷,张晓鹏.空调生产中的价值流分析及其改善[J].工业工程与管理,2009,(1):90-96.
[8]倪稷子,阚树林,沈军.基于价值流图技术的锁体生产系统优化[J].工业工程,2011,14(4):139-144.
[9]卓浩.精益思想重塑价值流[J].企业管理,2014,(6):112-114.
[10]谢庆红.基于价值流图析的复杂产品装配优化研究[J].2013,18(4):117-121.