摘要
随着中国经济的迅速发展,大量的制造型企业在中国得到了蓬勃发展,但同时也面对着前所未有的挑战。产品种类需求不断增加,顾客对产品质量的要求日益提高,对制造业的技术与成本方面提出了更高的要求。精益生产作为一种适合于小批量、多品种的生产方式,可以有效的缩短产品生产周期、减少产品生产过程中多余的浪费,降低库存,使生产线布局更为紧凑,缩短了产品物流距离,提高员工的生产积极性,并且不断地改善生产中遇到的问题。精益生产对于企业的目的在于通过降低生产成本,提高企业产品的利润空间,达到使企业利润最大化且持续盈利的目的。
本文通过对新飞通光电子技术有限公司的生产现状进行调查,分析了由于公司在迅速发展,产量不断加大、品种增多,公司现有的供应链体系越发吃力,物流速度、车间管理、库存、厂房大小等都趋于饱和,而阻碍了公司的进一步发展。面对公司的现状,公司领导层确定了推行精益生产方式改造现有生产模式的战略部署,目的在于为客户提供更高品质的产品,同时为自己创造更大的利润空间。通过对公司制造环节的详细调查,包括：公司产品的成本、效益调查；公司内部物流与库存问题调查；产品的生产工艺、质量特性及生产过程的可改进性调查；公司产品生产过程中遇到的主要问题等等,制定了初步的精益生产改造方案,包括单元式生产改进计划,生产线工位布局优化,生产线平均制造周期分析与改善,公司内部物流优化,公司库存品管理方法优化,全面质量管理理念的推行等方案。
在方案实施后,取得了显著的阶段性成果。试点生产线的产品一次直通率从原来的96%提高至98.5%,产品生产的时间缩短约40%,车间WIP减少约30%,提高了场地面积利用率37%,节约成本约380000人民币/月。
With China's rapid economic development, a large number of manufacturing enterprises in China have been booming, but also face unprecedented challenges. Increasing demand for product categories and customer requirements on product quality increasing, the cost of manufacturing technology and put forward higher requirements. Lean as a suitable for small quantity and variety of production methods, can effectively reduce the production cycle, reduce excess production process waste, reduce inventory, so that the layout is more compact production line, shortening the product logistics from the and improve employee productivity initiative, and continually improve the production problems encountered. Lean Production for the purpose of the enterprise by reducing production costs and improves profit margins of their products, to enable enterprises to maximize profits and the purpose of sustained profitability.
Based on the new fly-pass Optoelectronics Technology Co., Ltd. Production Status survey and analyze the company in the rapidly due to development, production continues to increase, the variety increased, the company's existing supply chain system, the more difficult, the logistics rate, shop management, inventory, plant size and so tends to saturation, impeding further development of the company. The face of the company's current situation, the company leadership to implement lean production methods to determine the transformation of the strategic plan of the existing mode of production, aimed to provide higher quality products, while creating greater profits for their own space. Through detailed investigation of the company manufacturing sector, including:the company's products cost-effective investigations; logistics and inventory issues within the company survey; the production process, quality characteristics and production process can be improved survey; company encountered during production The main problem, etc., developed a preliminary transformation of lean manufacturing program, including the cell type production improvement plans, the production line stations layout optimization, the average manufacturing cycle analysis of production lines and improve internal logistics optimization, the company optimize inventory management, comprehensive the implementation of quality management concepts and other programs.
After the implementation of the program has made significant initial results. A pilot production line of products through rate from the original 96% to 98.5%, the production time by about 40%, WIP reduced by about 30% of the workshop to improve the utilization rate of 37% of site area, cost about 380,000 yuan/month.
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