基于价值流的Y公司精益生产改善研究与优化应用.docxVIP

PAGE 89 基于价值流的Y公司精益生产改善研究与优化应用 摘要 随着全球经济的快速发展，市场竞争愈演愈烈。此时，客户需求趋于个性化和多样化的特点也日渐显露。精益生产作为一种有效降低生产成本、提高生产效率的先进理论方法，在企业中得到广泛的推广和应用。 Y公司主要生产铰链。国内市场对铰链的需求量逐年增加，而Y公司的铰链产能却基本不变，为了在激烈的行业角逐中赢得一席之地，Y公司生产线的改善与优化势在必行。以铰链OBN为研究对象，在现场调研和数据整理的基础上，绘制出OBN现状价值流程图。通过计算生产节拍，识别制约节拍的工序，并从图中发现较多在制品堆积，换模时间长，搬运路线迂回的问题。通过将精益生产和工业工程理论和方法相结合，设计改善思路绘制出未来价值流程图。运用程序分析、双手作业分析法、因果图、5W1H和ECRS原则等手法，分析并降低制约节拍工序时间。运用连续模，降低冲压工序之间的在制品堆积数量和时间。运用SMED减少换模时间，并形成换模标准指导书。运用SLP和EHS对OBN生产所涉及的车间进行布局和环境优化，减少搬运距离同时预防高温和粉尘的危害。最后对实施效果进行分析和总结。 通过投入自动化设备、改善流程、连续模、实现快速换模、布局设施规划和识别危害的方法对生产线进行改善优化，将增值时间272.9s减少为232.7s，减少了40.2s。非增值时间从53.18d减少为32.38d，减少了20.8d。总得搬运距离由660m减少为153m，减少了507m。有效地提高产能和生产效率。 关键词：精益生产、工业工程、价值流程图、快速换模、布局优化 Search and Optimization of Lean Production Improvement in Y Company Based on Value Flow Abstract With the rapid development of global economy, the market competition becomes more and more fierce. At this time, the customer demand tends to be personalized and diversified. Lean production, as an advanced theoretical method to reduce cost of production and improve production efficiency, has been widely used in enterprises. Y company mainly produces hinges. The domestic market demand for hinge is increasing year by year, but the hinge capacity of Y company is basically unchanged. In order to win a place in the fierce industry competition, the improvement and optimization of Y companys production line is imperative. Taking hinge OBN as the research object, based on the field research and data arrangement, the current value flow chart of OBN is drawn. By calculating the production beat, we can identify the process that restricts the beat, and find many problems such as the accumulation of work in progress, long time of mold change and circuitous transportation route. Through the combination of Lean Production’s and Industrial Engineering’s theories and methods, design and improve ideas to draw a future value flow chart. Using the methods of program analysis, two hand operation analysis, cause and effect