E公司精益生产的系统分析

上海交通大学硕士学位论文E公司精益生产的系统分析姓名：魏朝辉申请学位级别：硕士专业：工商管理指导教师：陈忠20070610E/EEEEEEEE5SUE29%25%ESYSTEMATICANALYSISECOMPANY’SLEANMANUFACTURINGABSTRACTLeanManufacturingisapowerfultooltocutcostbyeliminatingthewasteintheprocessandtoresponsequicklybyreducingtheleadtime.Ithelpsthecompanyadoptinglowcostmanufacturingstrategyanddifferentiationstrategy.Itcanhelpcompanytobuildcorecompetenceintheglobalcompetition.Speedandeliminationofwasteisthetargetofleanmanufacturing.SmallbatchsizeorOnePieceFlowmethodincreasestheflexibilityofprocessandmakesthemasscustomerizationpossibleinthecomplexprocess.Eliminationwasteaddsvaluedirectlyintoprofit.Theleansysteminmanufacturingcanimprovetheefficiencyandreducecostandencouragethemoraleofstaff.Ontheotherside,itcanreducetheresourcespending.Ecompanyfacestheproblemduringtheglobalizationandquickexpansion.Ononeside,theproductlineflourishesandproductlifecycleshortens,thisincreasestheoperationcost.Ontheotherside,theconsumerhasrequiredhigherqualityandlowercost.LeanManufacturingoperationstrategyisadoptedbyECompanytoprovidevariousproductswithlowercost.Thethesiswasorganizedinfiveparts:Inthefirstpart,itanalyzedthecompetitionenvironmentofplasticlensindustrybyfiveforcesdiagram.ItalsopositionedthevalueandfunctionsofECompanyonthegroup’ssupplychainsystem.ThemainproblemECompanyfacingwasbiasemergingwiththeexpandingofproductionlinecomplexityandlowcostrequirement.Secondly,thethesissystematicallyanalyzedtheLeanManufacturingsystemfromprinciples,keyelementsandevolutionprogressofmanufacturingsystem.Itbrieflyreviewedtheglobalandlocalstudyandapplicationofleanmanufacturingtheoryandpractice.Inthethirdpart,itidentifiedthewasteandproblemsinEcompanysuchasthehighwork-in-progressstock,longtimewaitingofpeople,equipmentandproduct,andnotstableofproductionperformance.Thenthefishbonediagramisusedtoanalyzetherootcauseofonemaindefect,whichimpactsthequalitygreatly.Inthefourthpart,EcompanyLeanManufacturingprojectswereanalyzed.Theprogramincludedthechangingenvironmentbuilding;5Sworkfloorimprovement;Ucellworklayoutsetup;Kanbancontrolsystem;SingleMinuteExchangeofDiemethod(SMED);andthecontinuousimprovementcompanyculture.Finally,thethesisshowedtheimprovementafterLeanManufacturingimplementation:visualcommunicationboardforauto-managementculture,andthepair/impairprogramcancellationofcastingdepartment,whichreducedthemoldsstock29%andfastenstheproductioncycle25%.ThroughLeanManufacturinginECompany,theworkshopfloorimprovedandtheproductivitywasincreased.ECompanyhasbuiltthecontinuousimprovementculturewithKaizenTeamActivities.Chinesemanufacturingcorporationsarerapidgrowingandseekingforgoodmanagementpractice.TheLeanmanufacturingsystematictoolsarehelpfultoimprovetheenterprisemanagementbyreducingtheresourceconsumptionandincreasingofproductivities.KEYWORDS:LeanManufacturing,SystematicAnalysis,PlasticLens2007042320070423MBAE1E19972003E2005EEE—EEEE51.2.3.4.5.1WTOMBAE2;;2MBAEMBAE3TPSTPSMBAE35SEEEEEE5SEEMBAE441.11MBAE5187519001925195019752000-----PPM187519001925195019752000-----PPM1215(JamesWomack)MITIMVP17901/21/31/101/21/431/2(DanielJones)(DanielRoose)(TheMachineThatChangedtheWorld)(ComputerIntegratedManufacturing,CIM)(AgileMBAE6Manufacturing,AM)2090216LeanAerospaceInitiative200178)90%90%91.2JIT-10//MBAE7=+111012JIT=/JIT1.2.1131(pull)(JIT)MBAE8//-/23TeamworkMBAE9,4ConcurrentEngineering1.2.214123451/23MBAE1041.2.41RelayoutUnit2/OPF,OnePieceFlow/3PullLeadTimeMBAE111.2.4TAKTVOCQFDMRPDFMSMEDOPFTPMTOCSOPTQMDOTWIMEJITKaizenHPWOEGO5SKanbanAITAKTVOCQFDMRPDFMSMEDOPFTPMTOCSOPTQMDOTWIMEJITKaizenHPWOEGO5SKanbanAI22TAKT-QFD-VOC-MRP-DFM-MBAE12SMED-/OPF-JIT-DOTWIME-///TPM-TOC-SOP-TQM-5S-Kaizen-HPWO-EGO-Kanban-AI-1.31983151985590199216MBAE13MBA-1718192021.GEA22A23SDM24%75%95%97%2.3%0.5%24MBAE14E2.1252.1.160%37%17%20052001200618%20051.21601.2150262.1.220%MBAE153123453MBAE162.1.34CR39-05101520253035M$1955197019902005201542.2EE1997EMBAE17E200550%SKUE2.2.1EE19975E2.2.2E1.501.551.601.671.701.74E1MBAE181E1.50--1.55------1.60------E2.2.36EE202499.9%499.5%MBAE196EE2.3E1234MBAE20MBAE21EBatch&QueueFunctionalProcessE3.1E=X=X22=3.1.118007900304803600MBAE220500100015002000180090073.1.2=+MUDAMUDAMUDAMBAE235%5%838%E220.6%25/606001200180024003000/02000400042%0.05%83.1.323.1.4“”MBAE24E2400480012002400360018007E1/33.1.5100%20%100%100%10%2.5AQL2.514%100%100%1/290018003.1.6E40%40%28000140000MBAE253.1.79/40%3040%60%40%60%9/3.2MBAE261000.511.522.533.52.92.251.23751.1651.251.561.72.251.831.50/=3.06s=2.6s10E3.3EE2003200520%MBAE27110.0%0.1%0.2%0.3%0.4%0.5%0.6%0.7%0.8%0%20%40%60%80%100%120%11MBAE2812//////123.4-40%40%MBAE29MBAE30EEEE20~30%EE5SU4.127MBAE3113123MBAE32---/---/1312345678MBAE334.25S6S5SSafety5SSSeiriSeitonSeisoSeiketsuShitsuke5S-------5S5S5S5S4.2.1-12345MBAE3464.2.24.2.34.2.4S4.2.55SMBAE354.2.6E5S5S5S145S00.20.40.60.81145S4.3:-JITJITMBAE36“”4.3.1E15E-100200300400500600ABC-100200300400500600ABC15EABCABC22EABCA74%16%B16%19%C10%64%ABCAMBAE37B30C100%20%40%60%80%100%120%0%20%40%60%80%100%120%A-16%74%30“”B-19%16%10~30C-64%10%100%20%40%60%80%100%120%0%20%40%60%80%100%120%A-16%74%30“”B-19%16%10~30C-64%1