精益生产在株齿公司中的应用

华中科技大学硕士学位论文精益生产在株齿公司中的应用姓名：杨鹏申请学位级别：硕士专业：工商管理指导教师：崔南方20081029IIIABSTRACTItfacesenormouschangeforthemanagementmodeofProductionsysteminthemanufacturingindustrywiththerapiddevelopmentofscientifictechnology,especiallyofinformationtechnologytheformationofcompetitivebuyer’smarketindividuationtendencyofconsumerconceptionestablishmentofglobalmarketandtradesystemthrivingofknowledgeeconomicsandtherisingattentiontocontinualdevelopmentandenvironmentalprotectionBeingatypicalmanagementmethodofsmall-batchandlot-varietyproductionleanmanufacturingmeetsthepracticalrequirementsofmarketchange.Productioncontrolasonetypicalcharacteristicandtheimportantcomponentoffoundationofleanmanufacturingisacrucialtechniquetorealizeproductionplanningandoperativemanagement.Thereforestudyingproductioncontrolholdsthebalanceforsuccessinleanmanufacturing.Inthisdissertation,theresearchofLeanProductionhasbeenstudiedwiththepracticalcaseofZhuzhouGearco.,Ltd(ZG).AndthethesismainlyfocusonCellProduction,ManagementofKanBanandContinuousImprovementwhichhadalreadybeenadoptedandappliedinZG.Throughthecomparebetweenthetheoryandpracticaloperation,andtheoreticanalysistothecompany,thethesishaveconcludedthekeypointinthecontrolofZG’sleanProductionprocess.TheaspectofproductioncapacityproductionorganizationpurchasingandlogisticsandmanufacturingprocesscontrolareanalyzedbyusingtheprinciplesandmethodsofLeanProduction.MeanwhilethethesisestablishesrespondingimprovingmeasuresfortheproblemsofproductionmanagementinaccordancewiththeprincipleofeliminatingallwastesandJIT.Intheendofthisdissertation,theconclusionsandthefurtherresearchplanareprovided.Keywords:LeanProductionCellProductionManagementOfKanBanContinusousImprovement_____11(LeanProductionLP)“”1990“”1.1.1908—1913TPS19471/8“”1974TPS[1]TPS19821400140001020079361002—387TPS50[2].P..T..TPSTPS“LeanProduction”[3]1.2813158%088200531.31.3.1[4]12344565S71.3.2“DQC”—DQC1-1[5]51-111“”232TQMTQMTPM5S6TQM[6]3IE(TPS)IE(CIMSMRP)[7]IEIEIE[8]4“”“”“”7[1]12“”“”34“”5“”5TPMTPM“”70“”“”TPMTPM68[9]——7SMED“”(SingleMinuteExchangeofDies)[10],-()SMED1950370385S5SSEIRISEITONSEISOSETKETSUSHITSUKE[11]95SISOTPMTQM5S5S33,1.410“”1122.1123412550%62.22.2.1P/Q[12]P/QST1/8HD132.2.2P/Q1[13]2-1P1→P2→P3P1a1R1→a2R2→a31020302-1a1R110a2a2R220a3P1a3R430P1b1R112b2b2R215b3P2b3R310P2c1R125R8c2R315R9P3c3R430P3142-12[14]2-2R1R2R3R4/1020030P1303006000900/1215100P2202403002000/2501530P31537502254509159004251350112291590021367590090090090091.50%90%21.30%67.50%/2-2R1R32.2.31[15]=++15=+=+PTS(PredeterminedTimeStandard)AWF(AbbreviatedWorkFactor)PTS[16]PTS(MTA)(WF)(MTM)(BMT)(DMT)(PHWT)PTSAWF=+3δ2WIPWIP[17]WIP=/+()30020/2WIP=300/20+2=173[18]16=/2.2.41OEM212173456WIPWIPWIP72.2.51[19]2U3“”“”“”[20]182.32.3.12-1ab123654(a)1237654(b)2-12-1192.3.21112-1ab6522/195030*6522/1950101020230010310340117010122044341140501012005480106510102110102020250990101050335095010101044509502010205412010106520070207610102.3.31111233σ4410KG8KG20KG212005890——+11706WIP99120781409TPM223[21]TPS3.1“”“”[22]1234235[23]3.2[24]1[2]→→→24→23.33.3.110[25]253.3.2,,,[26][27]3.3.3[28]:1262343.3.4122020.337060—6565/651950TPM3-1[29]273-126272829306565656565596359626191%97%91%96%93%(min)304183107330116314573443331503800120623130039803910363096062864315559581027148413771728126517371601716140103900000375303747037470374703879081%83%80%84%89%3-12619%0.4%8.39%4.12%3.95%TPM3.420502-36015703100[30]283.4.11[31]233.4.21→→→,→→2→→,3→→→→→–429/5:6:3.53.5.1[32]303.5.2[33]10KG10103.6[34]2005313.71=/[35]1=/A30/95%B27/90%A30/95%=32B27/90%=302=∑*A20/B15/=32*20+30*15=10903=-5S100=24*60-100=1340432=-=1340-1090=2505=/A80B70150=150/250=0.62=*A30/B25/A=30*0.6=18B=25*0.6=153=*+=+++=*A5B33-23-2A205100801040230326000.05313B15345701030155306000.058=*33=+++=/=*4=+A=13+12=25B=8+9=1753-3A1813547B1585353-35=/=+/A47B35344“Kaizen”[36]4.11[37]235344.2IE(TPS)IE(CIMSMRP)IE[38]IE4-1296IE术标编产导艺标业标国标术规术纲4-1IE36(V.A)IE[39]IEQC4.30860%4.3.11ST2/8/3/237344.3.21710/3822/34/45%1/17/39520045.15.1.12-19304050121040103040311221200TPM5.1.21241831320415.1.31TPMTPSTPM22100035.25.2.11422295%—105%VMI3445.2.21432VIM[40]345.35.3.112445.3.21245TPSTPS“”“”TPSTPS“Kaizen”462005PMBA147[1]2006[2]2007[3]JamesP.Womack&DanielT.Jones—2006[4]JeanThilmanyThinking,LeanMechanicalEngineering2005(7):4-7[5]JIT2006[6]JensJ.Dahlgaatd,SuMiDahlgaardparkLeanProduction,sixsigmaQuality,TQMAndCompanyCultureTheTQMManazine,2006(3):2629[7]2007(10):84-85[8]JohnKerrWhatDoes“Lean”ReallyMean?LogisticsManagement,2006(5):29-32[9]2008[10]2008[11]ChristopherDChapmanCleanHouseWithLean5SQualityProgress,2005(6):27-32[12],2006[13]EliyahuGoldratt,2006[14]EliyahuGoldratt&JeffCox,2006[15]RobertConti,JannisAngelis,CaryCooper,BrianFaraher,ColinGill.TheEffectsOfLeanProductionOnWorkJobStressInternationalJournalOfOperationsandProductionManagement,2007(9):10-13[16]—IE2008[17]RogerLevinInventoryManagementTheJournalOfTheAmericanDentalAssociation,2004(6):788448[18]2007[19]2006[20]MikeNorbutDrivingForEfficiencyAmericanMedicalNews,2005(37):28-29[21]QuartermanLeeKanBanSchedulingSystemManagementServices,2008(1):28-31[22],2007(3):1-17[2