上海一冷开利生产流程优化研究

上海交通大学硕士学位论文上海一冷开利生产流程优化研究姓名：具毅哲申请学位级别：硕士专业：工商管理指导教师：田澎20080601UU255W1HWhy,What,Who,Where,When,HowElimination,Combination,Rearrangement,SimplificationOptimizedProductionTechnologyACE(AchievingCompetitiveExcellence)THESTUDYOFPRODUCTIONPROCESSOPTIMIZATIONINSHANGHAIYILENGCARRIERABSTRACTProductionprocessoptimizationisoneoftheimportantobjectivesofmanufacturerproductioncontinuousimprovement.Corporationmayincreaseproductionefficiency,reducewaste,decreaseinventory,increaseproductioncapabilityingreatextent,andtherebyincreasemarketvariationadaptability,enhancecorporationcompetitivestrengththroughproductionprocessoptimization.Productionprocessimportancetocorporationisobvious,itnotonlydeterminetheinvestedsizeoffixassetsintheinitialstageofcorporationfoundation,butalsogreatlyinfluencetheoperationcostofmanpower,physicalresourceetc.,andproductionefficiency,productqualityandsoon.Thisthesisanalyzedcurrentsituationofitsproductionlineprocessanditsfutureoptimizationissuescompletely,incorporatingwithpracticalsituationofcentrifugalproductionlineinShanghaiYilengCarrier.Thisthesisbrieflyanalyzedfacilitylayoutcharacterofcommercialair-conditioningcentrifugalchiller,firstbeginningwiththereasonofcentrifugalproductionlineprocessoptimizationofShanghaiYilengCarrier.ThenfoundoutcentrifugalproductionlineprocessissuesofShanghaiYilengCarrier,i.e.productionlinefacilitylayoutissues,jobstudyissues,productioncapabilitybottleneckissuesandjustintimeproductionissueswithseparatelyprofoundanalyses,throughproductioncapabilitycomparisonbetweenShanghaiYilengCarrieranditsmaincompetitorTraneChina.Intheaspectofproductionlinefacilitylayout,ontheonehandreplaceunreasonabledoubleUshapeworkstationlayoutwithsingleUshapelayout,hencereducingonlineproducttransportdistanceby25%.Ontheotherhand,increasemanufacturingflexibilityofdoublecompressorcentrifugalproductionline,enablingtobuildsinglecompressorcentrifugalchiller,wherebyreducewasteofleavingfixassetsunused,andestablishsolidphysicalfoundationforproductioncapabilityimprovementofthosebottle-neckworkstation.Intheaspectofjobstudy,carryoutoptimizationmeasurei.e.elimination,combination(leaktestworkstation),rearrangement(hydraulictestworkstation)forthosekeybottleneckworkstation,withtheapplicationof5W1H(Why,What,Who,Where,When,How)jobstudymeasureandproductionlinerenovationtechnologyECRS(Elimination,Combination,Rearrangement,Simplification).Inthemeantime,establishfundamentalbasesfortheobjectiveimplementationofthoseproductionwasteelimination,corporatecostauditandcostreductionetc.throughjobhourrationrecertificationforeachworkstation.Intheanalysesofproductioncapabilitybottleneckissues,setobjectiveforthoseseveralbottleneckworkstation,baseonthemarketforecastofcentrifugalchiller.Then,findoutrootcauseofbottleneckandputforwardpertinentimprovementproposali.e.addtubeexpandingworkstationandvacuumworkstation,splitrefrigerantreclaimjobfromperformancetestworkstation,replacethoselowefficiencyfixturesandinstrumentintheperformancetestworkstation,withanalysesofoutstandingissuesofbottleneckworkstationitembyitem,applyingoptimizedproductiontechniqueandproductionlinebalancetechnique.Intheanalysesofjustintimeproductionissues,analyzeseveralcasesthatcausingwaste,withtheconceptthattimesavingisbasicofjustintimeproduction,beginningwiththeintroductionofjustintimeproduction.Inthemeantime,putforwardvariousproposali.e.partsdefectelimination,productionflexibilitybetweendifferentworkstation,flexiblejobworkerpractice,employeemulti-skilltrainingandemployeerespectetc.baseonthepracticalsituationinShanghaiYilengCarrier,sothatattainproductionprocesssynchronizationandimplementjustintimeproductionauthentically.Wetrustfullybelieve,ShanghaiYilengCarriercanincreaseproductioncapability&competencyandfinallyretainanddevelopitsleadingstatusinthecommercialairconditioningarea,onlybyproductionlineprocessoptimizationandcontinuousACEimprovement.KEYWORDS:productionprocessoptimization,jobstudy,bottleneckworkstation,flexiblejob,justintimeproduction200862200862200862MBA111.11.1.12006304002020————102007201520104020071-1132620%2715517%42%48%25060%2%200613.511)3.45252)2.74203)2.46184)1.86145)1.86146)1.159MBA2ChinaMarketReviewCarrierChina12006FIGURE1TheMarketVolumeofChinaCommercialAppliedAirConditioningin2006200620102020079205—20062006=$1,352MSource:WDB,Feb5th,2007($millions@07pfx)$18614%$24618%$34525%$18614%$1159%$27420%20062006=$1,352MSource:WDB,Feb5th,2007($millions@07pfx)$18614%$24618%$34525%$18614%$1159%$27420%MBA31.1.21)2)3)4)——5)6)2000200642,200631)120ARIISO9002502401913DFMHVAC1100MBA4ChinaMarketReviewCarrierChina220002010FIGURE2DevelopmentTrendofChinaCommercialAirConditioningin2000-2010ChinaMarketReviewCarrierChina32006FIGURE3VariousAirConditioningMarketShareofCarrierChinain20066988309661,1051,2301,1431,3521,4461,5481,6561,77216.6%18.0%16.4%16.3%16.4%16.0%16.0%16.7%05001,0001,5002,00020002001A2002A2003A2004A2005A2006A2007E2008E2009E2010E0%5%10%15%20%25%-2000-2010CAGR00-1010%(%)($)($millions@07pfx)Source:WDB,Feb5th,20076988309661,1051,2301,1431,3521,4461,5481,6561,77216.6%18.0%1