精益生产在B公司的实践应用

上海交通大学硕士学位论文精益生产在B公司的实践应用姓名：吴卫斌申请学位级别：硕士专业：工商管理指导教师：季建华20080601BBBTHEAPPLICATIONOFLEANINCOMPANYBABSTRACTCompanyBproducesultrasonicproducts,whosecharacteristicdeterminedbysalesmarketisvariouswithsmalllot.TheLeanwasusedinCompanyBtoimprovethemanufactureefficiencyandrealizethecustomervalue.ThisthesisexpatiatetheproblemsinCompanyB,whichhasaffectedthestockmanagement,ontimedelivery,efficiencyimprovement,therelationshipandcooperationbetweenCompanyBandcustomer.Inordertoresolvetheseissues,theleanprojectgrouptakessomeactionsonorganization,process,planningandpurchasingmethods,usevaluestreammappingtoanalyzeandimprove.TheleanactionhelpscompanyBtoreducesthestock,enhancestheefficiencyandimprovestheOTDprimarily,tokeepadvantagesinmarketcompetitionandbenefitcustomer,it’shelpfultoexpeditegrowupforcompanyB.KEYWORDS:leanproduction,KANBAN,valuestreammappingMBAB1120-JITJITMBAB222.11990D.RoosJ.P.WomackD.Jones1MBAB31FIGURE1TargetandkeypointsofLean2.22.2.1/MBAB42.2.21234562.2.32.2.4MBAB52.32.4MBAB61Table1ContrastBetweenLeanandMassProductionMRPMBAB73B3.1BBB194660B7020002BFIGURE2FactoryofCompanyBB1993200BMBAB83BFIGURE3ProductsB20032004ISO9001ISO14001MBAB93.23.2.1B20%4FIGURE4BusinessProcess4BBMBAB103.2.2B-B3.2.3MBAB113.33.3.1B206(B98)923578664BB2(101-132-1403)06Table2GeneratorSalesInFY06069061006110612071072073074075076077078303061642136021000030300601964MBAB123.3.2322886412422832011913Table3ShipmentDelayList07124CPN-968-136B1500E-MTVWR(withpackage)20722807320(19)07124CPN-968-137B1500E-MTHVWR(withpackage)20722807320(19)07124CPN-968-138B1500E-DTHVWR(withpackage)20722807320(19)07124CPN-968-236B2500E-MTVWR(withpackage)10722807320(19)MBAB1307124CPN-968-237B2500E-MTHVWR(withpackage)20722807320(19)07124CPN-968-238B2500E-DTHVWR(withpackage)20722807320(19)07124CPN-968-336B3500E-MTVWR(withpackage)20722807320(19)07124CPN-968-337B3500E-MTHVWR(withpackage)20722807320(19)07124CPN-968-338B3500E-DTHVWR(withpackage)20722807320(19)07124CPN-968-536B5500E-MTVWR(withpackage)20722807320(19)07124CPN-968-537B5500E-MTHVWR(withpackage)20722807320(19)07124CPN-968-538B5500E-DTHVWR(withpackage)20722807320(19)07124CPN-968-838B8500E-DTHVWR(withpackage)20722807320(19)3.3.36903.3.4576MBAB145FIGURE5IMMProductsManufactureProcess1234568910117MBAB15538103.3.5407112064.71%,906018.84%6051213ITO44.5HCDSCITO=MBAB164071Table4CleaningMaterialIncomingDays(2007Jan)()()3020622810.90%60751165.55%9030539418.84%120+1373135364.71%5Table5MonthlyCostofCleaning069061006110712071()3,093.143,292.743,831.393,718.453,784.20()1,526.701,295.361,616.332,452.661,922.88M824L6067061206608487.63.3%,MBAB176M824LTable6OrderStatusofM824L067530-008-111M824L106121308415PO-0278-A63.3.6B66BFIGURE6PlanningMethods71234MBAB1820%7Table7JobOnTimeCompleteRate200692006102006112007122007113%18%22%17%21%MPSBERPExcelExcelExcelExcelExcelExcelExcelExcelExcelExcelMBAB19ExcelExcelBMBAB204BB4.14.1.17MBAB217()FIGURE7CompanyFramebefore5MBAB224.1.28()FIGURE8CompanyFrameafterMBAB238B4.24.2.11MBAB248543218Table8SupplierEvaluationReport100%5100%5-20%590~100%4≥99%4-15~-20%485~89%3≥97.5%3-10~-15%380~84%2≥95%2-5~-10%275~79%1≥90%1-1~-5%170~74%0≤90%0-1~-1%065~69%-1≤88%-11~5%-160~64%-2≤85%-25~10%-255~59%-3≤80%-310~15%-350~54%-4≤75%-415~20%-450%-5≤70%-520%-540%RDSER20%QA20%LOG20%LOG5-4-3-2-1-MBAB259Table9SupplierAuditReportNO1?2?AVL?3(AVL)??45VCR?5/?6780%??89?10?1112?13?141516(FIFO)17?18,.19.2015,,24,,33,,42,51:75,,:`9MBAB261-52103090MBAB2710Table10LeadTimeofCleaningMaterial()000-175-048R12WIDE90890-157-437RIGBTIRG4BC30KB500SEA80000-802-167RXDCR40MEDIUM45100-170-013RHEATER2210E,BRANSONIC45100-170-015RHEATER3210E,BRANSONIC45100-170-017RHEATER5210E,BRANSONIC45100-246-967RTRANSDUCER40KHZBRAN45102-242-336RPCBDTIMER8210SMT45200-029-206,,3×4,0.198-145200-082-004,,,3×4,0.198,40890-200-000RB500S7006,203/4x123/4x6,3040.840890-200-001RB500S7164,67/8x63/8x43040.840690-022-006120VA,230V/115V30690-022-007240VA,230V/115V30690-022-008R360VA,230V/120V,B500SEA30690-022-010R120VAC,240V/245V30690-022-011R240VAC,240V/245V30690-022-012R360VAC,240V/245V30890-104-000R/20449,SB2200HT/T30890-104-001R/,SB320030Excel303030MBAB2811Table11Material’sYearlyUsage100-241-186P/OBOARD537231890-150-043/PC06-01SANG-A,MINIII-GV4542.75890-179-950(TAYLOR),M4×12,4170.31890-074-953(R)RY17-15K3W5%4990.38580-058-053M12:45#8401.2821890-156-032R5W15V1N5352B,S70003862.73200-085-245MF10.0K,1/4W,1%,AXL3990.09890-151-1503165198weidmullaVWFixture66411.54890-151-152165037weidmulla,VWFixture6646.84890-151-153165036weidmulla,VWFixture6646.8411100-241-186537231187EOQ=(2DS/H)1/2:D=537S=187H=23120%=46.2EOQ=(2DS/H)1/2=(2537187/46.2)1/2=65.91070TC=+=(EOQ/2)H+(D/EOQ)S=(70/2)46.2+(537/70)187=3051.56D/EOQ=537/70=7.7,8MBAB294.2.2B6000ABCA-B-CA-B-CA,B,CA80%20%B15%C5%A,B12ABCTable12ABClist1101-162-067F8700C376004194.41%2530-008-155Bran-sonix750W/20KHz375885848.74%3020-845-500M-624228608210.84%4CNS-2307-040FM502HJ128423612.93%10890-401-803GB2966-82TC4,52245.216765821.30%11890-016-040TU8C380V316443022.51%12560-281-003M624115758623.67%13TEM-000-061MINIII-GV114822024.76%14530-008-1588915A713605725.7