cap公司油漆车间精益过程研究

上海交通大学硕士学位论文CAP公司油漆车间精益过程研究姓名：刘胜春申请学位级别：硕士专业：工业工程指导教师：李树刚;胡东海20091001ICAPCAPIIABSTRACTIIILEANMANUFACTURINGSTUDYOFCAPPAINTINGWORKSHOPABSTRACTTogetherwithincreasingcompetitionofautomotiveindustryandhigherfunction&qualityexpectationfromfinalcustomer,lower-price-strategy,atthecostofbadquality,towinthemarketsharecannotachievegoodresultanymore.Instead,todeliverhighqualityproductwithlowerinternalproductioncosttoobtainmoremarginbecomeamajormethodtoreinforcethecompetenceofcompanyandenrichitsmarketvalue.Asonememberofautomotivepartssuppliers,CAPCompanyalsofacestheaboveproblems.Afterconqueringthosedifficultiesencounteringatthebeginningofinitiation,CAPhaveestablishedacertainscaleofthecompany,butatthesametime,thebottleneck,suchaswasteandmanagementinefficiency,appearsandbecomeobstaclesforcompany’sfurtherdevelopment.Thenewprogramobtained,deliveringpaintedinstrumentpaneltoaforeigncompany,becomestheopportunitytosolvetheseproblems.Newproductrequirement,newcustomerrequirementandnewmanagementmethodneedCAPtoimproveitself,thusthecompanyplantoapplyleanmanufacturingsysteminpaintingworkshoptofindadevelopmentway,fittingforitselfandthenimplementitinthewholecompany.ConsideringpresentChinesemarketconditionandtakingseveraltypicalleanmanufacturingmethodsandtools,whichareusedinawidescopeandtheefficiencytoimprovetheproductioncapacityhavebeenprovedbymanysamples,asreference,thisthesistriestosummarizeaprincipletooptimizeinternalprocessandeliminatewasteofthecompany,whichcouldfitforpresentconditionofthecompanyandbeappliedinternallytoimprovethemanagementlevelandcorecompetence.Thisthesisstartfromvaluestreamanalysis,analyzethewholeproductionprocesstofindthebreakpointofimprovementandisconductedbyfinalcustomer’sdesireandleanABSTRACTIVmethodologyandassistedbymanyleanproductiontools.Finallyuseanactualsampletotesttheprinciplesummarized,findoutthepointsneedimprovedandfeedbacktomakeacircleofcontinuousimprovement.Intotal,studyofleanprocessbasedonvaluestreamanalysisisamethod,whichconsidersthewholeproductionprocessandfindsproblemtosolveit.Bythisway,alltherootcauseswillberevealedandavoidthoseunilateralmistakesiftheresearchisonlyfocusonsomespecificworkstations.Asasimplemethodtoimproveproductionprocess,italsocouldbetakenasreferenceinmanyplacesofautomotiveindustry.KEYWORDS:valuestreamanalysis,lean,bottleneck,improvementVII(1)VIII(2)C/T:CycleTimeC/O:ChangeOvertimeAva:AvailabletimeUptime:11.1[1]1.21.2.12[2]1.2.21.31.3.1311Fig.1Frameofthethesis1.3.2(1)(2)4(3)(4)1.452.1leanproduction,20’[3][4]1990[4][5]6[6](1)(2)(3)(4)(5)[7](1)7(2)(3)2.2[8][9](1)[9](2)JIT(JustInTime)(3)8(1)i.ii.(2)3(3)U(4)i.//ii.iii.9(5)i.ii.(6)[10]2.32.3.1,1.2.3.4.105.6.7.5%[11]80TaiichiOhnosenseiShigeoShingo.,,,5%112.3.2PDCA(1)Plan()(ProductFamily)[12](2)Do(3)Check(4)ActionPDCA5M(1)2080(2)12(3)TAKTTIME(4)2.42.4.1[13][14]113,,,,,[15]191217“”8“”5“”4“”[16]2.4.2ECRSECRSECRSEliminateCombineRearrangeSimplify[17](1)Eliminatei.ii.iii.iv.v.14(2)Combine(3)Rearrange(4)Simplify2.4.315[18]2.4.4[19][19]162Fig.2Productionbybatch151/55511155111153Fig.3Continuousproductionofonepieceflow251/55537717i.ii.iii.2.5183.119(1)(2)(3)(4)(1)20(2)(3)(4)(5)(6)(7)363.2(1)21[20](2)[21](3)22[22](4)(5)a.23b.i)ii)11iii)c.24(6)[23]3.3(1)(2)25(3)(4)(5)(6)3.4(1)2644Fig.4Sampleofproductionflowchart[24]a.b.c.2755[25]Fig.5Sampleofvaluestreammap[26](2)2866Fig.6SampleofParetodiagram20-80[27](3)2977Fig.7Sampleofcause-effectanalysischart[28](4)8[29]3012345:8Fig.8Sampleoftechniquesflowanalysischart(5)9319Fig.9Sampleoflinebalanceanalysischart(6)1010Fig.10Productlifecyclechart32[30]3.5••••••334.11111Fig.11Finishgoodspicture50(1)3334MANKIEWICZ44700001346611166=18.7=176s200812122008Fig.122008monthlycarproductiontendchart35200840%200840%15%15%31(2)133613Fig.13Paintingprocesschart1414Fig.14Materialracks3756016017014238010016160030113981614140,0001211,365,00012745024502450280000125150125014.24.2.1381515Fig.15Productionflowchart:10,,..:.700001346112391616Fig.16VSMpresentstatus(First)(1)45Uptime100%0(,)(2)2700Uptime100%20(,,)(3)(),16,:()3;2;2;3;3;3903600,,,3600Uptime91%0(,)(4)3040Uptime100%20()(1.5%)(5),(1)CAP(2)CAP,(),(3),174117Fig.17VSMpresentstatus(Second),::70000,1346,..6,1210;4020450424.2.21818Fig.18Paretodiagramofproductiontime(1)20450(2)43(3)(4)17627001919Fig.19ImprovementofVSMpresentstatus(Second)(1)(2)44(3)4.2.3232020Fig.20Techniquesflowanalysischartofmasking452121Fig.21Cause-effectanalysischartofmasking(1)2222Fig.22Partinglinesketchmapa.b.462323Fig.23Partinglinemagnifyingpicture2424Fig.24defectpicturec.472525Fig.25Connermagnifyingpicture(2)1.4146(3)3(4)(1)44264826Fig.26profilemodelingtape(2)4~61100mm*30m2727Fig.27Coveringplasticfilm(3)5mm492828Fig.28rollingtool(4)(5)2929Fig.29Foaminsert50(6)(7)3030Fig.30FixingJig(8)315131()Fig.31Techniquesflowanalysischartofmaskingafterimprovement(first)2525160936%:(1)5(2)523232()Fig.32Techniquesflowanalysischartofmaskingafterimprovement(Second)(1)766766/176=5154(2)/5335333Fig.33Techniquesflowanalysischartofcleaning677/5=1363434Fig.34Linebalanceanalysischartofpaintingworkshop5488136.0154.090.030.0225.0225.0