i. project background
the company is a professional production and operation enterprise. the company occupies an area of 210,000 square meters. now it has more than 1200 employees and more than 450 professional and technical personnel. the company mainly produces the company's brand of copper valves, iron valves, stainless steel valves, plumbing equipment, water meters, aluminum-plastic composite pipes and copper pipe fittings and other products, with more than 3,200 varieties, with an annual output of more than 20 million (sets). the company is china's copper valve production and export base, and is also the vice chairman of china hardware products association, the chairman of the national valve and plumbing and sanitary ware industry association. amico brand products not only have many varieties and specifications, but also have the characteristics of beautiful appearance, good performance and excellent quality. they have won many titles and obtained a series of international certifications such as iso9001:2000 quality management system and iso14001 environmental management system. in 2002, the faucet products won the title of “top ten famous brands in the national water faucet industry”. with the rapid development of science and technology in recent years, the company has adopted internationally advanced technology for product design, using high-precision special machine tools for processing, and has a set of strict product management systems. innovative craftsmanship, a large and skilled team of experienced staff, make the brand products better and better, and won the favor and respect of consumers. many famous buildings and some national key construction projects have selected brand products. the company's products are sold all over the country and are sold all over the world.
2. customer needs
what problems did the customer encounter:
1. the field equipment is too old, lacking attention to lean production, and the material carrying methods are varied; the production line is more traditional; the space utilization rate is not high;
2. the flow of people, logistics, and detours lead to a large number of incidental operations without added value. the 5s on-site is poor, and there are too many wip products on site;
3. information transmission depends on information, information records are written, and information is lagging;
4. the material distribution method is a typical one-time large-volume delivery method. once an abnormality occurs in a material, it will cause batch errors.
5. there are a large number of incidental work with no added value during the operation.
lean production line analysis:
1. designing the layout and quantity of lean production lines according to tt;
2. the line body meets the requirements of flexibility and expandability, and can be continuously upgraded to meet the production needs of different products and different processes;
3. the lean production line equipment is modularized, and the lean production line can be assembled freely to improve the efficiency and longevity of the equipment;
4. according to pqpq (order quantity, process path), classify the line body.
lean production line benefits:
the production balance rate has been greatly improved;
the space utilization rate of the site is saved and the floor space is reduced;
optimize the 5s site for easy management and the overall look of the company;
the first mention is flexible, can be quickly switched, and quickly respond to the market;
reduce personnel and achieve provincialization.
3. project improvement
before improvement
after improvement
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