Customer introduction:

The company is a comprehensive enterprise specializing in the production of safety seats and children's products. It is the first company in China to produce car child safety seats. It is also the first company in China to pass the ECE R44/03 standard certification. The products are sold to 60% of the world. Multiple countries...

What problems did the customer encounter:

1. The material distribution method is a typical one-time large-scale distribution, which results in a large amount of materials on the site. It is difficult to trace the material once it is abnormal;

2. The flexibility of the wire body is not high (high, medium and low);

3. Low space utilization;

4. A large amount of waiting time between stations due to unreasonable material replenishment methods and process design;

5. Repeated product take-up to increase employee fatigue;

6. On-site information transmission is through "Roar";

7. No anti-detention, misplaced measures lead to quality insecurity;

8. The scene is chaotic (5S poor).

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:

1. The production balance rate is greatly improved (large materials are loaded by beats);

2. The space utilization rate of the site is saved and the floor space is reduced;

3. Optimize the 5S site to facilitate management and the overall look of the company;

4. The first mention is flexible, can be quickly switched, and quickly respond to the market;

5. The number of personnel is reduced and the experiment is saved.

6. Adopt visualization plus information management to achieve rapid feeding and reaction.

Improved

Before improvement

G3 line overall layout