基于价值流图技术的锁体生产系统优化

System Optimization of the Padlock Body Production Based on Value Stream Mapping

以某锁体生产线为实际研究对象,开展了生产线现场调研,收集了大量数据,进行了锁体生产线的价值流分析,明确了该生产线的生产流程,绘制了价值流现状图。在对现行流程中的主要浪费———"过量生产"和"库存"的产生原因进行分析的基础上,基于精益思想设计了锁体生产线价值流的未来状态图,确定了以生产链方式的价值流动生产方式,以看板-超市方式控制生产和库存,并对相关的生产计划、生产线平衡、质量控制、设备等进行了优化和改进。项目实施后生产周期减少92.8%;库存减少92.8%。

Investigation is made to improve the process of the production line of a padlock body. With massive data collected, value stream mapping method is applied to analyze the process. Special attention is paid to reduce the wastes of over-oroduetions and hizh level of inventory. Based on lean thinking, a future state value stream diagram is drawn. Then, the production process is redesigned such that the balance of the line, quality control, and production planning are improved. Furthermore, the operation of the produc- tion line and inventory are controlled by using Kanban-Supermarket-based methods. Consequently, both product through time and WIP are reduced by 92.8%.