精益生产理念在改进丝涟(Sealy)床垫工厂生产流程中的应用

Application of Lean Manufacturing Concept in Manufacturing Process Improvements of Sealy Mattress Plant

通过对全球最大床垫制造商丝涟公司位于美国纽约州格林岛的组装工厂目前的生产系统进行包括统计资料、产品类型、产能、一般生产步骤、循环时间、内部物料流通、零件识别与追踪以及自动化组装应用在内的综合性分析,找出生产瓶颈,提出利用精益生产理念来提高生产效率、降低总成本的改进建议。一种专门设计的自动推车被用来放置组装每个床垫所需的所有零部件,并使所有缝纫与组装工作在其上直接完成。工厂生产区域根据自动推车组装线重新布局以满足需要。最后对改进前后的生产效率进行定量分析比较以体现改进设计的价值。

The Sealy Mattress statistical data, product types, production capacity, general producing process, cycling time, interior material flow, components identification and automation assembly of the plant which is the biggest mattress manufacturer in the world and is located in Green Island, NY USA, are analyzed comprehensively in this paper. The producing bottleneck is found and an im- proved suggestion is made on implementing the Lean Manufacturing Concept, improving the production efficiency and reducing the production costs. The producing area of the plant is rearranged in order to meet the requirements of the new assembly lines. Through the quantitative analysis and comparison of the production efficiency,the improvement is of value.