本文選題：生產(chǎn)線平衡優(yōu)化　切入點：產(chǎn)能提升　出處：《吉林大學(xué)》2013年碩士論文

【摘要】：當(dāng)前，受全球性金融危機、原材料價格波動、新《勞動法》實施、出口退稅調(diào)整等因素的影響，中國制造業(yè)正面臨前所未有的挑戰(zhàn)。對于如何應(yīng)對這些挑戰(zhàn)，各界觀點不一。不過有兩點是比較一致的：一是通過技術(shù)創(chuàng)新，在創(chuàng)新中發(fā)展；二是通過管理創(chuàng)新，變粗放管理模式為精益生產(chǎn)模式。技術(shù)創(chuàng)新無疑是企業(yè)擺脫目前困境的最有效方法之一，但是對于中國絕大多數(shù)中小企業(yè)來說，通過建立自己的研發(fā)中心，開發(fā)具有獨立知識產(chǎn)權(quán)的產(chǎn)品，既缺乏雄厚資金的支持，又無必要的人才資源依托，心有余而力不足。而通過管理創(chuàng)新，充分利用企業(yè)現(xiàn)有的資源，低成本、高質(zhì)量地把產(chǎn)品交付到客戶手中，是企業(yè)擺脫困境、在激烈的市場競爭中立于不敗之地的一個行之有效的方法。 DA公司作為汽車及汽車發(fā)動機配套零部件企業(yè)主要為哈飛、東安動力、東安三菱、吉利、華泰、眾泰、比亞迪、江淮等汽車企業(yè)提供相關(guān)產(chǎn)品的設(shè)計、制造及售后服務(wù)等。企業(yè)從80年代中期進入汽車行業(yè)以來，，在生產(chǎn)經(jīng)營組織和物流上由于受傳統(tǒng)計劃經(jīng)濟的影響，所以在原材料采購、產(chǎn)品加工、搬運、儲存、包裝、發(fā)貨等活動中應(yīng)存在停止、等待、工序間產(chǎn)品大量積壓等各種浪費現(xiàn)象。目前，面對原材料漲價、主機廠降價的兩難困境，給企業(yè)的生存和發(fā)展提出了嚴峻考驗。不斷提高生產(chǎn)效率、消除各種浪費、降低各項成本、充分挖掘人員和設(shè)備的潛能、提高企業(yè)的綜合競爭力，是目前急需解決的問題。 通過借鑒和學(xué)習(xí)優(yōu)秀企業(yè)的成功經(jīng)驗，并不斷探尋行之有效的持續(xù)改善工具、方法與精益管理思想，經(jīng)公司研究決定選取汽車零部件生產(chǎn)現(xiàn)場為觀察分析點，研究整個生產(chǎn)過程的運作，并重點從生產(chǎn)線平衡、生產(chǎn)線的瓶頸環(huán)節(jié)、設(shè)施設(shè)備布局、工具工裝、人員及從原材料投入到產(chǎn)出整個流程進行分析。通過分析，提出存在的具體問題，利用ECRS（取消、合并、重排、簡化）等工藝技術(shù)以及SMED和目視管理等方法，通過工藝流程優(yōu)化、設(shè)備利用率提高、員工動作改善等，對生產(chǎn)線平衡和優(yōu)化提出了改進方案。通過對新方案的實施，消除了生產(chǎn)線的瓶頸工序及各種浪費，生產(chǎn)線產(chǎn)能大幅提升，產(chǎn)品質(zhì)量穩(wěn)步提高，制造成本大幅降低，滿足了客戶需求。生產(chǎn)線優(yōu)化后日班產(chǎn)由750臺提高到1200臺，并創(chuàng)造每年節(jié)約人工成本72萬元，質(zhì)量損失成本16.27萬元的直接經(jīng)濟效益。同時，為公司開展生產(chǎn)線產(chǎn)能提升和生產(chǎn)線平衡優(yōu)化積累了經(jīng)驗。
[Abstract]:At present, under the influence of the global financial crisis, the fluctuation of raw material prices, the implementation of the new Labor Law and the adjustment of export tax rebates, China's manufacturing industry is facing unprecedented challenges. There are different views from all walks of life. However, there are two points of agreement: one is through technological innovation, and the other is through management innovation. Technology innovation is undoubtedly one of the most effective ways for enterprises to extricate themselves from the current predicament, but for the vast majority of small and medium-sized enterprises in China, by establishing their own R & D centers, The development of products with independent intellectual property rights is not only lack of strong capital support, but also no necessary human resources to rely on, the heart is more than enough, and through management innovation, the enterprise can make full use of the existing resources, low cost, Delivering high quality products to customers is an effective way for enterprises to get rid of difficulties and stay in an invincible position in the fierce market competition. As an automobile and automobile engine accessory parts company, DA company mainly provides the related product design for Hafei, Dongan Power, Dongan Mitsubishi, Geely, Huatai, Zhongtai, BYD, JAC, etc. Manufacturing and after-sales service, etc. Since entering the automobile industry in the mid-1980s, enterprises have been affected by the traditional planned economy in the production and operation organization and logistics, so they have been purchasing raw materials, processing products, handling, storing, packaging, etc. There should be a variety of wasteful phenomena such as stopping, waiting, and a large backlog of products between working procedures in such activities as shipping. At present, in the face of rising prices of raw materials, the mainframe factory is in a dilemma of lowering prices. It is urgent to improve the production efficiency, eliminate all kinds of waste, reduce all kinds of costs, fully tap the potential of personnel and equipment, and improve the comprehensive competitiveness of enterprises. By learning from the successful experiences of excellent enterprises and constantly exploring effective tools for continuous improvement, methods and lean management ideas, the company decided to select the automotive parts production site as the observation and analysis point. Study the operation of the whole production process, and focus on the balance of production line, the bottleneck of production line, the layout of facilities and equipment, the tools and tools, the personnel and the whole process from the input of raw materials to the output of the whole process. The existing problems are put forward, using ECRS (cancel, merge, rearrange, simplify) technology, SMED and visual management, etc., through optimizing the process flow, improving the utilization rate of equipment, improving the employee's movement, etc. Through the implementation of the new scheme, the bottleneck process and waste of the production line are eliminated, the production capacity of the production line is greatly improved, the product quality is steadily improved, and the manufacturing cost is greatly reduced. The production line optimizes the shift production from 750 to 1200, and creates direct economic benefits of saving 720000 yuan per year for labor and 162700 yuan for quality loss. For the company to develop production line capacity and production line balance optimization accumulated experience.
【學(xué)位授予單位】：吉林大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2013
【分類號】：U468.4

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