基于价值流分析的F注塑成型厂生产改善研究

发布时间：2018-07-15 16:23

【摘要】：塑料制品是人们生产生活中非常重要的物资,而注塑成型是塑料成型的最主要方式。所以研究和改进注塑成型的生产管理过程并使其降低成本、提高效率具有重要的现实意义。精益生产通过在生产过程中推动准时生产,自动化等理念使企业能够达成零库存,杜绝浪费,提升系统柔性及零缺陷等管理目标,进而降低企业的运营成本,提升企业的竞争力。所以,利用精益生产的方式对注塑成型厂进行改造,并解决注塑成型厂所面临的实际问题,正是本文的目的所在。在对F注塑成型厂进行精益改善的过程中,本文首先从价值流管理的方法入手,对整个注塑成型厂的生产过程进行了完整的分析,发现影响注塑成型厂精益流动的最大障碍有四个：塑料原材料的库存,塑件零件库存,印刷件的库存及组立件的库存。针对所发现的问题,在结合了精益生产的原则思想及F注塑成型厂实际生产条件的前提下,对注塑成型厂的生产计划管理、生产加工工艺和生产物流管理等制定出了具体的改善方案。对于塑料原材料的库存,通过增加送货的频率及建立储存仓库的方式与供货商一起降低及控制原料库存的成本；对于塑件零件库存及组立件的库存,通过自动物料扫描系统、自动生产计划系统及快速切换的推行将生产计划由周计划改为日计划,降低了生产的批量,并使得注塑成型厂的生产能够快速的随客户的需求变化而及时调整,从而使库存减少；对于印刷件的库存,通过对印刷及装配生产工艺的改善将两个原本孤立的生产单元组合成一个生产单元,实现了“一个流”及“拉动”,彻底的消灭了印刷件的库存。F注塑成型厂通过对上述改善方案的实施,大大的降低了库存的数量,缩短了生产的周期,提升了生产的柔性。同时通过生产布局的改善等消除了物流过程中的迂回及倒流的浪费,并通过在装配线及仓库之间建立看板管理实现了生产的平稳的物流供应。在实现精益目标的同时也解决了注塑成型厂所存在的外租仓库,物流电梯瓶颈等现实的问题,较好的达成了预期的改善目标。
[Abstract]:Plastic products are very important materials in people's production and life, and injection molding is the most important way of plastic molding. Therefore, it is of great practical significance to study and improve the production management process of injection molding and to reduce the cost and improve the efficiency. Lean production enables enterprises to achieve zero inventory, eliminate waste, enhance system flexibility and zero defects by promoting the concepts of just-in-time and automation in the production process, thus reducing the operating cost of the enterprise. Enhance the competitiveness of enterprises. Therefore, the purpose of this paper is to transform the injection molding plant by lean production and to solve the practical problems faced by the injection molding plant. In the process of Lean improvement of F injection Molding Plant, this paper begins with the method of value flow management, and makes a complete analysis of the production process of the whole injection Molding Plant. It is found that there are four biggest obstacles to the lean flow of injection molding plants: the inventory of plastic raw materials, the inventory of plastic parts, the inventory of printing parts and the inventory of assembly parts. In view of the problems found, the production planning management of injection molding plant is carried out on the premise of combining the principle of lean production and the actual production conditions of F injection molding plant. Production and processing technology and production logistics management has been formulated specific improvement program. For the inventory of plastic raw materials, the cost of raw material inventory is reduced and controlled by increasing the frequency of delivery and establishing a storage warehouse with the supplier. For the stock of plastic parts and components, the automatic material scanning system is adopted. The implementation of automatic production planning system and quick switching will change the production plan from weekly plan to daily plan, which can reduce the production batch and make the production of injection molding factory adjust quickly and timely according to the customer's demand. As a result, the inventory of printed parts is reduced. For printing and assembly production processes, two originally isolated production units are combined into a single production unit to achieve "one flow" and "pull". Through the implementation of the above improvement scheme, the inventory of printing parts is greatly reduced, the production cycle is shortened, and the flexibility of production is improved. At the same time, through the improvement of production layout, the roundabout and backflow waste in the process of logistics is eliminated, and the smooth logistics supply of production is realized by establishing Kanban management between assembly line and warehouse. At the same time, it solves the problems of external rental warehouse, logistics elevator bottleneck and so on, and achieves the expected improvement goal.
【学位授予单位】：南京理工大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：F426.72;TQ320.662

【相似文献】