使用精益生产消除C公司在制品库存的研究

发布时间：2018-04-11 07:07

本文选题：精益生产 + 流程优化　；参考：《华南理工大学》2015年硕士论文

【摘要】：随着经济的发展,和全球化的推进,外资企业在中国的投资逐渐扩大,同时由于国家的鼓励和引导,民营企业也不断跻身进入化工领域,以及中国人口红利逐渐消退,人工成本不断攀升,制造行业的竞争越来越激烈。另外,由于化工行业的特殊性,国际上和国内,都对环保,节约能源以及安全提出越来越高的要求,这对中国的化工企业生产的管理带来了非常大的挑战,因此节能减排,提高工作效率和质量,降低生产成本,满足客户的各种高标准的要求,成为了企业生存和发展的重中之重。精益生产经实践验证是能有效提高企业运营水平的理论和方法,因此如何在工厂内系统有效的引入精益生产的理念,并创造效益的问题,显得尤为重要。C公司是一个从事化工生产和贸易的外资公司,在全球特种化工行业内具有领先地位。在面对复杂的经济环境和激烈的竞争中,C公司除了加大研发投入和固定资产投资外,也关注对工厂的运行的效率的提高,让现有的资产创造更多利润,并更有效的运行。而精益思想正是能实现这一目标的有效管理思想。本文使用精益思想的方法和理念,对C公司的某个工厂的价值流进行诊断,发掘工厂运行中存在的问题,根据流动的理念,工厂中在制品库存高企,阻碍物料在生产流程上的流动,并且平均库存比月销售量还大,月平均达到380吨,给工厂带来不小的浪费。进而对工厂内引起大量在制品库存的原因重点分析,找出根本原因。发现在制品的高企,主要原因在于生产排产流程缺失,产品质量波动大,一次性合格率低,同时员工操作技能低,生产线布局不合理及设备状况差等诸多问题。为了彻底有效的解决在制品库存高企的问题,本文提出全面引入精益生产管理理念的方案。在制品高企是整个流程各个环节造成浪费,为了消除公司内在制品的问题,需将精益生产引入到日常生产管理中去,从改变固有的生产方式上加以解决,才能有效的优化和消除。改进方案建议建立精益小组,包括管理团队的建设,基础工作的开展(5S管理,员工培训,绩效对话等)和相关改进项目的开展等。通过精益生精益项目的开展,全面的解决造成在制品库存高企的根本原因,从而优化生产流程,提高生产线的流动性,改变团队工作模式,降低和消除在制品库存,为工厂的持续发展搭建良好平台。本文总结了C公司使用精益生产的理念和工具,分析在制品库存高企的问题,发掘现有问题的根本原因并提出针对性的解决方案,对公司发展和对大部分的生产企业的精益生产的实施有一定的借鉴意义。
[Abstract]:With the development of economy and the promotion of globalization, the investment of foreign-funded enterprises in China has gradually expanded. At the same time, because of the encouragement and guidance of the state, private enterprises have also been continuously involved in the chemical industry, and the dividend of China's population has gradually receded.The labor cost is rising continuously, the competition of manufacturing industry is more and more intense.In addition, due to the particularity of the chemical industry, both international and domestic demands on environmental protection, energy conservation and safety have become increasingly high, which has brought great challenges to the production management of chemical enterprises in China, so energy conservation and emission reduction have been brought about.Improving work efficiency and quality, reducing production cost and meeting the requirements of various high standards of customers has become the most important for the survival and development of enterprises.Lean production is proved to be an effective theory and method to improve the operation level of enterprises. Therefore, how to introduce the concept of lean production into the factory system effectively and create benefits,Especially important. C Company is a foreign company engaged in chemical production and trade, and has a leading position in the global specialty chemical industry.In the face of complex economic environment and fierce competition, in addition to increasing R & D investment and fixed asset investment, the company also pays attention to improving the efficiency of plant operation, so that existing assets can create more profits and operate more effectively.Lean thought is the effective management thought that can realize this goal.In this paper, the method and idea of lean thinking are used to diagnose the value flow in a factory of company C, and to discover the problems existing in the operation of the factory. According to the concept of flow, the inventory of in-process products in the factory remains high.Obstructs the material flow in the production process, and the average inventory is bigger than the monthly sales volume, the monthly average reaches 380 tons, brings the factory not small waste.Then, the causes of large quantities of in-process inventory in the factory are analyzed, and the root causes are found out.It is found that the high quality of in-process products is mainly due to the lack of production scheduling process, large fluctuation of product quality, low one-off qualified rate, low operating skills of employees, unreasonable layout of production line and poor equipment condition.In order to solve the problem of high inventory of WIP, this paper puts forward a scheme of introducing the concept of lean production management.In order to eliminate the problem of internal products in the company, lean production should be introduced into daily production management to solve the problem of changing the inherent mode of production.In order to effectively optimize and eliminate.The improvement proposal suggests the establishment of lean teams, including management team building, basic work development, employee training, performance dialogue, and related improvement projects.Through the development of Lean and Lean Lean Project, the root cause of high WIP inventory can be solved comprehensively, so as to optimize production process, improve production line fluidity, change team work mode, and reduce and eliminate WIP inventory.Build a good platform for the sustainable development of the factory.This paper summarizes the concept and tools of lean production in C Company, analyzes the problem of high inventory of in-process products, explores the root causes of existing problems and puts forward targeted solutions.For the development of the company and the implementation of lean production of most enterprises have certain reference significance.
【学位授予单位】：华南理工大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：F273;F426.72

【相似文献】