Optimization of Production System Based on Lean Thinking

Abstract

Purpose: The purpose of this paper is to find hidden waste and non-value-added activities during the whole process of M company, and then optimize production processes, shorten the production cycle, improve production efficiency, and ultimately achieve just-in-time production mode which response to customer demand rapidly. Design/methodology/approach: In order to identify and eliminate such kind of nonvalue added waste, the authors draw a current value stream map and a future value stream map of the SM6 series products in one electric-equipment-manufacturing enterprise. By analyzing the value stream mapping of the whole process of SM6 series products, the authors find hidden wastes and non-value-added activities, and then the authors use industrial engineering ECRS principle and 5W2H principle” to adjust and make new production plan model, including the analysis and evaluation of the production process, production line layout and other aspects, then, the authors optimize the working process and set up a new production process. Findings and Originality/value: By using Kanban and other lean concepts and techniques, the authors finally achieved pull mode of production (just-in-time production), and shorten production cycle, reduce inventory of semi-finished product and end product, eliminate excess production, and save labor cost, realize the 5S management mode effectively. Practical implications: The successful application of pull mode of production in the SM6 series products has set an example in implementing lean activities for the company’s other product series and most other manufacturing enterprise, Social implications: it also has a significance guiding for value stream mapping and lean thinking to be practiced in Chinese manufacturing enterprise and other industries.