【作者】 梁勇；

【导师】 熊树平； 钟祥志；

【作者基本信息】 上海交通大学 ， 机械工程， 2012， 硕士

【摘要】 物流机械市场需求呈现出多品种小批量定制化的趋势,传统的大批量生产方式下提前期长且存在较高的库存成本和滞销风险。论文研究了L公司如何应用精益生产方式改进生产系统,提高了快速响应定制化的需求的能力,降低了运营成本,改进了装配质量,提高了生产效率。首先,运用战略管理理论分析了L公司的核心能力、业务组成以及市场环境,提出以多品种小批量的精益生产方式来支撑企业发展战略;以需求为导向设计、管理生产系统。其次,构建价值流图分析流程,运用五问法、鱼骨图等找出非增值活动产生的原因。针对物料不能准时齐套生产,在制品与整机库存较高的问题,改进生产计划,实施均衡生产。绘制各工序产能负荷表,找出瓶颈,重新分配资源消除瓶颈对产线能力的制约。文中应用ABC分类法分析需求,以整机、部件库存及订单生产的方式响应需求。基于设备、人员负荷的任务分配模式制定工段生产顺序计划,改善齐套率。绘制作业流程图实施产线平衡以消除产能浪费;改进工艺布局以缩短物流距离。运用5S、目视管理、看板等工具改善现场,实施单件流生产。按工序统计数据,在小批量装配生产中应用SPC方法改善了质量。最后,针对叉车生产中的库存问题建立了基于收益的库存优化模型。依据各类产品销售情况,分别按MTS、ATO、MTO方式储备库存,平衡库存成本与快速交付能力。更多还原

【Abstract】 The main purpose of this thesis is to improve Materials Handling Equipment manufacturer L’s productivity, on-time delivery rate and cost advantage for providing multi-varieties and customized forklifts. The competition within domestic market is becoming fiercer and fiercer. Company L must adapt its production system to multi-varieties, small batch and customized demand.Firstly, Strategy Management theories were adopted to analyze L’s strengthes and weaknesses, business profile and market trend. Lean production was then proposed to support L’s corporation strategy.Secondly, based on analytic results of Value Stream Mapping, value added time and non-value added time (NVAT) in processes, 5W and fishbone chart were used to find the root causes of NVAT. To solve the problem of non-match materials, high WIP and inventory, production planning was improved for balancing JIT production. Process utilization chart was applied to identify the process bottleneck. Production resource was reassigned to remove the limitation from bottleneck.This thesis applied ABC classification to analyze demand of each variety, and then designed main production plan mode. Inventory and“make to order”strategies were adopted to respond the requirement. Based on equipment and worker utilization rates, job assignment and production scheduling and sequencing were proposed to improve material matching rate. Process flow chart was used to balance production line and remove wastes. Process layout was further improved to reduce transportation distances. For one piece flow production, other lean tools including 5S, visual management and Kanban, were applied to improve production lines. Combining statistical data in each procedure, SPC was successfully applied in small batch assembly for improving production quality.Finally, inventory optimization model for revenue maximization was also proposed. Based on sales data of each variety, forklifts were sorted into 3 types and stocked by MTS, ATO and MTO modes respectively.更多还原