i. project background
founded in 1988, the company has grown into the largest integrated stationery supplier in china after 20 years of exploration and hard work. since the 1990s, the company has maintained rapid growth. in 2007, its global operating income exceeded rmb 1.2 billion, and more than 5,000 employees were located in 29 provinces and cities nationwide. since 2001, the company has maintained a rapid growth rate of 100 million yuan every year. in 2005, its sales revenue exceeded 700 million. in 2007, the company set up a sales branch in thailand, which marked that the successful brand has successfully entered the southeast asian market. it also marks a powerful strategic vision: “every office in the world is effective” and has made a big step forward. as the largest stationery supplier in china, the company has won the honorary titles of “national inspection-free products”, “top ten brands of chinese stationery”, “china export famous brand”, “china's best-selling stationery brand” and “china famous brand”. has passed iso9001, iso14000 and other system certification. in the future, the company's development goal is to become the world's leading integrated stationery supplier and create a globally competitive enterprise.
2. customer needs
what problems did the customer encounter:
1. the company was established for a long time, the company's internal production lines are varied; the tooling return line is too long, the flexibility is poor; the production line is more traditional; the space utilization rate is not high;
2. the flow of people, logistics, and detours lead to a large number of incidental operations without added value. the 5s on-site is poor, and there are too many wip products on site;
3. information transmission depends on information, information records are written, and information is lagging;
4. the material distribution method is a typical one-time large-volume delivery method. once an abnormality occurs in a material, it will cause batch errors.
5. there are a large number of incidental work with no added value during the operation.
lean production line analysis:
1. designing the layout and quantity of lean production lines according to tt;
2. the line body meets the requirements of flexibility and expandability, and can be continuously upgraded to meet the production needs of different products and different processes;
3. the lean production line equipment is modularized, and the lean production line can be assembled freely to improve the efficiency and longevity of the equipment;
4. according to pqpq (order quantity, process path), classify the line body.
lean production line benefits:
the production balance rate has been greatly improved;
the space utilization rate of the site is saved and the floor space is reduced;
optimize the 5s site for easy management and the overall look of the company;
the first mention is flexible, can be quickly switched, and quickly respond to the market;
reduce personnel and achieve provincialization.
3. project improvement
before improvement
after improvement
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