Developing the Delivery of Low-volume Products in a Chinese Fctory
Pan, Li (2015)
2015
Master's Degree Programme in Business and Technology
Talouden ja rakentamisen tiedekunta - Faculty of Business and Built Environment
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Hyväksymispäivämäärä
2015-04-08
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:tty-201503231138
https://urn.fi/URN:NBN:fi:tty-201503231138
Tiivistelmä
The capacity management of low-volume products manufacturers faces challenges such as unpredictable demands, manufacturing routings variety, product variety, and complex production control and scheduling system. To meet problems caused by these varieties and uncertainties, a handful of measures should be done based on the full understanding of the characteristics of low-volume production.
Metso Corporation aims to help to enhance capacity performance of its member company Shaorui Heavy Industries Co., Ltd. Therefore the objectives of this thesis are to identify and solve the capacity problems in this high-mix, low-volume Chinese factory through better utilization of its current resources thereby ensuring all the needed components are ready in time before assembly and meanwhile modifying the current shop floor control way into a more visualize and lean management style. Thereafter, the goal of lead time reduction and capacity improvement can be fulfilled.
After the information be collected and analyzed, the results of this thesis could be concluded as follows. Firstly, a capacity calculation framework is designed for Shaorui based on its standard hours, manufacturing procedures and routings. Capacity could be visually managed by changing the operating machine tools, upgrading shifts, or increasing working hours via this framework. The potential bottlenecks are defined and handled through pull control and safety stock. Secondly, by implementing new scheduling system, the lead time might be cut down by one third. Specially, more considerable scheduling system is conducted for reducing unnecessary queue time and move time. Methods such as single minute exchange of dies are employed to minimize setup time. Finally, a Kanban system is tailor-made for Shaorui production line. The information flow as well as the material flow could pass more smoothly than previous. With this new card system the production is easily controlled and monitored.
Metso Corporation aims to help to enhance capacity performance of its member company Shaorui Heavy Industries Co., Ltd. Therefore the objectives of this thesis are to identify and solve the capacity problems in this high-mix, low-volume Chinese factory through better utilization of its current resources thereby ensuring all the needed components are ready in time before assembly and meanwhile modifying the current shop floor control way into a more visualize and lean management style. Thereafter, the goal of lead time reduction and capacity improvement can be fulfilled.
After the information be collected and analyzed, the results of this thesis could be concluded as follows. Firstly, a capacity calculation framework is designed for Shaorui based on its standard hours, manufacturing procedures and routings. Capacity could be visually managed by changing the operating machine tools, upgrading shifts, or increasing working hours via this framework. The potential bottlenecks are defined and handled through pull control and safety stock. Secondly, by implementing new scheduling system, the lead time might be cut down by one third. Specially, more considerable scheduling system is conducted for reducing unnecessary queue time and move time. Methods such as single minute exchange of dies are employed to minimize setup time. Finally, a Kanban system is tailor-made for Shaorui production line. The information flow as well as the material flow could pass more smoothly than previous. With this new card system the production is easily controlled and monitored.