The most popular way of progressive lean productio

The way of progressive lean production

lean production was first produced in Japan. It is a successful production mode summarized by Toyota Motor Company in the 1960s and 1970s. Its main idea is to produce the required products according to the required quantity when needed. Lean production mode corresponds to the previous mass production mode, and its basic characteristics are zero inventory, low cost and rapid response. At that time, lean production was more about pursuing the concept of zero inventory, so today's lean production has a more clear and clear operation mode, which is to thoroughly change the manufacturing and logistics supply process, and improve production efficiency on the premise of rapid response to the market

after entering the 21st century, the business environment of Chinese automobile enterprises has undergone fundamental changes. Joint venture automobile enterprises and local automobile enterprises are gradually established, and the production scale is also increasing. The globalization of market competition, the diversification and personalization of customer and market demand, and the relative excess of production make the product life shorter and shorter, and the price competition intensifies. Only when there are more types of vehicle models, platforms and optional accessories, and the delivery time of OTD (order to delivery) orders that need to respond to market changes is shorter, can we strongly occupy more market segments and enable automobile enterprises to seize market opportunities. Therefore, automobile manufacturers are eager to produce new models on the existing manufacturing equipment to meet the diversified needs of the market. How should automobile enterprises gain the leading edge and win in the future competition instead of being eliminated? In order to survive and develop in the cruel competition, automobile enterprises must develop a low-cost and rapid response lean production mode

lean production is often based on flexible manufacturing. The feature of this system is to integrate computer-aided design, engineering and manufacturing into a whole, and produce small batch customized products. Its core lies in the timely adjustment of its automobile varieties according to customer demand changes before flexible collinear production. What kind of automobile has a good market, the quantity of this kind of automobile variety can go up, and can be adjusted in time when the market is bad. The realization of all this, in addition to the change of management concept and business process, also depends on the production line automation control equipment, quality inspection equipment and information system management platform of automobile enterprises. In addition to the fact that some joint ventures can invest a lot of money to build their manufacturing system and build flexible production lines based on the concept of lean management at the beginning of the establishment of the plant, which covers the whole vehicle manufacturing links such as stamping, body, paint and final assembly, as well as Powertrain such as engine and gearbox, and can realize the co production of medium and high-end cars, station wagons and compact cars with different sizes and configurations, In the same period, the information system platform supporting flexible manufacturing management was introduced, and lean production operation was carried out by relying on the perfect matching of information system and production mode, realizing large-scale order production in a short time

but all this is difficult to achieve for domestic local automobile enterprises that are just in the initial stage. The production line of these local automobile enterprises is transformed from the original low production line, but the simple production line of variety production. Moreover, due to the small accumulation of original funds, it is impossible to invest a lot of money in the automatic transformation of the original line, and the R & D ability of new automobile products is relatively weak, There are few vehicle models, platforms and types. At present, small batch production mode is often used to arrange production. The informatization construction of these automobile enterprises is also in the initial stage. Although they are also learning from and absorbing the advanced lean management ideas and successful enterprise informatization mode of foreign counterparts, it is difficult to find an information system that can match their current operation mode because the information systems widely used by foreign automobile enterprises are developed based on flexible production mode. Moreover, many automobile manufacturing enterprises have traditionally understood information systems as product software, planned to purchase various systems to support business function requirements, and their investment plans also reflect the investment plans of various information systems. It seems that when these systems are fully purchased, the informatization of enterprises can reach a high level, and the lean production goal of enterprises can be achieved accordingly, In fact, this is a misunderstanding

in fact, the lean production of domestic local automobile enterprises is a step-by-step process, and there is no unified standard and model. Only the way that can match the current business situation of the enterprise, reduce the cost of the production process, and improve the production efficiency is the correct way. After all, automobile manufacturing is not a simple product processing, and it is difficult to complete the whole process of production control without appropriate information system to support production, let alone how to achieve lean production. When Toyota engineers designed Kanban as a standard tool for lean production, they did not expect that the traditional lean production method has become increasingly difficult to adapt to drastic market changes, changes in sales forecasts, and product customization, resulting in frequent changes in product structure, process routes, and personalized packaging, making it difficult to determine the best number of kanban, It becomes extremely difficult to maintain the circulation of Kanban cards manually to better serve the rapidly growing customers, and it is difficult to adjust the material movement path and make Kanban cards quickly. At this time, information system has become a new tool to transform lean production

therefore, in order to achieve lean production, so that production information can be transmitted to key control links in time, it is essential to establish an accurate neural system, which is the production and manufacturing management system, which is mainly composed of order management, vehicle body tracking, data acquisition, information broadcasting, quality management and other functional modules. And it can be integrated with ERP system and directly participate in the field automation equipment control system. It can integrate the core business processes required by the production of automobile enterprises, such as orders, suppliers, property management, production, equipment maintenance, quality control, and provide real-time, multi production structure, cross company production control information exchange; It can flexibly adjust parameters with the changes of products, order types and delivery dates, and can effectively help enterprises manage inventory, reduce procurement costs, improve on-time delivery capacity, and enhance a small number of diverse production control capabilities of enterprises. The system must be able to meet the current business needs of most local automobile enterprises with multiple varieties and small batches, and help enterprises realize business integration and process reengineering, solve the current difficulties encountered in lean production, so as to build their unique core competitiveness, and can be accompanied by the continuous exploration and improvement of enterprises in lean production, and rely on the configurable mode of modeling to meet the development and change needs of business, Give play to the value of information platform to help enterprises achieve lean production

it was once heard that a research group in the automotive industry in the United States studied Chinese automotive enterprises and believed that, in addition to several large joint venture automotive enterprises implementing lean production, it is difficult for other Chinese domestic automobile factories to promote lean production at this stage, because the non standardized production mode is not lean production, and it is also difficult to find an information system that can support their business mode on the morning of September 19. CAMM (common automotive manufacturing model) is a powerful tool that can help enterprises achieve lean production. CAMM is a system model based on the extensible J2EE application architecture, which uses the business logic of Enterprise JavaBeans (EJB) to model on the websphere application server platform. The system combines the successful case implementation experience of IBM in foreign automobile enterprises, and fully tests 6. Number of samples that can be installed: 120 (impact sample size: 10 × ten × 55mm) considering the business characteristics and development trend of local automobile enterprises in China, the system is configured with a loosely coupled modular modeling method to meet the business needs of different automobile enterprises. It consists of twelve modules: order management, vehicle tracking, information broadcasting, data acquisition, storage area control, error prevention, workshop monitoring, vehicle inspection, logistics scheduling, quality control, production report and quality report. The system runs through the whole business process of production and supply chain management, so that all functional modules can realize information synchronization, resource sharing, and the content of each link of lean production is reflected as information flow, It greatly helps enterprises reduce production and operation costs and improve their adaptability to market changes

at present, domestic automobile enterprises will inevitably encounter the bottleneck of unable to effectively control production due to the lack of timely communication of information in the process of lean production. There is an urgent need to solve this problem through the implementation of information systems, but they are unable to find a system suitable for their operation mode. If the flexible production control system used by foreign automobile enterprises is adopted, It is bound to first invest in the transformation of highly automated production lines that can match the system. In the following information, we need to understand in detail the business process and responsibility division changes of business process reengineering design, which can easily lead to the adverse effects of acclimatization. Moreover, the high system maintenance costs are also unbearable for low-cost domestic automobile enterprises. However, some production control finished software in the market is often limited to one aspect of business functions, which can not fully support the complete production and manufacturing business functions of enterprises, nor can it be integrated with automatic control equipment and other systems. Unstable software operation will frequently cause production line downtime, and it is extremely difficult to maintain the system in the later stage, so it cannot realize function expansion and system business integration, Not to mention the synchronous development with the pace of enterprise lean production. There are many examples of automobile enterprises falling into the IT quagmire in the implementation of information systems. Some enterprises with a long history can't integrate their systems due to the use of product software. Almost hundreds of information systems operate at the same time, and the difficulty of maintenance and integration can be imagined. CAMM solution successfully solves these shortcomings of flexible manufacturing management system or production control product software, According to the current business operation mode and business function requirements of the enterprise, and taking into account the current situation of other systems that have been implemented by the enterprise, it can choose each module to be implemented independently and jointly, and cooperate with the gradual development process of the automobile enterprise business, choose the appropriate solution for it, and complete the synchronous implementation of the enterprise's lean production transformation by adding other modules or enhancing the functions of the original modules. CAMM system can also help enterprises establish a standard business process platform to integrate internal and external related process applications through identification, such as cross department order management, material scheduling, parts distribution and other functions, and use its business integration ability with ERP system to help enterprises solve the mode difference problems caused by ERP's plan oriented and lean production's actual pull oriented, Make ERP and CAMM further play their respective benefits and advantages after integration. Moreover, the cross platform openness of the J2EE application architecture of the system enables the seamless integration of its internal modules and many external systems. The scalability and security of the system provide a reliable guarantee for the continuous production of automotive enterprises. The graphical production line configuration user interface of the system can help users conveniently and dynamically complete the production line process configuration