Logistics lean, smooth manufacturing upgraded logistics “artery”

If a production line is the “bones” that build the manufacturing capacity of the factory, then the smooth continuous flow of materials is the “artery” of the factory to ensure the efficient operation of the entire production process. Over the years, the DC plant of Weiling Motor Shunde Factory has added capacity expansion areas, adjusted or upgraded existing production lines many times according to the changes in market demand, which has caused the workshop site to be crowded and the continuous flow between the lines is also more chaotic. According to Huang Gong recalled: “At that time, there were even backturns on the big logistics routes, with many crossing points, low distribution efficiency, and security risks. To improve the overall efficiency of the plant, smooth logistics is essential, so we are determined to open up the logistics’ artery ‘of the entire plant to inject new vitality into lean production.”

IC697BEM733 According to the actual operation of the plant, the flow lines of various materials in the DC plant are analyzed, and the overall layout of the production line is comprehensively optimized. Firstly, the unit matching is carried out around the physical flow of the two major workshops of stator-BMC-assembly and rotor-assembly to lay a good foundation for continuous flow. Secondly, according to the needs of each workshop, the nearby line warehouse is set up, so that the large logistics can realize one-way flow, and the logistics distribution distance is shortened by 50%. Finally, the continuous flow connection of the front and back processes was optimized to effectively reduce the frequent production conversion caused by the last number of non-production, and the production efficiency of the single line body was increased by 20% after adjustment, and the overall park was increased by 25%. Not only that, the optimized workshop layout is more spacious, and the length of the line body is lengthened, which lays a solid foundation for the next step of automatic production line introduction and “black light” production.

In addition to the optimization of logistics routes, the DC factory has also carried out lean management and digital intelligent upgrading of the material distribution process. Huang Gong introduced: “In response to the chaos of the factory logistics site, distribution difficulties and other problems, we adopted the material sorting set of rules, greatly reducing the time to find materials, and material management has become clear, if there is any abnormal daily operation, we can quickly identify the cause by reviewing the rules, targeted improvement.”

IC697BEM733 The so-called set rules, on the one hand, is to optimize the distribution process, by reviewing the set, sorting and sorting and AGV automatic distribution to the production line, to ensure production stability and site balance control; On the other hand, it is to make full use of accounting processing informatization, digitization of material instruction and other numerical intelligence methods, and clearly display the material distribution process through a complete set of Kansigns to ensure the synchronization of relevant personnel information. Through the adoption of a complete set of rules, the DC plant of Weiling Electric Shunde Factory effectively improves the distribution efficiency by 50%, the accounting accuracy rate reaches 98.5%, and the factory runs more orderly.