Establishment and Implementation of Manufacturing System for Precision Vacuum Pump Multinational Co., Ltd
Project background
This is an international precision vacuum pump developer and manufacturer. The group's products are widely used in fields such as power, glass coating, metallurgy, pharmaceuticals, and chemical industries. Since its establishment in Qingdao High tech Zone in 2012. The factory introduced lean manufacturing system consulting services from the beginning of the new factory construction in 2014. Since then, its market share has continued to expand, forming a complete industrial chain and technical team from technology research and development, precision manufacturing to assembly and testing. Its products dominate and lead the high-end vacuum pump market. In 2016, the output value was 220 million yuan, and in 2017 it reached 400 million yuan.
Overall Lean System Strategy
- During the planning stage of the new factory, lean principles were integrated to avoid the common problem of "investing first and then making improvements later" in the industry. A low-cost automated layout was adopted to reduce material handling and reserve space for flexible production line expansion.
- Precise investment was made by eliminating unnecessary automated equipment through value stream analysis.
Working contents:
- Lean Leadership Training and Coaching
- Production Line Layout Planning and Optimization
- 5S Zoning and Visual Management
- Key Indicator Measurement and Lean Daily Management Model SIM
- Problem Solving Group Activities & 6 Sigma Improvement Activities
- Standard work, Autonomous Maintenance and Preventive
- Maintenance Material Pull System and Kanban Production
Effect and Benefit
- Design and build the factory in a lean manner, implement comprehensive visual factory, and establish continuous flow and kanban-driven production lines.
- Establish a complete lean daily management system, Tired regular meetings, and on-site problem-solving mechanism.
- Complete the introduction of the lean manufacturing system and team personnel training and development.
|
Result |
Indicators |
Improved |
|
Efficiency |
OEE |
68% → 89% (+31%) |
|
Quality |
Reject rate |
4.2% → 0.8% (-81%) |
|
Quality |
Unit cost |
12% ↓ |
