Lean Manufacturing System of Shenzhen Electronic Co., Ltd
Project background
This is a multinational company specializing in the design and manufacture of cables and wire harnesses for computers and mobile phones. The main processes are injection molding and assembly. In order to promote business development and achieve simultaneous growth in production capacity, quality and efficiency in the short term, the group headquarters has signed a contract with a consulting company to establish and implement a lean manufacturing system
Challenges
Due to the continuous growth of its major client Apple Computer's business and a sharp increase in sales, the factory is facing huge challenges including of insufficient production capacity, timely delivery and quality improvement. Apple has put forward a strict requirement of zero defects for its products. It is urgent to build a renovated model production line (with capacity target of 6K per day) within the limited space. Then build and fully implement the advanced lean manufacturing system.
Working contents:
- Lean leadership development, design and implement lean manufacturing systems and Six Sigma quality system;
- 5S zoning, factory visual management, lean daily management, standard operations, error proof design, application of industrial engineering techniques to build lean model production line;
- Tooling and molds improvement and new product development process improvement.
Effect and Benefit
- Build the lean manufacturing system including of KPI’s, lean daily management, Quality Assurance system, updated product development process, Trained for management team and front-line leaders, 5S and visual management has been fully established and copied to all production lines. The model line’s efficiency increased 50%, first time pass rate improved 50, the throughput has broken the historical record, production capacity has been increased 30%.
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