【作者】 余穗；

【导师】 潘尔顺； 许卫华；

【作者基本信息】 上海交通大学 ， 工业工程， 2008， 硕士

【摘要】 随着目前原材料价格的不断上涨和汽车市场价格的持续下降,对汽车产业的降本增效提出了更高的要求。在这种情形下,为了消除生产过程中存在的浪费,提高生产效率,缩短生产周期和提高产品质量,有必要运用价值流图析技术分析制造过程中存在的问题,并针对这些问题结合其他基础工业工程分析工具进行改善。本文将以上海英提尔交运汽车零部件有限公司汽车座椅制造过程为对象,期望能够通过建立看板拉动系统、实施质量改善和控制等一系列活动,更好地降低成本、提高产品质量、满足顾客的需求、提升企业的综合竞争力。本次设计中,选取了一条POLO基本型前座骨架生产线为研究对象,首先采集了制造过程中的大量实际数据,根据生产计划与控制信息传递方式、生产工艺流程、以及制造过程中的库存、设备开机率等信息,绘制出了价值流现状图。通过价值流现状图的分析,发现了目前生产中存在的问题,针对在制品库存过大和产品的合格品率较低两大关键问题提出了改进的策略。在库存的改善方面,建立了以看板为手段的拉动式生产系统,设计了看板运作的流程,并就看板的数量进行了计算分析。在质量改善方面,重点就质量功能展开(QFD)、失效模式与后果分析(FMEA)及两者的整合进行了分析。最后,在改善后的价值流图的基础上分析了改善策略的实施效果,总结出一些经验以期发挥借鉴作用。更多还原

【Abstract】 With the continuous rising of price of raw materials and continuous falling of price of cars, it is important to consider how to reduce cost for automobile industry. In order to eliminate all kinds of waste in manufacturing process, reduce cycle time, and improve productive efficiency and quality of products, it is necessary to analyze the manufacturing process using value stream mapping, and solve existing problems with IE tools. In this thesis, Shanghai Intier Jiao Yun Automobile Parts Co., LTD will be taken as the research example. This work presents that how to reduce cost, improve quality, satisfy customers and promote the company’s competence through building up a Pull System and carrying out a series of quality improvement and control activities.A product line of Polo basic front seat framework is studied in this thesis. The current value stream mapping is firstly drawn based on the data collected from production information, process, inventoy, and efficiencies of equipments. The wastes in manufacturing process are exposed through the value stream map, which provide the direction for further improveing. In this case, inventory and quality are the most important factors to improve. The pull system is then built based on the Kanban. The process of Kanban operation is given and the quantity is calculated. In quality improvement, quality employment function (QFD) and failure model and effect analysis (FMEA) are used and the integration model of QFD and FMEA are given. Finally the effect based on the improvement is evaluated and the conclusion is given.更多还原