Lean six sigma application in Automobile Engine production processwhp.docx
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1、How to use Lean Six Sigma to improve corporation process-Learn“Lean Six Sigma Overview”and practice in real operationIntroduction: Zhang Dong:Lean Six Sigma Manager at Ingersoll Rand,Deputy president of Lean six sigma committee,Chief editor of Asia Lean six sigma weekly magazine,China quality associ
2、ation six sigma promotion committee member,author of ,She dedicate to promote Lean Six Sigma method in real world and serves to teach as Honorary Professor in Shanghai Jiaotong University,Antai College of Economic and Management.William Liang:Shanghai Jiaotong University Antai College of Economic an
3、d Management,China Leaders for manufacturing Programme.After received B.E. degree of Material Physics from Central South University in 2004,he served in Laird technology and Saint Golban.He devotes to lean system building and lean implement in corporation.As student,William Liang studies Lean Six Si
4、gma in Zhang Dongs course.Forward:On 19th Dec,2010 we warmly welcome Ms Zhang Dong to bring a vivid lecture combined with her many years accumulated consulting experience and research achivement. The lecture opened from core concept of DMAICL,which means “define,measure,analysis,improve,control and
5、leverage”,a creative concept developed traditional DMAIC method and 6sigma tools that initial from Motorola, GE to a modern broadly implemented 6sigma concept not only used in manufacturing industrial but also in service industial such as great logistics circle (SIPOC),from suppliers,producer,wholes
6、aler to distributor. The lecturer brought a newly developed concept for todays evolutionary cooperation model in industrial chain and devote to widely leverage this advanced concept and theory to promote competence of individual companies as well as network in wholly industrial chain.After absorb th
7、is concept,I combined my work content to study how to apply 6sigma and DMAICL steps to improve our effectiveness in corporate operation.Text:With the living standard rising dramatically,automobile consumption keep increasing and has been witnessed to become the largest market globally.In 2010,domest
8、ic sales volume reached 18,060,000,with acceleration 32%.We confidently forecast that this rising trend will hold for many years.Engine production and sales benefit from this trend and domestic manufacturing advantage,with profit rate over 20%,even 40% in some core firms.As vehicle parts manufacturi
9、ng is a capital and labor intensive industry,contribute high weight to region economic,it is meaningful to research how to promote process capability and productivity in this industry.Lean six sigma method combine lean and six sigma and developed traditional Lean or Six sigma method,bringing new opp
10、ortunity for enhancing corporation process,accelerating delivery,turnover while eliminate waste within process or firms. The firms that adopt this advanced method perform highest profitability and competitiveness in market. Chart 1.1 China and U.S. Automobile and vehicle consumption trend among 2007
11、2010Chart 1.2 China automobile market trend of various kinds from 2003 to 2010.Chart1.3 Domestic automobile sales trend in decade for Large,big,medium,small and mini type.Raise our plant for example,we daily produce and assemble thousands of engines which broadly used in various vehicles,sale to top
12、 6 automobile OEMs,including domestic and joint venture firms.Quality and on time delivery is vital for engine plant as well as for our client.Aluminum ingot,and assemblies supplierOur plantAutomobile& vehicle producer Distributor(4S store)InputOutputSIPOCTo be leverage.Chart2: SIPOC flow chart of o
13、ur plant.From the chart mentioned above,we know that Supplier,our plant and clients form a link,and among upstream and downstream there exist many similar links.These links form a chain,which can also be called circle,and turnover rate,inventory volume/value be set as benchmark.Meanwhile,accompanied
14、 with material flow,information flow and cash flow(or capital flow) form the whole value flow system among the chains,involve internal and external departments for engine marketing and sales, order acceptance,design,supplier contracting,production and assembly,product&service delivery,finance settle
15、ment.Among the process we add value to raw material resource that we procured from upstream and deliver this value to customer.The information flow moving backward from downstream to upstream,including customer requirement,market forcast,rejection or rework,etc.Here we raise a product line as an exa
16、mple to explain our process improvement.CylindeChart 3.1 VSM(value stream map) for Cylinde process before improvementAfter identify value added steps and value added time in each steps,we find out non-value added time in steps respectively.Further improvement measures based on these identification a
17、nd analysis.Eg,we reduced casting set up time from 40h to 24h by keeping melting furnaces temperature and casting machine preparation.In these way,we dramatically reduce time waste.Owing to lead time reduction,we can quickly response to customer order and reduce inventory.These effort contribute to
18、tens of thousands RMB per month for each product.Chart 3.2 VSM for Cylinde process after improvementAccturelly,we continuously contribute to reduce cost through minimize waste and promote productivity,quality and service level.Emerging technical innovation may push process reengineering and progress
19、 in operation.In 2010,we adopt 2 new process technology.Process chart:MeltingPretreatmentCastingStorage &transportStorage &transportC/T=90 minC/T=4.5minC/T=4.3hValue added time:32 minVAT:3 minVAT:19 minNon-value add:58minN-VAT:1.5 minN-VAT:4hDefect:2%40 hDefect:4%20hDefect:1%Chart 2.1: Before improv
20、edC/T=90 minC/T=4.5minC/T=1.3hValue added time:32 minVAT:2.6 minVAT:19 minNon-value add:58minN-VAT:1.2 min(Ageing annealing)N-VAT:1hDefect:2%24 hDefect:3.2%20hDefect:1%Chart 3.1: After improvedContinuedStorage&transportHeat treatmentShot blastingStorage&transportRough machining50hC/T=9h1minC/T=30min
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