随着我国汽车工业的快速发展,汽车零部件市场也逐步扩大。在经济全球化、客

户需求多样化的竞争环境下,如何提高企业的竞争力和市场应变力是每个汽车零部件企

业必然面临的现实问题。伴随经济的持续发展,不断增加的人工成本己经成为影响企业竞

争力的重要因素。提升人工效率是有效控制人工成本的唯一途径。工厂布局是一切生产

活动的基础,将精益思想合理应用到工厂布局规划中,给人工效率的提升提供必要的保

证,是企业优化成本结构并提升综合竞争力的关键手段之一。

本文基于精益生产理论的研究,通过归纳精益生产核心思想,运用工业工程和系统

布局的基本方法与理论,以全球前十的汽车零部件制造的F公司作为原型,针对工厂目

前面临的人工效率提升的瓶颈问题,对其现有工厂布局进行观察与研宄。首先,论文通

过整体联系局部的过程,分析其工厂现有布局的特点以及问题,重点研宄工厂布局模式

和整体方案的解决;其次,综合运用精益布局的方法及评价体系,对现有工厂布局进行

分步优化,并跟踪优化结果,同时对造成现有布局缺陷的原因进行深层次的分析,总结

得出物流系统分析、评价体系、以及调整流程三方面的原因;最后,针对上述三方面的

原因提出相应的工厂布局改进建议。

论文根据这些问题提炼出适用于汽车零部件工厂的关于精益布局的9大原则、结合

KPI的模糊理论评价体系、布局调整流程等理论,为其全球其他工厂作为样板以及理论

依据,并对整个过程做出总结,希望能找到不仅适合F公司的布局原则,也为其他类似

企业提供一条思路。

关键词:汽车零部件;精益生产;工厂布局;模糊综合评价;流程管理

第II页
华东理工大学硕士学位论文

Plant layout improvement research based on lean production in F Company

Abstract

With the rapid development of Chinese automobile industry, auto components market is

gradually expanding. In the competitive environment of economy globalization and

diversification of customer needs, every auto parts enterprise is supposed to face this real

problem, i.e., how to improve self-competitiveness and market strain capacity. Following the

sustainable development of economy, the increasing labor cost has become an important

factor affecting the competitiveness of enterprises. To enhance labor efficiency is the only

way to control labor costs effectively. As plant layout is the foundation of all production

activities, reasonably applying lean thinking to plant layout will provide necessary guarantee

to labor efficiency promotion, and it is one of the key means for enterprises to optimize the

cost structure and enhance comprehensive competitiveness.

Based on the research of lean production theory, through inducing the core ideas,

employing the basic methods and theories of industrial engineering and system layout, this

paper takes the world's Top 10 auto parts manufacturer F Company as its prototype,

addressing the bottleneck problem of labor efficiency that plant now facing, conducts

observations and researches on the existing plant layout. First, through the process from the

local to the aggregate sum, the paper analyzes the characteristics and problems of plant's

existing layout, focusing on the layout pattern and the overall solution scheme. Secondly,by

integrated use of lean layout method and evaluation system, optimize the existing layout step

by step,and track the results; meanwhile, make deep analysis on the root cause which lead to

the defects of existing layout, and then comes to the conclusions of the three reasons, logistics

system analysis, evaluation system and process adjustment. Finally,the paper also gives

suggestions on the layout optimization accordingly to the three aspects.

As per these problems, the paper extracts nine principles on lean layout, suitable for auto

parts companies, and by combing the theory like fuzzy evaluation system from KPI and

layout adjustment process; it demonstrates as a model for F company's other plants

worldwide a theoretical basis also. And it makes conclusions on the whole process,trying to

find a layout principle, not only suitable for F Company, but also may provide a train of

thoughts for other similar enterprises.

Key Words: Auto Parts, Lean Production, Plant Layout, Fuzzy Comprehensive Evaluation,

Process Management