Lean Precast Production System based on the CONWIP Method

摘要

To enhance the level of precast production management, and to reduce the costs of precast production, a lean precast production system is developed based on the constant work-in-process (CONWIP) method. Then the performance of this system is verified using the Discrete Event Simulation (DES). A quantitative performance evaluation between the lean precast production system and the current precast production process is provided using the JaamSim simulation platform. Cases and site visits to precast concrete plant in China are combined to collect the production procedures and initial parameters involved in precast production. Through simulations, Non-value Adding (NVA) activities, as well as bottleneck workstations, are identified in precast production. The optimal number of cards to be used in the lean precast production system is also presented. Our simulation experiments show that the lean precast production system provides an effective way to control queue length and shorten the WIP and cycle time, while also maintaining throughput and saving 25.4% of labour cost.