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1. INTRODUCTION
Nowadays Customers need customized and diversified
products. A lot of manufacturers are producing more
and more kinds of products in less and less batch.
However if the small batch products are produced in
Mass Production (MP), the cost must be high,
production cycle must be long. So how to lower the
production cost, shorten the production cycle in Batch
ProductionOBPO is an important project that is being
researched in many countries at this time. Experts put
forward quite a few methods that may resolve this
problem. Among these, Group Technology (GT) and
Lean Production (LP) are two fruitful theories in
production organization and management. But usually
they are used separately. If GT can be integrated into
LP, it may put forth the advantages of LP more
completely, and lower the production cost, shorten the
cycle, and improve the product quality more.
2. INTEGRATION OF LP AND GT
The main idea of GT is to divide parts into different
families in their design, manufacturing and
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3. LP MODEL BASED ON GT
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Delivery
Marketing
forecast
Marketing
Scheduling of design,
manufacturing,
assembly,debugging
Marketing
Marketing
I
I
:
Scheduling
design,
manufacturing,
assembly,
Purchasing parts
&components
of 4-------Purchasing parts
& components
dl
I
Manufacturing parts
%components
I
Checking
Assembly, debugging
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Group Technology
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4. A CASE STUDY
A punch company in East Zhejiang, China has
accomplished this production method to a large extent.
The procedure is as following. First, the company
programmed the new method of production
management to be accomplished as a whole, and
planed
rational
approach
for
step-by-step
implementing. Second, all employee are trained at
different levels according to the above programming to
understand the new method deeply. Third, effects are
focused on. Focusing on effects is the center of the
management philosophy of this company. Up to now,
this company has accomplished CE, TQM and GT, and
has obtained obvious achievements. The detailed
implementation procedure is (1) GT. All nonstandard
parts have been coded. Product Data Management file
(PDM) has been constructed. The structural design,
process planning, production preparation, and
manufacturing of new parts were all done by selecting
same or similar technological documents in PDM
according to the codes of the parts. So the fares and
cycles to design and manufacture the parts were
reduced greatly and also the management of the parts
became convenient. ( 2 ) TQM. This company has paid
much attention to the cultivation of Company Culture.
Every employee agrees Product quality is produced by
me, is taken charge of by me, Same defectives are
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5. CONCLUSION
From the above analysis, it can be seen that by contrast
to traditional production method, LP based on GT will
shorten production cycle, reduce particular checking
process, lower inventory, improve product quality, and
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IEEE
REFERENCES
[l] Y. Chen, X. Wang, X. Huang, Practical Group
Technology, Beijing: Mechanical Industry Press, ch. 1,
pp. 3-7, 1992.
[2] J. P. Womack, D. T. Jones, D. Roos, The Machine
That Changed the World, New York: Rawson
Associatea pp. 48-137,225, 1990
[3] L. Zhang, Lean Production, Industrial
Engineering and Management, vol. 2, no 2, pp. 1216, April 1997.
[4] J. Wang, X. Zang, E Zhu, Lean Production of
Advanced Manufacturing Technology, Journal of
Yanshan University, vol. 22, no 2, pp. 176-178, April
1998
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IEEE