Revolutionizing Electric Vehicle Body Painting: A Lean Production Approach in the Digital Age

The Urgent Need for Sustainable Automotive Painting

The global push for greener transportation has put electric vehicles in the spotlight. However, many electric vehicle painting processes, often adapted from traditional methods, are riddled with inefficiencies. These outdated systems grapple with high pollution, exorbitant costs, and low automation, hindering the industry's growth and competitiveness. China, a global leader in electric vehicle production, faces the unique challenge of balancing rapid industrial expansion with ambitious sustainability targets.

This research tackles these challenges head-on, exploring the transformative potential of lean production and digital transformation in revolutionizing electric vehicle body painting.

Lean Thinking and the Power of Value Stream Mapping

Lean production principles, centered on eliminating waste, offer a powerful framework for optimizing manufacturing processes. Value Stream Mapping (VSM), a core lean tool, provides a visual representation of the entire production flow, highlighting both value-added and non-value-added activities. This study leverages VSM to pinpoint bottlenecks and inefficiencies in a real-world case study at TJ Automobile Manufacturing Plant.

By meticulously analyzing the body painting process, from pre-treatment to final inspection, this research identifies key areas ripe for improvement.

Digital Transformation: A Catalyst for Change

The digital revolution is reshaping industries, and automotive manufacturing is no exception. Digital technologies, including the Internet of Things (IoT), artificial intelligence (AI), and big data analytics, offer unprecedented opportunities to enhance efficiency, quality, and sustainability. This research demonstrates how digital transformation can be seamlessly integrated with lean principles to create a synergistic effect.

Imagine robots precisely applying paint with minimal waste, machine vision systems instantly detecting defects, and intelligent control systems optimizing energy consumption. This is the future of automotive painting.

ECRS: A Four-Step Path to Optimization

The ECRS (Eliminate, Combine, Rearrange, Simplify) framework provides a structured approach to process improvement. By systematically applying these four principles, the research identifies and addresses seven key issues impacting the value-added ratio of the body painting system at TJ Automobile. These include long cycle times, unstable quality, and environmental non-compliance.

Transforming the Painting Process: A Case Study in Action

This research goes beyond theory, detailing specific improvement measures implemented at TJ Automobile. These include:

• Optimizing sealing and gluing processes through digital tools and machine vision.
• Introducing automated spraying robots for increased efficiency and consistent quality.
• Implementing digital monitoring and inspection for real-time quality control.
• Utilizing digital paint mixing for precise color matching and reduced waste.
• Deploying intelligent waste gas treatment technology for environmental compliance.

Reaping the Rewards: Tangible Benefits

The results speak for themselves. The implemented improvements led to significant gains, including:

• A 9.5% increase in value-added operation time.
• A 12.5% reduction in non-value-added operation time.
• A 53-minute reduction in total system working time.
• An 18.8% reduction in personnel.
• A 15% reduction in defect rate.
• A 66% increase in exhaust gas purification rate.

These improvements translate to substantial cost savings, enhanced productivity, improved product quality, and a reduced environmental footprint.

Looking Ahead: Implications for the Future

This research provides a compelling case for the combined application of lean production and digital transformation in the automotive industry. It offers valuable insights for both enterprises and policymakers, demonstrating the potential for achieving both economic and environmental sustainability. As the automotive industry continues its rapid evolution, embracing these transformative approaches will be crucial for success in the digital age.

"With the advancement of high-end equipment manufacturing, the continuous development of industrial robots and intelligent system equipment, and the rapid development of information detection and management technologies, future lean production management research will ultimately integrate further with intelligence and informatization." - The Authors