基于IE方法的家用电器生产线平衡改善研究

文章以重庆A公司某家用电器生产线为研究对象,运用工业工程的方法和作业测定的基本理论,对该生产线的平衡问题进行分析研究,同时对影响生产线平衡的工装夹具、产品结构改良、物流方面进行了改善优化,最终使得该家用电器生产线的平衡率从51.24%提高到83.77%,实现了"一件流"的生产方式。     

生产线的平衡及优化研究

本文描述了水龙头基本的结构和生产的工艺过程,将水龙头的生产方式由原来的离散型生产变换成以流水线的方式连续生产,并重新对水龙头的组装方式以及组装工序进行了优化。计算出每个工位最佳的人员配比,使生产线平衡率尽可能地提高,经过一系列的分析及优化,生产线平衡率由原来的75.57%提高到了84.81%。     

换装生产线均衡生产探讨

随着某型号空空导弹批产的进行,原有装配车间生产模式由科研状态下的小批量生产方式转向批产后大批量的生产模式,生产模式的转变势必对装配车间生产线的均衡化生产提出更高的要求,如何适应研究院的发展,提高生产线的整体效率,减少工序间的在制品,以及追求同步化生产越来越受到重视。这里通过对装配生产线平衡的研究,结合自身部门产品的特点,对现有生产进行了探讨,说明了现有工业工程技术在生产线平衡改善中的作用。首先叙述了生产线平衡理论、评价方式,及影响线平衡的要素,同时根据工业工程基础理论定义了改善生产线平衡的方式。对于所讨论的某型号空空导弹火工品换装生产流程,针对其平衡率不高的问题,通过分析现状。然后根据生产线平衡的步骤及方法,按照工序节拍均衡的原则,使各工序节拍趋于一致,且将各工序生产准备方式标准化,提出了问题的解决方向。     

S公司减速器生产线平衡优化研究

生产线平衡对企业生产效率有着非常重要的作用,文章选取S公司减速器生产线进行优化分析,以生产线平衡率和平滑性指数作为评价指标,分别采用布局优化、生产工艺程序分析、不合理动作改善三种方法进行优化,并对每种优化方法的效果进行具体分析,发现单独采用一种方法进行分析,效果都不是很理想,最后将三种方法结合起来进行优化,生产线平衡率从62.2%提高到93.1%,平滑性指数由17下降到3.2,改善效果显著。     

基于位置加权法的单发热生产线平衡优化研究

以单发热生产线为研究对象,以优化生产线为出发点,本文在对单发热生产线现状分析的基础上,采用位置加权法获得了单发热生产线优化方案。研究结果表明,一方面,减少5个工位的同时,提高了车间利用率,降低了人力成本;另一方面,生产线平衡率提高了33.40%,大大缩短了产品交付周期。     

WH公司生产线平衡研究

生产线平衡研究一直以来都是制造业生产车间提高生产效率的一项重要课题。文章以WH公司燃气采暖热水器产品生产线为研究背景,通过改进车间布局将总装流水线和离散部装生产区进行重组,使该生产线平衡率由改善前的65%提升到90.1%,从而达到改善效果。     

基于多种群遗传算法的T公司装配生产线平衡问题研究

本文将对T公司光伏逆变器装配生产线平衡问题进行研究,通过建立以生产节拍,生产线平滑指数相结合的多目标优化数学模型,采用在matlab环境下的双种群遗传算法对装配生产线进行优化,以期达到生产节拍尽可能小,工位间负荷均衡,从而提高装配生产线效率,提高产能。     

工业工程对制造业工作效率的影响分析

工业工程对我国制造业的发展有着深远的影响,但今传统制造业的流水生产线存在着平衡率低下的问题,这成为阻碍其发展的因素。通过提高操作员以及机器设备的工作效率,进而提高生产线平衡,提高人均产量以及生产应变能力,从而满足客户的需求,提交出高质量,低成本的产品。本文介绍了我国工业工程在企业中的现状,接着以YQ公司激光笔流水生产线为研究对象,运用工业工程思想,根据其原先由的各个工序的标准时间并计算出节拍和平衡率,接着确定瓶颈工序以及其他的问题工序。通过运用方法研究、程序分析、ECRS等工业工程方法对问题工序进行优化改善,提高企业的生产力、竞争力,降低成本。     

基于Petri网和Flexsim模型的注塑生产线仿真与优化

针对某制造企业注塑生产线在实际生产中存在的生产效率低、操作者空闲率高、产线不平衡等问题，采用Petri网建模方法，分析离散动态型注塑生产线各对象间的关系，建立传递关系网。运用Flexsim可视化仿真软件对该动态系统建模仿真，找到制约注塑生产线生产效率提高的瓶颈问题，提出改进方案并对系统进行了优化。优化后的仿真结果表明，改进后操作者人数由18人/天降低为12人/天，人员利用率提高了33.3%，有效降低了生产运营成本，注塑生产线的生产效率有了很大提升。该结果证明了Petri网与Flexsim软件相结合是一种科学有效的分析方式，能够为企业生产线的实际运行提供理论依据,为升级改造生产线提供新的方法。     

生产物流平衡的持续优化在硬盘磁头制造业的应用

以广东某硬盘磁头代工企业生产线为研究对象，运用装配线平整技术，以生产物流平衡为目标分析了设备能力、任务分配、工装改善以及生产计划排配等方面存在的问题：提出并实施了改善方棠。保证了生产线的物流负荷平衡。优化方案的实施使企业生产能力提高并有效地降低了生产线在制堆积的问题，在制品周转从3．2天缩短到2．5天，生产现场的环境也得到了改善。     

电动三轮车装配流水线的平衡分析与改进

在生产线平衡原理及改善方法的基础上,以电动三轮车装配流水线为研究对象,运用工作研究的方法分析工艺流程,测定流水线各工位的作业时间,找出瓶颈工位;运用"5W1H"提问技术和ECRS(取消、合并、重排、简化)原则对流水线进行分析与改进。通过对比分析,改进后该流水线大大节省了空间和人力,工位减少6个,工人减少11个,与此同时,平衡率提高27.6%。     

基于DELMIA的汽车装配线建模与仿真

汽车装配线直接决定了汽车生产的效率,因此,对汽车装配线进行建模与仿真,优化装配流程十分必要。基于DELMIA的DPM(Digital Process for Manufacturing)模块,对汽车装配线的装配序列规划、装配干涉以及装配路径规划进行研究,按规划的工艺流程对总装线进行模拟仿真,分析装配线的平衡率,通过仿真结果验证该装配线的可达性、可行性以及装配线的人因工效性。文中研究工作对优化及改善汽车装配过程,缩短工艺规划时间,实现汽车装配线的流水化具有一定指导意义和应用价值。     

A cost-effective approach to stochastic line balancing with off-line repairs

The layout of production facilities is an important determinant of the productivity potential of a manufacturing enterprise. It is particularly important in the design of assembly lines where the objective is to assign tasks to work stations in such a way as to minimize total variable production costs.Early approaches to the line balancing problem assumed known constant task times and sought a line layout which would produce the desired output with the fewest number of work stations, which is equivalent to minimizing idle time. Studies have shown that task times are random variables, therefore the cost of task incompletion must be considered a part of total production cost. Incompletion cost will be the cost of repairing or completing tasks which cannot be completed within the cycle time after the item has reached the end of the assembly line.This paper describes a methodology for designing approximately minimum cost paced assembly lines under conditions of random task times and off-line repair of incompleted tasks. Task times are assumed to be normally distributed random variables with known means and variances. The methodology consists of heuristically identifying a large number of feasible balances for each of which total costs are computed. The line design with the lowest total is retained as the “best.”In order to evaluate candidate line layouts, a total cost model is developed. Total cost is the sum of normal operating cost—which is simply a function of the number of work stations—and the cost of repairing products containing incompleted tasks. Because this latter cost is a random variable for a given balance, the expected value is used to evaluate a candidate layout. The cost associated with one or more workers exceeding the cycle time is the product of the probability of this happening and the expected cost of off-line repair.The heuristic method for generating feasible balances builds work stations from continually updated lists of precedence satisfying tasks. Qualifying tasks are added to the station as long as the probability of the station exceeding the cycle time remains below a pre-specified threshold. The methodology requires systematically varying this threshold to permit a lowest total cost solution to emerge. The process of generating a large number of balances for a particular threshold is efficient. Evaluating the total costs of the resulting balances takes the majority of the computational time.An experiment was conducted in order to compare the above cost-effective methodology with a purely deterministic approach and a commonly used industrial approximation method for dealing with task time variability. The experiment applied the three methods to four problems from the literature under a variety of repair cost and time variance conditions. In 21 of the 24 cases studied, the stochastic method produced a lower cost balance than the two alternatives. In the remaining 3 cases, the deterministic method also found the lowest cost balance. The stochastic method saved an average of 22.5 percent in total operating cost over the deterministic method and 8.4 percent over the industrial method.The experiment clearly showed the need to explicitly consider task time variability in arriving at a line balance. The stochastic approach of this paper offers large potential savings with no risk of obtaining a less desirable balance and so should be considered for implementation whenever there is a variation in task times. Even for large-scale problems, the computational cost is infinitesimal in the context of assembly line balancing, where very small improvements in productivity can mean substantial increments to profitability.     

基于FLEXSIM的某生产线物流仿真优化

通过收集某企业挖掘机装配流水线的工艺路线、工序设备处理率、生产节拍和生产线平衡等方面数据,利用FLEXSIM物流仿真软件构建装配流水线仿真模型,比较装配流水线优化前后指标,发现优化后的装配线具有生产节拍时间缩短、瓶颈工序缓解、生产线产能平衡等优点。     

某减速器装配线平衡的精益改造研究

从装配线平衡和精益生产的概念出发,以某企业减速器装配生产线为实例,介绍了精益生产理论在改造装配线平衡问题上的应用。考虑装配生产现场,用鱼刺图分析了影响装配线平衡的各种制约因素,并系统的应用全员"5S"活动,制定标准作业时间,连续流改造以及团队互助协作等精益手段对原装配生产线进行改造。改造结果显示,装配线各工作站作业负荷趋于均衡,整体生产效率得以提高,改造效果明显。     

纸质印刷品输送方式

在现代社会中大量使用纸质印刷品,为提高生产效率,印刷品的裁切、包装等诸多工序都都是在自动化生产线上完成的.在不同的工位之间,将产生不同形式的印刷半成品的输送过程.本文根据生产实际需要,设计了不同形式的纸张输送方式,并对各种输送方式的结构和原理进行了详细阐述.实际生产过程表明,各种输送方式都可以稳定地、可靠地完成工艺要求     

第四方物流运作模式下供应链集成管理的优化

供应链管理围绕核心企业,把握控制产业链条上企业的信息流、物流、资金流,为降低运作成本,保证产销平衡、降低产品库存、缩短交货周期、满足客户需求、降低运营成本等管理上的优化做出了贡献。随着物流技术的不断发展,第四方物流对物流的集成优化作用越来越明显,如何借助第四方物流理论,来提升供应链集成管理的水平,成为企业关注的重要方面之一。据此,探讨第四方物流运作模式对供应链管理在多功能流程优化,业务流程再造等方面的运用及实践,以此为供应链管理优化的研究提供新的思路。     

Staffing and equipment decisions for services: An experimental analysis

Many service-oriented firms face demand/work load variations that occur both within and between days, and seasonally during the year. These service firms tend to develop staffing plans based on peak periods, resulting in substantial idle time during low demand periods. To counter this, some firms hire part-time employees to work peak periods to improve productivity. In this way, the cost per customer/transaction (unit) can be reduced.However, the staffing decision is more complex than just determining the number and timing of the work force. The development of good staffing plans must consider the impact of available work stations like telephone consoles and data entry terminals. To use effectively more personnel during peak periods, the firm must have sufficient work stations to assign this work force. Effective staff scheduling must consider simultaneously the work load variations, employ capabilities, and equipment requirements. This article presents a model that incorporates these factors into the decision-making process and examines their interaction.The model analysis illustrates how uncertainty in work load forecasts and staffing flexibility influence expected cost performance and equipment requirements. A set of computer simulation experiments are conducted using operating data from the proof and encoding departments for Ohio National Bank and Chemical Bank. The results suggest that increased staffing flexibility reduces the needed equipment investment, since part time staff can be scheduled more conveniently to meet varying work loads. Also, basing capital equipment decisions on peak work load levels can substantially increase total operating costs. With these costs explicitly estimated, managers can weigh them against desired service level goals to determine the appropriate balance.     

某企业盆式支座装配线基于达宝易软件的工作研究

经调研发现诸多企业装配生产线普遍存在着装配作业效率不高的情况,为提高装配效率,本文提出了将计算机和工作研究相结合的方法对装配线进行分析研究,突破传统的手工研究方法。首先通过现场调研与摄像,然后利用达宝易软件对装配线上的瓶颈工序进行动作分析和时间研究,删除无效动作,改善不合理之处,优化作业时间,以提高装配效率。最后结合某企业盆式支座装配线的具体实例,对其进行分析、改善和优化,将装配线上的装配效率的百分比提高了16.60%,从而验证了本方法的可行性。