应用基础工业工程理论提高装配线的生产效率

结合手工装配线的改善实例,详细阐述了应用基础工业工程中的流程分析、单元设计、装配线平衡等理论,结合柏拉图分析法,探讨改善手工装配线效率和管理水平的方法.改善前后的定性和定量对比分析说明结合柏拉图分析的基础工业工程理论和方法对提高企业生产效率的显著作用.     

基于仿真技术的生产线平衡优化研究与应用

以某压缩机厂装配车间为研究对象,运用面向对象的仿真建模技术建立压缩机装配线的仿真模型.并基于仿真数据分析装配线瓶颈,运用生产线平衡优化方法设计装配线平衡优化方案.根据企业需求及经济性因素,利用仿真模型对优化方案进行测试并选择合理的生产线改进方案.通过对压缩机厂装配线进行改进,达到了提高装配线产能、平衡各工序负荷的效果,实际数据和仿真数据吻合,验证了仿真技术的有效性和生产线平衡优化方法的可靠性.     

基于工作研究的点钞机装配线平衡改善

以某点钞机企业装配线为研究对象,运用秒表测时法测定出装配线各工位工时,识别瓶颈工位.制作标准作业指导书对瓶颈工位进行初步改善.进一步绘制双手作业分析图,分析装配线上的装配工艺过程、工人操作方法与内容以及工位布局等方面存在的问题,结合ECRS原则、山积图以及流水线平衡化中工位作业内容的重新分配等理论,重新设计装配线.经过两次改善,装配线平衡率总体提升8.1%,日产量提升43.9%,企业日产量达到了订单要求.     

变速箱多品种混流装配线信息管理系统设计

基于现代汽车制造企业信息化、网络化和柔性化的要求,设计并开发了一个变速箱多品种混流装配线信息管理系统,该系统以信息技术、计算机应用技术和质量管理方法为手段,对变速箱装配线上的信息进行采集、监控、分发与管理,并保存产品质量信息,提高了汽车零部件企业生产现场的信息化水平,具有良好的应用前景.     

工作研究在组合开关装配线平衡改善中的应用

针对温州汽配企业遭遇的效率低下、人力成本上升困境,以某汽配企业组合开关装配线为研究对象,在运用秒表测时法测定装配线各工位作业时间的基础上,通过双手作业分析、工装夹具设计、工作台布局设计、工位重划分等方法,以及流水线平衡设计理论对原有流水线进行了平衡改善设计.通过改善,单件作业时间降低了14.6%,生产线平衡率提升了13.6%,人均产量提升了39.3%,同时作业环境及员工工作疲劳度也得到了很大的改善.     

装配线平衡系统研究与开发

装配线的平衡问题已有大量理论研究,但缺乏应用工具.为了消除该问题理论与实际应用之间的鸿沟,利用有效的算法,开发了一个装配线平衡的系统.简要介绍了装配线平衡问题及其求解算法,阐述了系统的功能及其实现过程.企业界的工程技术人员利用该系统可以有效地解决装配线平衡问题,从而提高装配线的生产效率.     

基于混合蝙蝠算法的多约束双边装配线平衡问题研究

包含位置约束、区域约束、同步约束等额外约束的双边装配线平衡问题,称为多约束双边装配线平衡问题,与双边装配线第I类平衡问题相比,复杂度显著提升,目前研究成果还很少。而现实中的装配线平衡问题往往包含额外约束,因而,研究多约束双边装配线平衡问题更具有实际意义。针对以上问题,本研究在分析额外约束的数学表达的基础上,建立了多约束双边装配线平衡问题的优化模型,提出了拓扑排序矩阵编码方法、面向位置约束的解码方法、变邻域搜索策略,与标准蝙蝠算法相结合,形成了混合算法的求解机制。以标杆算例为对象,与多种典型的启发式算法进行了比对实验研究,实验结果表明了所提算法的可靠性和优越性。     

某电器公司装配流水线平衡研究

在分析装配线规划内容的基础之上，运用流程作业分析方法对工时定额进行了分析，通过测时、工序同期化等工作来调整流水线负荷，给出了具体的基于工时定额的装配线作业指导书。通过以上工作，保证流水线平衡，为企业制定工时定额合理的装配线、提高自主规划生产的能力提供途径。     

X公司工时与作业方法研究

基于流水线不平衡的现状,运用流程作业分析方法对工时定额和作业方法进行了分析,通过测时、工序同期化等工作来调整流水线负荷,规范作业线形图,给出了具体的基于工时定额的装配线作业指导书.通过这些工作,为企业提高生产能力,组织工时定额合理的装配线,提高工作效率提供了途径.     

基于流水线作业的制造企业生产效率管理

以电动车制造企业的装配线为研究对象,对装配线的生产效率相关数据进行收集和整理,转化为直观的生产效率数据,并以天为单位进行监控;然后寻找并分析前后生产效率发生改变的根本原因,引导全员参与思考和行动;最后针对根本问题设定目标,进行计划性解决.旨在为企业提供可借鉴的管理思路,解决生产系统效率低下及其不受控的问题.     

基于标准作业时间和仿真的装配线规划

在分析装配线规划内容的基础上,提出了基于标准作业时间及系统仿真的装配线规划方法并开发了相应的原型系统。通过建立装配操作树,定义装配操作约束,规划合理平衡的装配工位,同时生成装配作业表。以此作业表为输入,建立装配线的仿真模型,为装配线系统布置中的流参数等优化提供环境。通过这些工作,为企业制定工时定额合理的装配线,提高自主规划生产系统的能力提供途径。     

我国机械制造企业的单件流应用研究

分析了机械制造企业因其行业特点而大多采用批量生产,从而难以适应当前市场的多样化和个性化的需求.实施单件流可有效解决这一难题.对单件流进行了概述,并详细介绍了精益生产的最新发展形式--单元化生产,并简要概述了单元生产在很多日本知名企业(如索尼)中的应用情况和取得的成效.而后分析归纳了我国机械制造业实施单件流时所面临的几个关键问题,如工序间的平衡问题、缩短换产时间(推行快速换模技术)、重型件的流动、瓶颈工序的消除、混流生产、全员参与等,及其各自处理对策,同时重点探讨了如何通过推行快速换模技术来缩短换产时间.最后通过案例分析国内外相关企业应用单件流后的明显效果,从而说明了单件流在我国机械制造企业中实施的可行性.     

Development of a parallel processing multi-agent architecture for a virtual CIM system

Global manufacturing enterprises tend to rely on fully integrated manufacturing systems to satisfy constantly changing market requirements. In addition, small to medium enterprises are in a dilemma when competing with large organizations. Virtual computer-integrated manufacturing (VCIM) is a realistic concept that can provide the integration requirements for the globally distributed manufacturing resources and it has the potential to satisfy the market requirements of small to medium enterprises. The vision of the VCIM is to improve the efficiency and effectiveness of manufacturing enterprises by seamlessly integrating globally distributed manufacturing resources as much as possible. Meanwhile, intelligent agent technology provides a better means to implement distributed components as integrated application systems. The paper provides a parallel processing multi-agent architecture to support a global integrated manufacturing system in the form of the VCIM. In this architecture, a three-layered structure is proposed to accommodate all the agents no matter where they are located. Multiple Facilitator agents are proposed with similar functionalities to smooth the information flow across the integrated system in a parallel connection manner. In addition, a multi-agent VCIM model that describes the agent identification approaches for VCIM, Java environment implementation approaches and a simulation system to demonstrate the parallel processing multi-agent architecture are also discussed.     

中、少批量生产中JIT拉式生产的实现

在中、少批量生产的制造过程中之所以推行JIT拉式生产比较困难是因为不存在实现JIT所必需的流水线.本文对中、少批量生产中如何实现拉式生产进行探讨,通过应用成组技术对生产进行流程再造,组建(虚拟)成组生产单元,进行必要的平衡调整后,在单元内部创建类似大量生产的准流水线,进而在其上按JIT的原则组织生产就可以得到拉式生产的好处.并根据国内实际情况探讨了企业的精益改造与信息化相结合的具体做法.     

Manufacturing lines under surplus-based control: multiple products and bounded buffers

Challenged by the scheduling complexity for production flow processes in industrial facilities, we study the performance of multi-product producing lines. We analyse the performance of multi-product lines that consist a number of machines and bounded buffers with preselected base stock levels. It is assumed that each manufacturing machine in the line is capable of working with several product types, but only operate on one product at a time. The network is operated under a surplus-based production control policy in the presence of perturbations and production demand fluctuations. We derive bounds on the demand tracking accuracy for each product type, regardless its flow direction in the multi-product line. In addition, for a multi-product line with unidirectional product flow, we obtain a quantitative relation between demand tracking accuracy, its inventory levels, numbers of product types, buffer capacity limits and perturbations. The accuracy of the obtained demand tracking bounds is illustrated by numerical simulations. By means of simulation experiments, we show that the obtained results have a valuable meaning and can be used as a reference tool in practice.     

Production line 3D visualization monitoring system design based on OpenGL

New production line management technologies are required and adopted recently with the development of modern manufacturing industry. In this study, a production line three-dimensional (3D) visualization monitoring system based on OpenGL modeling, open database connectivity (ODBC), and database management technology is established on a VC++6.0 platform to satisfy effective production. A client/server model is adopted in the system, and data on processing information, interactive operation, and failure process are stored in the server side database. A client reads the workpiece process information from the server, and the machining process of every workpiece is visually represented in the form of 3D visualization. Production line 3D visualization provides production capacity simulation to optimize the parameter settings. When compared with the analysis results of production line capacity, the key parameters possess the same optimal values, and this proves the accuracy of production line 3D visualization monitoring system. The system provides effective data support for production line monitoring and management in enterprises. The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-018-0217-x     

One-piece flow manufacturing on U-shaped production lines: a tutorial

Now-a-days shorter product life cycles and increased demands for customization make it difficult to produce some products on traditional production lines. Often the best that can be done is to produce them in batch flow systems that have been improved through the incorporation of line flow principles. This is one-piece flow manufacturing. Traditional cells with irregular material flows are replaced by U-shaped production lines within which flow is regular and paced by a cycle time and between which flow is controlled by pull signals. This tutorial examines the research literature on one-piece flow manufacturing. It begins with the decisions rules that determine when one-piece flow is appropriate. Next the unique elements of one-piece flow (takt time, standard work, flow manufacturing on U-shaped lines, pull production, and jidoka) are reviewed. Then the mathematical models that are used to design one-piece flow systems are examined. Finally areas where more research is needed are discussed.     

生产制造业物流模型研究

以生产制造业的物流过程为对象，进行了物流管理技术的研究，提出了相应的物流管理模型，该模型对企业物流系统建立有重要的参考价值。     

Improving the performances of part dispatching based on multiple process plans using graph theory

An intrinsic characteristic for manufacturing a part is the existence of diverse processing routes. In this paper, we deal with the improvement of part dispatching performance based on the availability of multiple process plans of a machined part. Procedures to represent multiple process plans with a graphic representation are developed so as to facilitate the utilization of process plans. We propose a simulation model to test the impacts of multiple process plans on the performances of real time scheduling. The study shows that by applying the simulation model to multiple processes in the manufacturing of machined parts, the flexibility of the manufacturing system can be increased; the total production flow time can be reduced; and the efficient utilization of production resources is improved.     

基于五轴加工中心智能生产线的数字孪生应用研究

智能制造是我国近年来大力倡导的重点发展方向之一.随着智能制造试点的不断建立、发展和完善,数字孪生技术逐步得到应用.基于此,以五轴加工中心智能生产线为例,对数字孪生技术的应用情况进行总结.基于数字孪生技术,按1:1的比例构建五轴加工中心智能生产线上实体设备的数字模型并配置对应的物理属性,使得数字模型具有与实体设备相同的动...