某汽车发动机生产线规划及仿真研究

发布时间：2018-03-29 23:32

  本文选题：SLP布局规划　切入点：witness仿真　出处：《上海交通大学》2015年硕士论文

【摘要】：发动机是汽车的关键零部件,制造工艺相当复杂,其高效的生产离不开一条规划水平先进的生产线,其中生产线布局的好坏将会直接影响到最终的实际运行效果。工厂平面设施布局就是指在给定的使用空间内,对特定的生产单元以及工作区域进行组合布局,将各类资源进行最佳的优化,使其能为企业运作有效服务。一般情况下,在规划一个全新发动机工厂时,将会受到以下一些因素的限制,厂区使用面积的限制、将来可扩展方向的限制以及厂内物流运输路线的限制等。同时,考虑到生产线布局的再次调整难度高,不同的设备布局方式会造成车间场地利用率、设备可维修性的差异等,将会直接对今后的使用造成困难。因此,必须对生产线的布局进行系统性的规划,并对考虑了不同影响因素的方案进行评审、比较,最终选择布局合理性更高,对实际生产影响最小的方案,以帮助企业获得最佳的经济效益。在以往的制造系统规划中,特别是中小型企业的项目规划系统中,工程师大多注重制造工艺的实现,使设备能够加工出合格的产品,但对于生产线的精益规划理念以及制造系统整体运作的效能评估能力考虑相对不足。因此,在生产线布局规划完毕,尚未投入大量资金建造厂房、购买生产设备之前,如何能根据已有的规划信息并结合以往生产经验数据来预判这条虚拟生产线的生产效率,将帮助企业管理层进行系统的生产线规划能力评估,并对组成生产线的设备开动率以及人员负荷、排班频次等关键生产运作元素有更好的认识。针对前文所述,并结合本人在公司内实际的工作内容,本论文开展了以下几个方面的研究。1.对发动机生产线进行布局规划。一般新工厂的规划都存在一系列限定因素,如土地使用面积的限制、扩建能力的限制以及车间外部厂区规划限制等,本论文将利用系统化布局规划(Systematic Layout Planning,SLP)方法,对发动机生产线的各主要生产单元进行系统的布局与规划,同时针对不同的设备布局方案,对组成发动机关键生产专线进行详细分析和评估,最终通过方案对比,选择相对合理的方案,以达到提高生产线规划资源利用率的目的。2.构建生产线仿真模型。使用witness仿真软件初步建立该发动机生产线的模型框架,包括一系列的变量、仿真关键元素的定义及内部公式设定。对发动机机加工线内的典型设备及零件输送方式等进行仿真模型的构建。3.对生产线能力进行仿真。收集发动机生产线的基本生产数据,包括设备加工节拍,设备故障数据,设备换刀时间,手动操作时间、生产换型时间和排班数据等等,首先通过对设备加工节拍的分析,了解设备单机开动率的大致情况并找出生产线的初步瓶颈工位,然后根据项目生产纲领设定仿真目标,验证考虑到设备加工节拍、停机和换刀等一系列生产制约因素后的生产线输出能力。最后根据不同的换型排班策略,来模拟该生产线每周换型运作情况,分析不同换型频次对该生产线的产量输出影响,并对不满足换型频次的情况加以分析并给出实际解决方案。
[Abstract]:The engine is the key spare parts manufacturing process is very complex, its efficient production cannot do without a planning level of advanced production line, the production line layout will directly affect the actual operation of the final result. The factory facilities layout plane is refers to the use of a given space, the combination of the layout of the specific production unit as well as working area, all kinds of resources for the best optimization, so that it can work effectively to serve the enterprise. Generally, in the planning of a new engine factory, will be some of the following factors, the use of factory area restrictions, the future direction of propagation of constraints and internal logistics transportation route restrictions. At the same time, considering the production line layout adjustment again is high, the layout of the equipment in different ways will cause the workshop space utilization rate, the maintainability of the difference will be. The direct cause difficulties for future use. Therefore, must be on the production line layout of the system of planning, and to consider the scheme of different influential factors for evaluation, comparison, the final choice layout more rational, the scheme of the minimum impact on the actual production, to help enterprises to obtain the best economic benefits in manufacturing planning. The system in the past, especially the project planning system for small and medium sized enterprises, implementation engineers pay more attention to the manufacturing process, so that the equipment can produce the qualified product, but the lean concept for the production line planning and manufacturing efficiency of the system overall operation capacity assessment considering the relative lack. Therefore, in the completion of production line layout yet, invest a lot of money building, before the purchase of production equipment, how can the information according to the planning and production data with previous experience to predict the virtual production line The production efficiency, will help the enterprise management ability evaluation planning production line system, and the utilization rate and load on the composition of production line equipment, scheduling frequency key operation elements have a better understanding. According to the above, and combined with my actual work in the company, this paper carried out research.1. the following aspects of the layout planning of engine production line. The general program of new plant has a limited set of factors, such as land use restrictions, the expansion of capacity constraints and external restrictions on workshop factory planning, this paper will use the systematic layout planning (Systematic Layout, Planning, SLP) method of engine the production line the main production unit layout and planning system, and according to the different layout scheme, the key components of production line engine in detail And the final assessment, through the scheme contrast, choose a relatively reasonable scheme, in order to improve the production line planning resource utilization rate of the construction of.2. production line simulation model. The model framework of witness simulation software is used to establish the engine production line, including a series of variables, the definition and formula of the key elements of internal simulation settings. Construction of.3. the simulation of production line equipment and parts of the typical machining line inside the engine transmission mode of the simulation model. The basic production data collection engine production line equipment, including equipment failure data, processing time, tool changing time of equipment, manual operation time, changeover time and the scheduling of production data and so on, first through the analysis the equipment processing time, to understand the general situation of equipment operation rate and find out the bottleneck station preliminary production line, and then according to the project production program. 瀹氫豢鐪熺洰鏍，

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