基于约束理论造船厂分段流水化制造管理研究
发布时间：2018-11-20 09:56
【摘要】：在订单充足坞期紧张的情况下,分段制造往往会成为造船厂高效生产的约束瓶颈。绝大多数船厂都会忽视提高自身产能而采取外包的方式欲以缓解分段供给压力。在分段的整个制造流程中胎架利用率的高低与胎架周期的长短是决定分段能否高效生产的关键因素,也是分段制造的瓶颈所在。实现分段的流水化制造可以从根本上消除分段制造对整个船舶建造周期的影响,提高船厂的竞争能力,具有重大的生产指导意义。本文正是基于约束理论的相关原理通过对中海江苏造船基地流水化分段制造瓶颈的深入分析,从全局着眼找出一直以来影响分段高效产出的几大原因,并提出质量管控前移、DBR对预制件集配的管理、钢材的微库存管理、分段制造营运成本的精细化管理等方法从产销率、库存、经营成本3个方面入手,松绑约束瓶颈实现分段产销率的大幅提升。首先,文章将对课题的来源,研究的目的与意义进行阐述,对分段流水化制造国内外研究的现状进行总结,并对中海江苏造船基地的分段制造现状进行介绍,提出分段流水化制造的必要性。其次,文章将对约束理论的原理及其提供的5步聚焦法、思维流程分析法、物流分析法、DBR生产管理模型进行介绍。第三,通过对公司分段制造流程的再梳理,利用约束理论提供的相关方法应用总结出中海江苏造船基地分段流水化制造的瓶颈。这些瓶颈主要包括:分段制造产销率低的瓶颈、预制件集配供应混乱的瓶颈、钢材库存管理的瓶颈以及分段制造营运成本过高的瓶颈。第四,利用约束理论提供的相关方法分别对这些主要瓶颈进行深入分析并提出应对措施。通过分段制造质量管控的前移与组织机构的约束调整来实现分段产销率的提高;通过分段预制件集配的DBR管理、用工模式的转变、集配与质量管控的结合实现预制集配的高效管理;通过钢材的先进先出管理和钢材的预估与采购实现钢材的微库存管理;通过分段生产耗材的合理控制与生产现场的5S管理实现分段制造运营成本的精细化管理。第五,通过应对措施的实行检验中海江苏造船基地64000T散货船分段流水化制造的效果。根据基地现有的分段制造场地与配套设施以及64000T散货船分段制造的特点提出平直分段、曲面分段、上建桅屋类分段的流水化制造方案,实现全船分段的流水化制造。最后,文章将会对实施流水化制造的效果进行评价,对过程中出现的问题进行总结,对文章的不足之处提出进一步优化的方向。
[Abstract]:In the case of tight docking period, piecewise manufacturing often becomes the constraint bottleneck of shipyard's efficient production. Most shipyards neglect to increase their own capacity and adopt outsourcing to ease the pressure on segmented supply. In the whole manufacturing process of the segment, the utilization ratio of the tire frame and the length of the cycle are the key factors to determine whether the segment can be produced efficiently, and also the bottleneck of the segmented manufacturing. The realization of piecewise flow manufacturing can fundamentally eliminate the influence of subsection manufacturing on the whole ship construction cycle and improve the competitiveness of shipyards. It has great guiding significance in production. This paper is based on the relevant principles of constraint theory, through the in-depth analysis of the bottleneck of subsection manufacturing in China Shipping Jiangsu Shipbuilding Base, from the overall point of view to find out the main reasons that have been affecting the high efficiency of segment production, and put forward the quality control forward. The methods of DBR, such as the management of preform assembly, the micro-inventory management of steel, the fine management of the operating cost of segmented manufacturing, etc., start from three aspects: production and sale rate, inventory and operating cost. The bottleneck of loosening constraints can greatly improve the production and marketing rate of segment production and marketing. First of all, the article will explain the source of the subject, the purpose and significance of the study, and summarize the domestic and foreign research status of subsection flow manufacturing, and introduce the current situation of subsection manufacturing in China Shipping Jiangsu Shipbuilding Base. The necessity of piecewise flow manufacturing is put forward. Secondly, the paper introduces the principle of constraint theory and the five-step focusing method, thought flow analysis, logistics analysis and DBR production management model. Thirdly, through the re-combing of the segmented manufacturing process of the company, the bottleneck of segmented flow manufacturing of China Shipping and Jiangsu Shipbuilding Base is summarized by using the relevant methods provided by the constraint theory. These bottlenecks mainly include: the bottleneck of low production and marketing rate of piecewise manufacturing, the bottleneck of confusion of prefabricated assembly and supply, the bottleneck of steel inventory management and the bottleneck of high operating cost of piecewise manufacturing. Fourth, using the relevant methods provided by constraint theory to analyze these main bottlenecks in depth and put forward countermeasures. The improvement of production and marketing rate can be realized by moving forward of the quality control of segmented manufacturing and adjusting the constraint of the organization. Through the DBR management of piecewise prefabricated parts, the transformation of employment mode, the combination of assembly and quality control, the efficient management of precast assembly is realized, and the micro-inventory management of steel is realized through the first-in-first-out management of steel products and the prediction and purchase of steel products. Through the reasonable control of the consumable material and the 5S management of the production site, the fine management of the operation cost of the piecewise manufacturing is realized. Fifthly, the effect of 644000T bulk carrier subsection flow manufacturing in China Shipping Jiangsu Shipbuilding Base is tested through the implementation of countermeasures. According to the existing subsection manufacturing site and supporting facilities of the base as well as the characteristics of 64000T bulk cargo ship segment manufacturing, this paper puts forward a flow manufacturing scheme of straight section, curved surface segment and upper mast house segment to realize the whole ship segment flow manufacturing. Finally, the article will evaluate the effect of the implementation of pipelined manufacturing, summarize the problems in the process, and put forward the further optimization direction for the shortcomings of the article.
【学位授予单位】：上海交通大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：U673
本文编号：2344591
[Abstract]:In the case of tight docking period, piecewise manufacturing often becomes the constraint bottleneck of shipyard's efficient production. Most shipyards neglect to increase their own capacity and adopt outsourcing to ease the pressure on segmented supply. In the whole manufacturing process of the segment, the utilization ratio of the tire frame and the length of the cycle are the key factors to determine whether the segment can be produced efficiently, and also the bottleneck of the segmented manufacturing. The realization of piecewise flow manufacturing can fundamentally eliminate the influence of subsection manufacturing on the whole ship construction cycle and improve the competitiveness of shipyards. It has great guiding significance in production. This paper is based on the relevant principles of constraint theory, through the in-depth analysis of the bottleneck of subsection manufacturing in China Shipping Jiangsu Shipbuilding Base, from the overall point of view to find out the main reasons that have been affecting the high efficiency of segment production, and put forward the quality control forward. The methods of DBR, such as the management of preform assembly, the micro-inventory management of steel, the fine management of the operating cost of segmented manufacturing, etc., start from three aspects: production and sale rate, inventory and operating cost. The bottleneck of loosening constraints can greatly improve the production and marketing rate of segment production and marketing. First of all, the article will explain the source of the subject, the purpose and significance of the study, and summarize the domestic and foreign research status of subsection flow manufacturing, and introduce the current situation of subsection manufacturing in China Shipping Jiangsu Shipbuilding Base. The necessity of piecewise flow manufacturing is put forward. Secondly, the paper introduces the principle of constraint theory and the five-step focusing method, thought flow analysis, logistics analysis and DBR production management model. Thirdly, through the re-combing of the segmented manufacturing process of the company, the bottleneck of segmented flow manufacturing of China Shipping and Jiangsu Shipbuilding Base is summarized by using the relevant methods provided by the constraint theory. These bottlenecks mainly include: the bottleneck of low production and marketing rate of piecewise manufacturing, the bottleneck of confusion of prefabricated assembly and supply, the bottleneck of steel inventory management and the bottleneck of high operating cost of piecewise manufacturing. Fourth, using the relevant methods provided by constraint theory to analyze these main bottlenecks in depth and put forward countermeasures. The improvement of production and marketing rate can be realized by moving forward of the quality control of segmented manufacturing and adjusting the constraint of the organization. Through the DBR management of piecewise prefabricated parts, the transformation of employment mode, the combination of assembly and quality control, the efficient management of precast assembly is realized, and the micro-inventory management of steel is realized through the first-in-first-out management of steel products and the prediction and purchase of steel products. Through the reasonable control of the consumable material and the 5S management of the production site, the fine management of the operation cost of the piecewise manufacturing is realized. Fifthly, the effect of 644000T bulk carrier subsection flow manufacturing in China Shipping Jiangsu Shipbuilding Base is tested through the implementation of countermeasures. According to the existing subsection manufacturing site and supporting facilities of the base as well as the characteristics of 64000T bulk cargo ship segment manufacturing, this paper puts forward a flow manufacturing scheme of straight section, curved surface segment and upper mast house segment to realize the whole ship segment flow manufacturing. Finally, the article will evaluate the effect of the implementation of pipelined manufacturing, summarize the problems in the process, and put forward the further optimization direction for the shortcomings of the article.
【学位授予单位】：上海交通大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：U673
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