F企业汽车扶手装配线精益改善研究与应用

发布时间：2018-04-27 14:30

本文选题：精益思想 + 装配线平衡　；参考：《江西理工大学》2017年硕士论文

【摘要】：随着现代科技的不断进步,市场经济的飞速发展,人们对物质文化需求越来越高,致使顾客对产品的个性化需求日益多样化,这一趋势给我国汽车零部件制造企业带来了诸多新的挑战,无论是现有生产模式,还是经营理念。此外,在人力和原材料成本不断上涨的双重压力下,迫使企业急需转型,由传统的推动式生产向拉动式生产转变,推行精益生产。然而在转变的过程中,现有装配线平衡技术的很多方面都与精益生产一个流的理念存在较大差距,尚未完全做到精益化,致使由装配线不平衡所造成的产能不足、资源利用率低、在制品库存高等不良现象严重,无法做到及时响应客户需求变化,从而使企业处于劣势,缺乏市场竞争力。因此,基于精益生产思想的指导,充分运用精益思想的精髓,不断优化和改善装配线平衡问题,从而提高企业产能以满足市场需求等已显得十分重要。本文以F企业的汽车扶手装配线为研究对象,首先利用精益IE技术及约束理论对车间装配线进行分析,发现该扶手装配线各工作站的作业时间不均衡,存在多个瓶颈,装配线失衡较严重,并指出该装配线存在的诸如现场基础管理较乱、装配线产能不足、生产流程不合理、工作台设计不宜人等若干主要问题。其次针对上述存在的问题,本文主要运用精益生产的思想及精益化IE技术给出了相应改善优化措施:(1)对该车间进行现场精益化管理,规范物品摆放,消除一切外在浪费,通过有效推行精益5S达到提高现场管理水平的目的,同时也为基于精益生产的装配线平衡改善奠定一个良好的作业环境。(2)对F企业扶手装配线布局进行精益化改善,通过采用“U”型生产布局,将现有的2条独立直线型装配线合并成1条U型装配线,有利于消除过多搬运浪费,从而使整个装配过程更加连续有序,同时也有利于降低在制品数量及其管理成本。(3)运用程序以及双手操作分析,借鉴单元追兔生产思想,按照ECRS、动作经济原则重点对瓶颈工作站进行局部改善;接着从整体角度出发,提出该装配线的第一类平衡问题,在重点对局部瓶颈改善的前提下,以求解最小化工作站数目为目标函数,运用数学建模方法对扶手装配线第一类平衡问题建立0-1线性规划模型,并利用Lingo编程求解,优化后装配线平衡率达到89.9%,与改善前比提升显著。(4)基于精益生产以人为本的思想,在充分考虑工人生理和心理特点的基础上,对装配线工作台进行改善设计,合理安排作息,使操作者能更舒适、高效地进行生产,为装配线平衡提供保障。最后利用ED仿真软件对改善后的装配线进行建模仿真,以产能为指标作改善效果评价分析,仿真结果表明,产能较改善前提升显著,基于精益生产的装配线平衡改善优化有效可行。
[Abstract]:With the continuous progress of modern science and technology and the rapid development of market economy, the demand for material culture is becoming higher and higher. This trend has brought many new challenges to the automobile parts manufacturing enterprises in our country, whether it is the existing production mode or the management idea. In addition, under the double pressure of rising labor and raw material cost, enterprises are in urgent need of transformation, from traditional push production to pull production and lean production. However, in the process of transformation, many aspects of the existing assembly line balance technology have a big gap with the concept of lean production one stream, which has not been fully lean, resulting in insufficient production capacity caused by the imbalance of assembly line. Low utilization of resources, high inventory of in-process products and other adverse phenomena, can not timely respond to customer demand changes, so that enterprises are at a disadvantage and lack of market competitiveness. Therefore, it is very important to make full use of the essence of lean production thought, to optimize and improve the balance of assembly line, and to improve the production capacity of enterprises to meet the market demand. This paper takes the automobile handrail assembly line of F enterprise as the research object. Firstly, using lean IE technology and constraint theory to analyze the workshop assembly line, it is found that the working time of each workstation of the handrail assembly line is not balanced, and there are many bottlenecks. The unbalance of assembly line is serious, and it is pointed out that there are some main problems in the assembly line, such as disorderly basic management on the spot, insufficient production capacity of assembly line, unreasonable production process, unsuitable design of worktable, and so on. Secondly, aiming at the problems mentioned above, this paper mainly uses the idea of lean production and the lean IE technology to give corresponding improvement and optimization measures: 1) to carry on the on-site lean management to the workshop, to standardize the goods arrangement, and to eliminate all external waste. Through the effective implementation of Lean 5S to achieve the purpose of improving the level of on-site management, and at the same time to establish a good working environment for improving the balance of assembly line based on lean production. By adopting "U" production layout, the existing two independent straight line assembly lines are merged into one U-shaped assembly line, which is helpful to eliminate excessive handling waste and make the whole assembly process more continuous and orderly. At the same time, it also helps to reduce the number of in-process products and its management cost. It is also helpful to use the program and the two-hand operation analysis, draw lessons from the idea of "unit chasing rabbit" production, and focus on the partial improvement of the bottleneck workstation according to the ECRSs and the economic principle of action. Then, from the whole point of view, the first kind of equilibrium problem of the assembly line is proposed. The objective function is to solve the minimum number of workstations under the premise of improving the local bottleneck. The 0-1 linear programming model of the first type balance problem of the handrail assembly line is established by using mathematical modeling method, and solved by Lingo programming, the balance rate of the optimized assembly line is up to 89.9, and the improvement of the former is significant. 4) based on the idea of "lean production", it is based on the idea of "lean production". On the basis of fully considering the physiological and psychological characteristics of the workers, the design of the assembly line worktable is improved, the work and rest are reasonably arranged, the operator can be more comfortable and efficient in production, and the balance of the assembly line can be guaranteed. Finally, the improved assembly line is modeled and simulated by Ed simulation software, and the improvement effect is evaluated and analyzed with productivity as the index. The simulation results show that the productivity is significantly improved than that before the improvement. It is effective and feasible to improve the balance of assembly line based on lean production.
【学位授予单位】：江西理工大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：F273;F426.471

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