搅拌主机连续流装配线建设方法研究

发布时间：2019-01-29 19:47

【摘要】：我公司的混凝土搅拌站每年的销量大概在2500台套左右,其中搅拌主机作为搅拌站的核心部件,其生产能力和质量的管控一直是把控的核心。作为批量生产的一级部件,随着生产规模的逐步扩大,搅拌主机装配线也在进行不断的改善,以满足生产的需求,从最原始的单台套定点装配,到轨道式人工流动装配线,再到自动化的装配流水线,然而因为人员流动性大、频繁的变更生产制造地点以及装配线的设计、施工及物流方面存在的问题或缺陷,如下所述：1、生产线传输设备落后——机2、生产布局不合理——环3、物流布局不合理,未实现配送——料4、装配方法落后,工艺文件不完善——法5、五、人员素质不高,管理水平有待提升——人6、检验把关不严,不良品流入装配线,检验方法有待改善——测因为存在以上几个方面的问题,以致目前我们的搅拌主机装配线零部件的合格率不高、检验不过关、停工待料的现象经常出现,延误了后续工序的加工,严重影响了产品质量和生产效率。在生产任务紧时,员工必须加班加点才能满足交货需求,造成员工和设备负荷过大；生产任务少时,员工工作量过小,经济收入也随之减少,对员工工作积极性造成影响；另外,生产现场的布置不合理,工作时间过长等因素使员工容易疲劳,增加了不规范操作和安全事故的可能性。场地布置不合理、工装设备先进性不够、研发更新过程较慢等原因,导致各生产环节不协调,工序间产生了大量的库存,从而导致了流水线瓶颈的出现,产生了不必要的动作和可避免的等待。因此,提升搅拌主机装配线的工作效率,成为了我公司缩短产品生产周期的重中之重。本课题通过对搅拌主机装配流水线建设的一些方法、手段和措施的研究,按照精益思想的原则,通过引进新设备、新方法,消除落后工艺等,并对各工位进行工序能力平衡分析,进行作业再分配,从而实现了连续流作业,该种作业方式严格控制了生产的节拍时间,提高了生产线的产能,提高了生产效率。通过对装配流水线进行改进,实现了搅拌主机装配线的连续流,降低了员工的劳动强度,提升了产品质量,缩短了产品的生产周期,提高了生产线的产能,为公司的产品保供提供了有力的保障。
[Abstract]:The annual sales of our concrete mixing plant is about 2500 sets, in which the mixing machine is the core component of the mixing plant, and its production capacity and quality control have been the core of the control. As a first-grade component in batch production, with the gradual expansion of production scale, the assembly line of the mixing engine is also continuously improved to meet the needs of production, from the most primitive single-set fixed-point assembly to the track type manual flow assembly line. Then to the automated assembly line, however, due to the high mobility of personnel, frequent changes of production and manufacturing locations, as well as assembly line design, construction and logistics problems or defects, as follows: 1, Production line transmission equipment backward-machine 2, production layout unreasonable-ring 3, logistics layout unreasonable, unrealized distribution-material 4, assembly method backward, process file imperfect-method 5, 5, personnel quality is not high, The level of management needs to be improved-people 6, inspection controls are lax, bad goods flow into assembly lines, inspection methods need to be improved-because there are problems in the above aspects, As a result, the qualified rate of the parts and components of the assembly line of our mixing engine is not high, the inspection is not up to standard, and the phenomenon of stopping work and waiting for material often appears, which delays the processing of the subsequent working procedure and seriously affects the product quality and production efficiency. When the production task is tight, the staff must work overtime to meet the delivery demand, resulting in excessive workload of the staff and equipment; when the production task is small, the workload of the staff is too small, and the economic income will be reduced, which will have an impact on the enthusiasm of the staff. In addition, the unreasonable layout of the production site and long working hours make the staff easily tired and increase the possibility of non-standard operation and safety accidents. The unreasonable layout of the site, the advanced nature of the equipment, the slow process of R & D renewal, and so on, lead to the incoordination of the various production links and the production of a large amount of inventory among the processes, thus leading to the emergence of the bottleneck of the assembly line. Unnecessary actions and avoidable waiting are generated. Therefore, improving the efficiency of the assembly line of agitator has become the most important thing for our company to shorten the production cycle. Through the research of some methods, means and measures of assembly line construction of agitating engine, according to the principle of lean thought, by introducing new equipment and new method, eliminating the backward technology, etc. The continuous flow operation is realized by analyzing the process ability balance and redistributing the work, which strictly controls the production rhythm time, improves the production line productivity and improves the production efficiency. Through the improvement of assembly line, the continuous flow of assembly line of mixing engine is realized, the labor intensity of staff is reduced, the quality of product is improved, the production cycle of product is shortened, and the production capacity of production line is improved. For the company's products to provide a strong guarantee.
【学位授予单位】：福州大学
【学位级别】：硕士
【学位授予年份】：2013
【分类号】：TU642

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