微电机生产中看板系统的仿真建模与分析

上海交通大学硕士学位论文微电机生产中看板系统的仿真建模与分析姓名：李建留申请学位级别：硕士专业：工业工程指导教师：董明;王承军20060901IIIPromodel:PromodelIVSIMULATIONMODELINGANDANALYSISABOUTKANBANSYSTEMOFSMALLMOTORPRODUCTIONABSTRACTWithmoreandmoreglobalmarketingcompetition,acompanyisfacingmoreandmorestresstoobtainthemarketshare.Toreachthisgoal,anenterprisehastoenhanceitscorecompetence,improveitsmanagementlevel,reduceitsproductionoperationcost,minimizeitsinventorylevel,andincreaseitsmaterialturnover.Theseareallmajorproblemsthatourcompanyneedstosolve.ThisthesisisbasedontheresearchofKanbanmanagementmethod,usinganalysistoolsofsimulation,withconsiderationofthecompany’sactualsituation.ThisthesistriestobuildaKanbanmanagementsystemthatfitstocompanyrealsituation,thereby,decreasinghighWIP,lowingmaterialturnover,andreducingqualityriskproblems.Atthebeginningofthisthesis,thecurrentsituationofKanbanmanagementinChinaisprovided,andthesignificanceofthisresearchispointedout.Then,adeepanalysisandstudyismadeonimplementingleanproductiontheoryintothecompany’scurrentsituation.Thepullsystemisoneofthemostimportantmethodsofleanproductionthinking,andKanbanisaneffectivetooltorealizethepullsystem,withintegrationofcompanyrealsituation.Inthisthesis,theKanbansystemwasdesigned,andasimulationmodelwasestablished.Basedoncollectedproductiondata,Promodelsoftwareisappliedtosimulatethesystem,usefulinformationisprovidedfordecision-making.KEYWORDS:LeanProduction,PullSystem,KanbanManagement,SystemSimulation,PromodelI2007115II√___√2007115200711511.1WTO[1]B1999-50012130BB21.2••PromodelPromodel•B•1.3FORD320[2]197990201991801996:8090904[3][4]60GPSSGASPSLAMSIMAN_50[5][6]1.4BKANBANBBKANBAN52.12.1.1TOYOTAPRODUCTIONSYSTEMTPS2090IMVPInternationalMotorVehicleProgra-mmeJamesWomacLEANPRODUCTION1994JamesWomacLEANENTERPRISE1996JamesWomac(LeanThinking)[7]6JITEdwardDemingJosephJuranKaoruIshikawa20802090Themachinethatchangedtheworld[8][9]2.1.2JITJustInTime[10][11][12](1)(2)(3)(4)(5)[13][14]72.2(1)(pull)(JIT)[15]Kanban2[16][17]3Teamwork[18]84ConcurrentEngineering[18]CIM2.312349[19][20]2.4MRP1MRP2-12-22MRPMRP[3](2-3)MRP(2-4)[21]2-2Figure2-2PullProductionStyle2-1Figure2-1PushProductionStyle103MRPMRP2-4Figure2-3PullProductionSystem2-3Figure2-3PushProductionSystem11[22]2.52.5.1HeijunkaLeveling(2-5)2-62-5Figure2-5ActualCustomerRequirement2-6Figure2-6ActualProductionSituation12237080%232-72-82.5.2Q=N*C=PT*RT*(1+)(1)1Q2-7Figure2-7LevelingforMulti-producttypes2-8Figure2-8MaterialandInformationFlowafterLeveling13NCPTRT1NPT*RT*(1+)(2)RT=Ti+Tw+Tp+Td(3)TiTwTpTd[3]2.6123(Totalqualitycontrol)4[1]N=C143.1DESDiscreteEventDynamicSystem[23][5]DESDiscreteEventDynamicSystem1DES23DES153.212316[24]3.3DES[25]12345678910173-13.3PromodelArenaExtendFlexSimWitnessAutoModProModelProcessModelSimProcessMedModelArenaCallCenter[26]3-1Figure3-1FlowChartofSystemSimulation18ProModelPromodel(ProductionModeler)PROMODELProModel:Entities()Locations()Arrivals()Processing()Activities()Resources()Controls()[27]Entities()Location(Arrival()EntitiesProcessing()LocationLocationLocationProModelProcessingActivities()Resources()Controls()ProModel(OutputProgramManagement)()Excel19B20B4.1BBB123456789B4.2B4.2.1BB214-14-2xx160x85x450012SPCBOM(BillofMaterial)4-14-110020011002Ø74Ø74145(133.5)GearCoverDriver(cabledrumtype)Insulatingslab(Damper)WormWheelGearHousingBrushHolderArmatureMagnetPoleHousingScrew4-1Figure4-1ProductAssemblyDrawing4-2Figure4-2ProductDrawingB22150MRP4.2.24-34-3Figure4-3ProcessFlowChartB23101:202:303:403.1504:605:706:807:908:1009:4.3B4.3.115S5S5S5S”””5S5SSafety6S6S6S6S5S5S5SB2499%5S”B5S5S5SB5S5S5S5S5SPDCA5S2””””””B254.3.2JIT[28]B12B345B26BKanbanKanban4.44.4.1BB”onepieceflow”14.4.24.4.2.1BMRPB27(4-4)A500WLMF52620510550()550(B)550520500:110525502(24)34805505504500550:4-4Figure4-4ValueStreemMapbeforeKanbanImplementationB28190%25503450050554.4.2.2BKanbanKanban4-5:14-5Figure4-5ValueStreemMapafterKanbanImplementationB292A21B1134B14-6::.:()(100):4-6Figure4-6RunningModeofProductionKanbanB304-7Milkrun4-8/4-7Figure4-7LevelingProductionInformationBoard4-8Figure4-8ExchangeableHeadlineB3124-9:()MilkrunMilkrunMilkrun”(onepieceflow)”Milkrun4-9Figure4-9RunningModeofMaterialKanbanB324.5XY,.ZX:1000Y:600Z:4004-24-2200014-34-3B4-4B33WLMF5267560WLMF5302100WLMF5268400100100WLMF52618WLMF5305WLMF526224-54-44-5500121500/1/608.34-10MonTueWedThuFriPlannedWLMF5263434418WLMF530202015WLMF53601010255555///WLMF5267,5603601003.618WLMF5302,1001001001.05WLMF536840401000.424-10Figure4-10KanbanCardArrangementB344.64.6.1UBUUUU4-114-11UBU15581012151.51214-11UFigure4-11UShapeB35B4-124-131.5-33115–201288m2–1079.2m26–6724.6.2MilkrunUMilkrunMilkrunMilkrun4-12Figure4-12BeforeReconstruct4-13Figure4-13AfterReconstructB36MilkrunMilkrunBBMilkrunMilkrunUUMilkrunU4-14MilkrunMilkrunKanbanMilkrun100LevelingMilkrunMilkrun4-14MilkrunFigure4-14MilkrunPathB37Milkrun4.7onepieceflowB100Milkrun4-64-6:B4-154-16Polehousing25050Magnet380100Armature8050Gearhousing15050Gear40045Gearcover350554-15KanbanFigure4-15MaterialKanban4-16KanbanFigure4-16ProductionKanbanB38()N=PT*RT*(1+)/CRT=Ti+Tw+Tp+TdTiTwTdTpRT100121RTRT=100*1/10