组装物料供应及时性与均衡性分析研究

上海交通大学硕士学位论文组装物料供应及时性与均衡性分析研究姓名：刘洪群申请学位级别：硕士专业：工业工程指导教师：褚学宁;陈信政20071201上海交通大学工程硕士学位论文IV组装物料供应及时性与均衡性分析研究摘要近年来产品更新换代速度加快，价格战波及制造商，各制造商迫于生存压力只能竞相杀价抢夺制造订单制造利润一降再降。运营成本地高低，直接影响着企业在竞争中的表现。企业经营目的是获得利润，方法之一是降低成本。成本取决于制造的方式——彻底消除生产过程中的浪费。在各种产品的制造环节中存在着不必要的原材料、零部件和产品的储存、装卸和搬运等部分，一方面导致资源的浪费，另一方面制约了组装线生产能力的提高。通过实行Jit生产方式能够增强企业的竞争力，在激烈的竞争中获得优势。本文采用一个流生产、单元生产等实现准时化生产的主要工具，根据方法研究、作业测定、布置研究、生产平衡的现代IE方法，改进了适应小批量大批量兼顾多品种的生产模式，改变组装线传统侧边供料方式为前方供料方式。通过价值流分析，优化了物料供应流程，删除了不增值环节，减少了存货，部分消除了产品组装中的浪费。把生产平衡理论应用到物料供应中，依平衡率的高低来衡量及时性及均衡性,并把甘特图表法应用到物料供应调度。初步做到供应节拍与生产线生产节拍达到一致，最大限度地减少因物料供应不平衡造成停线生产损失及库存过多空间的浪费，使企业能够满足用户快速变化的、多样性的、个性化的需求并获得丰厚的利润。关键词:物料供应，生产平衡，甘特图，及时性，均衡性上海交通大学工程硕士学位论文VTHEANALYSEANDREASERCHOFJITANDBALANCEFORMATERIALSUPPLYINGINASSEMBLYLINEABSTRACTDuringthelastfewyears,astherenovationofproductacceleratesthespeed,thepricewarhasspreadtomanufacturer.Undersuchsubsistencepressure,allkindsofmanufacturershavenochoicebuttocompeteforthemanufactureorderbyreducingthemanufactureprofitagainandagain.Thelevelofoperationcostwilldirectlyaffectthecompany’sperformanceincompetition.Thetargetofcompanymanagementistoreducethecostandincreasetheprofit.Thecostisdecidedbythemethodsofmanufacture----completelyremovethewasteduringtheproductionprocess.Therearequantitiesofrawmaterialsinstorage,componentsunderassembling,productsundertransport.Andsomanymanufactureandcirculationlinkswouldconfinetheproductcapability.ToimplementtheJITproductmethodwillhighlystrengthenthecompany’scompetitionpower,soastocatchtheadvantageinthecompetitivemarket.ThearticleappliedOnePieceFlow/CellproductionandsoonmainJITmethods,andmodernIEmethodssuchasMethodResearch/OperationInstrument/LayoutResearch/ProductionBalance.Anditproposedtheproductionmodeaccommodatedwithbothofsmallandlargeserialproductionandmultipletypes.Thearticlealsoproposedtheideathatchangedthetraditionalunilateralmaterialsupplymethodbyassemblylinetothematerialsupplymethodbythefront.ItanalyzedtheValueprocess,optimizedthematerialsupplyprocess,reducedtheun-valueaddedprocess,reducedtheholdingmaterialsinstorageandremovedthewaste.ItappliedtheProductionBalancetheorytomaterialsupplyprocess,assotojudgethetimelyandbalancebythelevelofbalancerate.ItalsoappliedGanttcharttodispatchthematerialsupply,assotoaccomplishthebalanceofthesupplyfrequencyandtheproductionfrequency,andtohighlyreducethelossforlineshotdownandwastageforoverstoragewhichallcausedbyunbalanceofmaterialsupply.Itcouldsatisfythecustomer’svarious,multipleandpersonalrequirements,andgetmuchmoreprofitforcompany.KEYWORDS:MaterialSupply,ProductionBalance,GanttChart,Justintime,ProportionII20071220III200712202007122011.11.1.1/[1]90%10%[2][3]121Fig1DispatchFlowChart501000100Loss[4]!A1A2A3B1B2B331.1.2JIT-(Dis2tributionCenterDC)[5]DantzigRamser1959[6]VehicleSchedulingProblem(VSP)VSP()()()504[7][8]1.2[9](),5[10]1.3IEJITJITJIT6IEIEAA7JIT2.1JIT2.1.1JITJIT206020601973JIT2019538JITJIT“”JITJITJITJITJITJITJIT9JITJIT«JIT«JIT«««««102.1.2JITJITJITJIT1112JITJIT12JIT«««JIT2.22Fig2ProductionSystemDirections13[11]2.2.180[12]DVDM+MMid-volume14Mid-mixM+M18502.2.171830——1900190520E.WhitneyOliverEvonsF.TaylorHenryFord15————50501.2.3.162.2.CELL80——cellproductioncellularproductionlowcostautomation,LCA17currentproductionplant-within-plantdistribution2.2.118«««««21)))31)««««2)«««19««3)4)««««20A2410003~42SMTBlu-rayDVDDigitalVideoDisc/Diskdrivedrive2193%时3Fig3OperationStationWorking-hourProportion3.2.1L-1L-2L-3L-4L-5D/LEL-6FT-1FT-2L-7SS0MPSTU()27.5927.728.4127.6127.5628.0123.9328.628.825.9924.8926.1327.2723.77A-1A-2A-3A-4A-5A-6A-7A-8A-9A-10A-11I-1I-2I-3()27.9227.8227.7227.727.1827.3627.7827.5727.5925.6928.2428.0825.5626.04I-4I-5A-12CI1I-6CI2I-7I-8P1P2P-AP3-BP-4()25.7723.527.9327.928.1922.827.62725.1826.6426.7925.8426.27cycletime()28.893.80%22[13]1)4Fig4ShotDownforPendingMaterials2)123Fig5SecondaryTransport()80%4)24A-810004005)6)256Fig6StocksWastage123AVCON.1150057326123452767)1001150150501234285S[14]A729[15],375SFig75Sdisorder30drive,5drive2211271000857drive1224713205[16][17][18]31[19]32IE4.1IEIE(MethodsEngineering)(Workmeasurement)[20][21][22]33IE.1.1PTS8Fig8MethodResearch&AnalysisSkills3435.1.2[23]36LineBalancing12PTS37PTSWFMTM()()()9Fig9OperationInstrumentSkills38123(ti)=(tij)/n(ij,j=1,2,…n)5-104=ti(i=1,2…)590%10%110%10%64%5%3%12%3922110()Fig10PlantLayout(Pre-improved)40243336614410AA114~52611()Fig11PlantLayout(Improved),CELL41/[24]()123451261215cm2.55153037.5(Mod)123455102080100:1Mod=0.1294212()Fig12ProductionAssemblyLayout(pre-improved)JIT(1)(2)(3)(4)(5)(6)A-8A-7A-6A-5A-4A-3A-2RearpanelDCFANSubfram(3)(3)()Dcfan(4)(1)(3)4313Fig13ImprovedProductionLinesLayouts22IEIE()5S()A-8A-7A-6A-5A-4A-3A-2SubframeDCREARPANE44()ESCRI5W2H()()45ESCRI«(Eliminate)«(Simplify)«(Combine)«(Rearrange)«(Increase)14&()Fig14MaterialsSupply&ConsumptionFlowChart(Pre-improved)2146[25]IEESCRI14«21615()16()Fig15MeansofTransport(Pre-improved)Fig16MeansofTransport(Improved)«2(18)«471718()Fig17MaterialssupplybythebackFig18Materialssupplybythefront(Improved)««4819&()Fig19MaterialsSupply&ConsumptionFlowChart(Improved)19&495.15.1.150(streamli