基于IE方法的客车生产现场改善研究

上海交通大学硕士学位论文基于IE方法的客车生产现场改善研究姓名：吴正彬申请学位级别：硕士专业：工业工程指导教师：周炳海;尚爱民20091001IIE(IE)IEIE1.IE2.IE3.IEII(IE)IEIEABSTRACTIIISTUDYONTHEIMPROVEMENTOFTHEPASSENGERCARPRODUCTIONSITEBASEDONIEMETHODSABSTRACTIndustrialEngineering(IE)methodsintegratethemanagementandtechnology,itformsseriessystemoptimizationtechnology,usingoperationsresearch,systemengineeringandcomputerscience.IEandprocesssupplywitheachother.Ithasaveryimportantactiontopromotetheprocessstandardizationandoptimization.ThetraditionalPassengerCarProductionSiteManagementorProcessManagementSystemdoesnotcombinewithIE,soitcannotoptimizeandmanagetheprocesswithIEtechnology.ThisthesisisbasedonIEandintroducesprogramanalysis,operationalanalysis,linebalancingandprocessoptimizationintothepassengercarproductionsitemanagement.StudyonthepassengercarproductionsitemanagementbasedonIEmethodsisproposed.Forthispurpose,thecontentsinthepaperarebelow:1.Thefirstpartofpaperdiscussedthedevelopmentandkeyitemsofprocesstechnologyandmanagementofpassengercarproductionsitemanagement,theapplicationofIEtechnologyintheprocessdesignandmanagement.ItalsodiscussedthecorrelativetheoriesandtechnologiesaboutABSTRACTIVprocess,IE,SystemDevelopmentMethodandsoon.2.ThepaperusedIEtheorytodesigntheimprovementofthePassengerCarProductionSiteandimprovetheproductionsiteoftheWeldingproductionlineandthechassisproductionline.3.Somepracticesareintroduced,suchasstrengtheninglocalemanagement,implementingJITproductionandsoon,inthisthesis.Theresultsshowthat,asagoodtechniqueofdecreasingcostandboostingproductivity,IEmethodswillplayanimportantrolewhenitisputintopassengercarproductionsitemanagement.CorporationscanfindrightinnovationapproachbymeansofIE,andthemaximumeconomicbenefitcanbeobtained.KEYWORDS:IndustrialEngineering(IE)Method,PassengerCarProductionSiteManagement,AssemblyProcess11.160IEIndustrialEngineeringIEAIIE1955[1-3]IEIEIE[4]IEIE2IE[1,5,6]()IE[7]IEIEIEIEIEJITIEIEIEIEIE1.260MRPMRPMRPIIIE[8-10]90BPRIE60~70TQP80JIT/LP/TPSIE32021[11]90[12,13]8090100[14]IEOTISMOTOROLAIE()IEIEIEIEIEIE2000IE4[15,16]IEIEIEIEIEIEIEIEIEIEIEIEIEIEIE2007[17]IE[10,12,18]IEIEIE()IEIEIEIEIE5IE[1,3]1.()2.(ABC)(LineBalancing)3.PTS4./MRPIIERPIE(IE)IEIEIE.IE1.3IE6IEIE1.IE2.IE3.IEIEIEIEIEIEIEIEIE7IEIE1.4IE8IE2.1IEIEIEIE[7,19-22]1.182030IE1900IEIE20IEIE191019141913191719311927-1933IE92.20201IE2040IEIEIEIEIEIEIE2IEOR40-70IEIEIE40ORIE10IEORORIEORIEORIEORIE5010IEORIEORIEORSAIEOR3IESE70IEORORORIEORIEORIE5060SSSEIESEIESEORIEIE4IECNCCADIE11CAPCAQCAEIE[23-32]IEIEIEDNCCAD/CAMFMS1973IEJCIM[25]CIMS2.2IE2.2.1IEIEIE[5,18,26,32]1.2.IE12IE1.()()2.IESEOR3.[31]PERTCPM(EOQ)(EPQ)MRPMRP-IIJIT4.IE5.6.[28]IE13-TQCTQM7.(HumanEngineering)HumanFactors(Ergonomics)IE8.9.IEMRP-IIERPPDMCIMS10.IEGTFMCFMSRe-configurableManufacturingsystem(HolonicManufacturingSystem)(Agent-basedManufacturingsystem)[14]IEIEIEIE14IEIE1.2.3.4.5.6.7.()2.2.2IEIE[1,4]1.2.3.IE1.()IE152.()3.()IEIEIE1./IE()PERT2.3.5W1HECRS94.5.6./7.8.IE162.2.3IEIE1IE21IEFig.1IntroductoryprogramofIEmethodsandtechnologiesIE172IEFig.2ContinualimprovingstructureofIEmethodsIE182.3IE2.3.1“5S”5S5S5S[33]5S5S(SEIRI)(SEITON)(SEISO)(SEIKETSU)(SHITSUKE)[34]1.2.3.4.5.6.1.2.IE193.()4.5S5S5S[34]5S5S2.3.25S[35]()[34]1.IE20ABCCBA2.:3.IE21123456()2.3.32.3.4IE22122.3.5123451.12IE18IE23abc32.12345678910113.PDCA3IE24/3Fig.3Theorderandkeypointofoperationanalysis2.3.61.12IE253452.12VTR31.IE26=1+=1+2.1234567891011122.3.7IE27[18,22]=/1001001.2.3.4.5.1234561.2.3.IE284.2.3.81.2.(Layout)1IE2923LUS4562.4IEIEIEIE303.1200340,7.91232801100454314Fig.4ProductionFlowChart3.244376323.2.15S5SSEIRISEITONSEISOSEIKETSUSHITSUKE55S5S3.2.23.2.3333.2.43.2.53.355S344.112IE1351Tab.1OrganizationofImprovementGroup35365Fig.5TrainingachievementsDisplay313721234545S54.2384.34.3.160240+CO2141518453945810262Tab.2ProductionSituationofBusbodyWeldingProductionLine1437238334354446558664057393840694814l0447114141239413393l4382406Fig.6LineBalancingDiagram-BeforeImprovementE=73%58485S5S5S5S5S15S5S24135S45S5S555S5S5S785S75SFig.7Achievementsof5SImprovement4285SFig.8Achievementsof5SImprovementA439449Fig.9ProcessChartofBusSideWallSkins-BeforeImprovement4533Tab.3ComprehensiveAnalysistableonEvents-BeforeImprovement%%1557.732'4957415.47'4813519.213'142327.74'472610057'55100357.7%57%19.2%23%4464Tab.4ImprovementMethods14714.461010000mm800mm1200mm11500mm1011Fig.10StorageRacking-BeforeImprovementFig.11StorageRacking-AfterImprovement12134812Fig.12LayoutsofWorkStation-BeforeImprovement13Fig.13LayoutsofWorkStation-AfterImprovement3249214’48”5’11”1’56”3145014Fig.14ProcessChartofBusSideWallSkins-AfterImprovement5515Tab.5ComprehensiveAnalysistableonEvents-AfterImprovement%%%%1173.415.434'5478.7-3.6213.33.85'2212.14.30023.10022.8213.304'49.201510042.344'2010023.5151115.4%32'49”34'54”3.6%5023.1%13'14”022.8%261542.3%57'55”44'20”23.5%H0.9/0.6/(33%)17.41325.2%152421515Fig.15TimeComparisonDiagram3531616Fig.16TimeDistributingGraph412341166546Tab.6PartsList-AfterImprovement5164551.29/0.79/77Tab.7StatisticalTableofQualityImprovement455665023632432812781.290.700.770.600.792484311.2*10*10.7%8Tab.8StatisticalTabl