柴油发动机装配线平衡研究及应用-工业工程专业论文 word格式.docx

柴油发动机装配线平衡研究及应用
摘要
柴油发动机零部件数量多,装配工艺复杂、体积和重量大等特点。SH 公司为缩短 P 系列柴油发动机装配线的长度,减少产品搬运的次数,采用了双边装配线生产柴油发动机。为满足不断增长的市场需求,SH 公司迫切需要提高柴油发动机装配线的产能,同时提高装配线的可靠性,确保稳定生产。装配线平衡是提高装配线产能及其可靠性的有效途径之一。
首先,分析了 SH 公司现有装配线的特点,收集了柴油发动机的装配工序和先序约束等数据,并建立了装配任务作业时间的统计规律。利用 eM-Plant 软件工具建立现有装配线的仿真模型,通过仿真分析指出装配线的现有产能仅为 65 台/天,无法到达 75 台/天的要求。
然后,依据柴油发动机装配线的实际生产情况和装配工艺,拆分了装配时间较长的油管等装配任务。提出了一种基于工位任务负荷差的启发式算法,将负荷较大工位上的任务调整到负荷较小的工位,并考虑了任务调整的约束条件,从而以尽可能少的任务调整平衡工位负荷,缩短节拍,在装配线长度不变的情况下提高产能。
最后,针对实际生产环境下零部件质量波动及工人疲劳程度导致的装配作业时间随机波动,利用在 eM-Plant 仿真软件建立了平衡后的柴油发动机装配线仿真模型, 通过仿真分析工位的负荷,调整装配线的实际生产节拍,确保装配线在作业时间随机波动情况下的可靠性。P 系列柴油发动机装配线节拍为 390 秒的情况下,日产能 75 台,确保装配线在任务作业随机波动下可靠性接近 %。与平衡之前相比,产能提高了 %。
关键词:柴油发动机,双边装配线平衡,节拍,可靠性
A DIESEL ENGINE ASSEMBLY LINE BALANCE STUDY AND APPLICATION
ABSTRACT
A diesel engine is usually large and heavy, combining with hundreds of parts, plicated to be assembled. Company SH uses a two-sided assembly line to assemble the diesel engine in order to minimize the length of assembly line and reduce the movement of parts. In response to the rapidly increase of the market requirement, it is an urgent target to both increase the production capability and level up the reliability of the line. To reach the target above, assembly line balance could be a good method.
Firstly, the features of the assembly line in SH are investigated. The assembly process, position and procedure constraints, and the tasks’ time statistics data are established. With the simulation by eMPlant, the result told when the circle time was set to 450sec, the production capability was around 65 per day, less than the target of 75 per day.
Secondly, some tasks, taking longer assembly time such as oil pipe assembly, were broken, depending on the diesel engine assembly line process and actual conditions. A heuristic algorithm basing on the stations’ load difference was proposed, and then tasks were moved from the stations with more loads to stations with fewer loads, considering the constraints, so that the stat