基于FlexSim机群式布置木质家具生产线仿真

Simulation on Cluster Layout Wooden Furniture Production Line Based on FlexSim

【目的】针对木质家具生产线机群式布置易发生瓶颈环节导致生产效率低的问题,通过实际生产线对排产方案进行有效性和可行性验证,比较实际生产结果与仿真验证结果是否一致,以节约木质家具生产线的实际运行成本,为提高木质家具生产效率提供思路和方法。【方法】以一条机群式布置的木质家具生产线为例,基于FlexSim7.lnk构建仿真模型,根据其生产工时、运输工时、生产批量以及各订单的订货计划进行参数设置和仿真,通过各工序的平均加工率和暂存区的释放率识别生产线的瓶颈工序,设置生产系统的时间缓冲,并按加工时间最短优先(SPT)规则对订单进行排产。【结果】通过FlexSim7.lnk仿真模拟,得到下料、铣型、砂光、组装、喷漆和检测工序的平均加工率分别为45.30%、62.70%、74.13%、52.80%、54.53%和54.20%,暂存区的释放率(即堆积率)分别为42.00%、57.50%、72.40%、22.70%、30.90%和29.90%,砂光工序的平均加工率和暂存区的释放率最高,为木质家具生产线的瓶颈工序。时间缓冲计算模型结果表明,各订单的瓶颈缓冲时间依次为24、31.5、30、36 min,出货缓冲时间依次为30、54、54、72 min。运用SPT规则对订单进行排产,瓶颈工序的平均加工率达90.28%,比原始方案提高16.15%。生产线实际生产结果与仿真验证结果对比表明,各工序的平均加工率和平均空闲率误差均在±5%范围内。【结论】基于FlexSim7.lnk构建机群式布置木质家具生产线模型,可有效识别生产线的瓶颈工序;设置生产线时间缓冲,可消除瓶颈工序;运用SPT规则对订单进行排产,能够有效提高木质家具生产效率。

【Objective】In order to solve wooden furniture production line of machine-group layout under multi-product and small lot-size production is prone to create bottlenecks,then resulting in low productivity,we study how to determine the bottleneck and improve the production efficiency in this paper,and through the actual production line to verify the validity and feasibility of the scheduling scheme,the consistence of actual production results and the simulation results are also compared.This paper establishes a model of cluster layout production line with FlexSim.This model trends to save the actual running cost of wooden furniture production line,and it also can be used as a reference for improving the efficiency of other wooden furniture production lines.【Method】Taking a cluster layout wooden furniture production line for an example,by setting parameters of source,processor,storage area,transport and other entities according to production hours,transportation hours,production batch and order plan of each order,the model with FlexSim is simulated.Through analyzing simulation results,namely the average process rate and release rate of each process,we can identify the bottleneck process in production line,set time buffer for production system and schedule the orders according SPT(shortest processing time)rule.【Result】We can get the state parameters of each working procedure in production line by FlexSim simulation,in which the average process rate of blanking process,milling process,sanding process,assembling process,painting process and testing process is 45.30%,62.70%,74.13%,52.80%,54.53%and 54.20%,and the release rate of these processes is 42.00%,57.50%,72.40%,22.70%,30.90%and 29.90%,respectively.Therefore,the average process rate of sanding process is the highest,at 74.13%,and the release rate of sanding process is the highest too,at 72.40%,so the sanding process is the bottleneck of the wooden furniture production line.According to time buffer calculation model,the bottleneck time buffer of each order is 24 min,31.5 min,30 min and 36 min,the delivery time buffer of each order is 30 min,54 min,54 min and 72 min.Through simulation by FlexSim,we can get that the average process rate of SPT scheme is 90.28%,which increases 16.15%compared with the original plan.By comparing the results of the actual operation and the simulation results,the average processing rate and the average idle rate error of each process are within the range of±5%.【Conclusion】This paper investigates a cluster layout wooden furniture production line model with FlexSim7.lnk,and it can effectively identify the bottleneck of the production line and predict the production results.The bottleneck process might be eliminated by setting the production line time buffer,and a fine schedule according to SPT rule could greatly improve production efficiency of the wooden furniture production line.