基于eM-Plant的某粉末冶金车间生产线平衡和厂区布局优化研究

Research on production line in a powder metallurgy workshop based on eM-Plant and factory layout optimization

选取某粉末冶金企业的汽车减震器压缩阀座本体生产现场为观察分析点,通过对该粉末冶金车间生产线布局的充分调研和生产过程中的各个工序时间、人与机配备情况等信息的准确获取,结合精益化管理思想对生产线存在的瓶颈工序、人机协作不协调、物流滞后3大问题进行分析解决;运用仿真软件对车间布局改善前后的各个工序时效实现对比验证,并提出一套适用于本粉末冶金车间布局重构的解决方案。首先,把平均一天的消耗总量作为整条生产线的传动量,记录每道工序的时间数据,将瓶颈工序分解、重组,绘制工序时间直方图,同时运用eM-Plant软件对改进前后的生产线进行模拟验证,结果表明,配料和拌料这两道工序整合、精整工序与清洗工序重组,生产线平衡率大大提高;将车间的主要工序进行人机作业分析,绘制人机作业图并计算出人机的理想配置,同时对一人三机作业时的生产线进行仿真,结果表明一名工作人员兼顾操作三台成形设备可以提高人机利用率;运用系统设计布置法(SLP)对厂区的生产现场的物流强度进行研究,提出了一种合理改善车间布局的方案。

The production site of the automobile shock absorber compression seat body of a powder metallurgy enterprise was selected as the observation and analysis point. This layout was sufficiently investigated in the workshop production line, and the most of information such as working time, human-machine condition of equipment together with other things was accurately acquired in the process of production, and the thinking of lean management was adopted to analyze and solve three problems including bottleneck process, incongruity of human-machine collaboration and logistics lag of the production line. At the same time, the simulation software was used to compare and verify the effectiveness of each process before and after the workshop layout improvement, and a set of solutions suitable for the layout reconstruction of the workshop was proposed. First of all, the total consumption of the average day was taken as the transmission amount of the whole production line, and the time data of each process was recorded. Additionally, the bottleneck process was decomposed and reassembled, and the process time histogram was drawn. The eM-Plant software was used to simulate and verify the production line before and after improvement. The results show that the balance rate of line is greatly improved by the integration of batching and mixing processes as well as the reorganization of finishing and cleaning processes. Meanwhile, human-machine operation analysis is carried out on the main processes of the workshop and its date diagram is drawn and the ideal configuration of human-machine is calculated to simulate the production line when one person with three machines on the working. The results show that the human-machine utilization rate can be improved by one worker taking into account the operation of three forming equipment. Finally, the systematic layout planning(SLP) is applied to study logistics strength of factory production, and a reasonable scheme that could decrease logistics strength is put forward.