基于精益生产的机加分厂的诊断与改善
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摘要
根据精益生产的要求,对于现有的机加分厂的起升减速机、蜗轮蜗杆式回转减速机和回转分配器的机加工过程和装配过程进行优化,并且通过对整个机加分厂的现状价值流图进行分析,对于机加部分利用遗传算法进行计算后提出了改善意见,目标是在保证质量的前提下提高产能。计算分析结果证明:利用布局规划的改善能够有效地解决生产现场杂乱的问题,缩短工件的等待时间和运输距离,进而减少在制品的库存量,并且同时降低工人的劳动强度,提高了生产效率。
本篇论文主要是运用基础工业工程的方法来对现场所收集和记录的数据进行分析,进而画出该企业的现状价值流图,根据价值流图中的信息和反映出来的问题对实际的现场管理进行一定的指导,并运用遗传算法对机加分厂的新厂房的布局提出合理性的规划建议。
According to the requirements of lean production, the existing machining factory of hoisting speed reducer, slewing worm gear and the rotary-type rotary distributor of the process of machining and assembly process optimization, and through the entire machining factory Value Stream Mapping analysis of the status quo, for the machine plus some calculation using genetic algorithms to improve the views put forward, the goal is the capacity premise of guaranteeing quality productivity. Calculation and analysis results show that: the use of layout planning of improvements to effectively solve the messy problem of the production site, to shorten the waiting time for the work piece and the transport distance, thereby reducing in-process inventory, and reduce labor intensity and improve production efficiency.
This paper is mainly to make use of basics industrial engineering method to collect and analyze the site’s data recorded, and then draw the enterprise’s recently value stream map, according to the presented problem from the value stream map and the information we give some guidance for the site management, and use genetic algorithm for the new factory machinery manufacturing workshop’s layout to give some rationality planning advices.
本篇论文主要是运用基础工业工程的方法来对现场所收集和记录的数据进行分析,进而画出该企业的现状价值流图,根据价值流图中的信息和反映出来的问题对实际的现场管理进行一定的指导,并运用遗传算法对机加分厂的新厂房的布局提出合理性的规划建议。
According to the requirements of lean production, the existing machining factory of hoisting speed reducer, slewing worm gear and the rotary-type rotary distributor of the process of machining and assembly process optimization, and through the entire machining factory Value Stream Mapping analysis of the status quo, for the machine plus some calculation using genetic algorithms to improve the views put forward, the goal is the capacity premise of guaranteeing quality productivity. Calculation and analysis results show that: the use of layout planning of improvements to effectively solve the messy problem of the production site, to shorten the waiting time for the work piece and the transport distance, thereby reducing in-process inventory, and reduce labor intensity and improve production efficiency.
This paper is mainly to make use of basics industrial engineering method to collect and analyze the site’s data recorded, and then draw the enterprise’s recently value stream map, according to the presented problem from the value stream map and the information we give some guidance for the site management, and use genetic algorithm for the new factory machinery manufacturing workshop’s layout to give some rationality planning advices.
引文
[1]张树武,孙义敏,皇甫刚.基础工业工程[M].北京:机械工业出版社,2000.
[2]刘树华,鲁建厦,王家尧.精益生产[M].北京:机械工业出版社,2010.
[3]肖智军,党新民,刘胜军.精益生产方式JIT[M].深圳:海天出版社,2002.
[4] [美]杰弗里莱克著李芳龄.丰田汽车案例———精益制造的14项管理原则[M].中国财政经济出版社,2004.
[5]王二乐.工具生产车间计算机辅助设施布置的研究.北京:北京科技大学,1993.
[6]理查德.缪瑟.系统布置设计[M].北京:机械工业出版社,1988.
[7]陈祖涛.实践工厂平面设计.中国汽车工业公司技术经济情报中心,1983.
[8]李志华等.制造系统中的单向环型设备布局设计[J].计算机辅助设计与图形学学报,2003,(7):818-822.
[9]周明等.遗传算法原理及应用[M].国防工业出版社,1999.
[10]袁苗龙.基于约束的三维几何布局原理与求解方法研究[D].博士学位论文.华中理工大学,1997.
[11]康立山.非数值并行算法第一册模拟退火法[M].科学出版社,1994.
[12]杜运普,杨月新.装配生产线的平衡问题研究[J].机械设计与制造,2003(2):104-106.
[13]牛占文,柯桢.实施精益生产提升企业核心竞争力[J].工程机械,2006(6):66-70.
[14]迈克.鲁斯.价值流图分析[M].北京:人民交通出版社,1999.
[15]刘义乐,李红广,梁斌.价值流分析在精益维修中的应用[J].工程机械,2006,(6):66-70.
[16]李文杰,徐克林.基于价值流图分析的精益生产研究[J].机电设备,2009,(1):41-44.
[17]马钦海,关志民,何志明.工作研究方法在生产作业过程优化中的应用[J].人类工效学,2000,9(2):26-28.
[18]鲁建厦,兰秀菊,陈勇,陈呈频,陆松.工作研究在生产装配线优化设计的应用[J].工业工程与管理,2004,(1):79-80.
[19]张景霞,王润孝.面向装配顺序规划的产生式规则应用[J].组合机床与自动化加工技术,2004,(1):79-80.
[20]李娟,刘旭,精益化装配管理[M].北京:中国计量出版社,2005.
[21]路士利,鲁建厦.精益生产中的快速换模技术研究[J].轻工机械,2006:24(3):496-499.
[22]冯云翔.精益生产方式.北京:企业管理出版社,1995
[23]贾大龙,韩玉启等.应用工业工程.北京:兵器工业出版社,1999.
[24]兰海.生产现场改善实例.[M].深圳:海天出版社,2008.
[25]魏大鹏.丰田生产方式研究[M].天津:天津科学技术出版社.2000.
[26]孙林岩.生产运作分析[M].北京:中国科学技术出版社.2001.
[27]李赞明.工业工程在生产实践中的应用[J].工业工程.2000(第11期).
[28]刘颖,孔庆丽.仓库规划问题的研究[J].学术探讨.2008年(第12期).
[29] [日]今井正明,华经.现场改善——低成本管理方法[M].机械工业出版社,2000.
[30]刘正刚,姚冠.新设施布置设计的回顾现状与展望[J]江苏理工大学学报(社会科学版),2001,3(l):74一77.
[31]马汉武.设施规划与物流系统设计[M].北京:高等教育出版社,2005.
[32]计三有,钟华.物流中心规划与设计中的问题探讨[J].物流技术,2006,(3):93-95.全
[33]顾孝锋.现场改善实物.[M].广州:广东经济出版社,2005
[34]朱益颉.现场进阶管理技法.[M].广州:广东经济出版社,2002
[35]黄少坚.现场改善运营战略.[M].北京:经济科学出版社,2008
[36][美]戴伦多尔斯迈斯卡罗著,任建标,顾静怡.译.价值流管理面向全局供应链的精益方法[M].中国财政经济出版社,2008
[37]杨青,邱万华.项目精益价值管理及价值流分析方法研究[M].科学学研究,2006
[38]杨青,邱万华.精益价值管理的基本原理方法研究[M].科研管理,2007
[39]杨青,邱万华.精益项目研发过程中的非增值活动分析[M].工业工程与管理,2007
[40]董海,梁迪.设施规划与物流分析[M].北京:机械工业出版社,2005.
[41]Don Tapping,Tom luyster,Tom Shuker.价值流管理:计划、描绘及保持精益化革新的八个步骤[M].大连:东北财经大学出版社,2005,5:3-5.
[42] Tompkins J A. Facility Planning[M].2nd edition, New York: John Wiley,1996.
[43] Jaydeep Balakrishnan, Chun-Hung Cheng, Kam-Fai Wong. FACOPT: a user friendly FACility layout OPTimization system[J].Computers & Research ,2003,(30):1625-1641.
[44] S Sofianopoulou. Application of simulated annealing to a liner model for the formulation of machine cells in group technology [J].INT J prod RES,1997,35(2):501-511.
[45] PANAGIOTIS,WEN-CHYUAN CHIANG.A simulated annealing procedure for single row layout problems in flexible manufacturing systems [J].INT J prod RES,1992,30(4):717-732.
[46]Won You-Dong. Linear programming approach to linear machine layout problem [J].Industrial Mathematics, 1997,47(2):59-68.
[47] Ha,S.H.,&Krishnan,R.. A hybrid approach to supplier selection for the maintenance of a competitive supply chain .Expert System with Application,2008,34(2):1303-1311.
[48]Yang Y, Chute C G.An example-based mapping method for textcategorization and retrieval[J] .ACM Transaction on Information Systems(TOIS),1994,12(3):252-277.
[49]Ponnambalam S G.,Aravindan P.,MogileeswarNaiduG. A Comparative Evalution of Assembly Line Balancing Heuristics.The International Journal of Advanced Manufacturing Technology ,1999,15:577-586.
[50]Hadi Gokcen,Faruk Baykoc O.A New Line Remedial Policy for the Paced Line with Stochastic Task Times.International Journal of Ptoduction Economics,1999,58:191-197.
[51]Subhash C Sarin, Erdal Erel,Ezey M.Dar-EI.A Methodology for Solving Single-model,Stochastic Assembly Line Balancing Problem Omega,The international journal of man agement sience,1999,27:525-535.
[52]Michalewicz Z,et .al.A Modified Genetic Algorithm for Optimal Contro.Problems.Computers Math.Applcation,1992,23(12):83-94.
[2]刘树华,鲁建厦,王家尧.精益生产[M].北京:机械工业出版社,2010.
[3]肖智军,党新民,刘胜军.精益生产方式JIT[M].深圳:海天出版社,2002.
[4] [美]杰弗里莱克著李芳龄.丰田汽车案例———精益制造的14项管理原则[M].中国财政经济出版社,2004.
[5]王二乐.工具生产车间计算机辅助设施布置的研究.北京:北京科技大学,1993.
[6]理查德.缪瑟.系统布置设计[M].北京:机械工业出版社,1988.
[7]陈祖涛.实践工厂平面设计.中国汽车工业公司技术经济情报中心,1983.
[8]李志华等.制造系统中的单向环型设备布局设计[J].计算机辅助设计与图形学学报,2003,(7):818-822.
[9]周明等.遗传算法原理及应用[M].国防工业出版社,1999.
[10]袁苗龙.基于约束的三维几何布局原理与求解方法研究[D].博士学位论文.华中理工大学,1997.
[11]康立山.非数值并行算法第一册模拟退火法[M].科学出版社,1994.
[12]杜运普,杨月新.装配生产线的平衡问题研究[J].机械设计与制造,2003(2):104-106.
[13]牛占文,柯桢.实施精益生产提升企业核心竞争力[J].工程机械,2006(6):66-70.
[14]迈克.鲁斯.价值流图分析[M].北京:人民交通出版社,1999.
[15]刘义乐,李红广,梁斌.价值流分析在精益维修中的应用[J].工程机械,2006,(6):66-70.
[16]李文杰,徐克林.基于价值流图分析的精益生产研究[J].机电设备,2009,(1):41-44.
[17]马钦海,关志民,何志明.工作研究方法在生产作业过程优化中的应用[J].人类工效学,2000,9(2):26-28.
[18]鲁建厦,兰秀菊,陈勇,陈呈频,陆松.工作研究在生产装配线优化设计的应用[J].工业工程与管理,2004,(1):79-80.
[19]张景霞,王润孝.面向装配顺序规划的产生式规则应用[J].组合机床与自动化加工技术,2004,(1):79-80.
[20]李娟,刘旭,精益化装配管理[M].北京:中国计量出版社,2005.
[21]路士利,鲁建厦.精益生产中的快速换模技术研究[J].轻工机械,2006:24(3):496-499.
[22]冯云翔.精益生产方式.北京:企业管理出版社,1995
[23]贾大龙,韩玉启等.应用工业工程.北京:兵器工业出版社,1999.
[24]兰海.生产现场改善实例.[M].深圳:海天出版社,2008.
[25]魏大鹏.丰田生产方式研究[M].天津:天津科学技术出版社.2000.
[26]孙林岩.生产运作分析[M].北京:中国科学技术出版社.2001.
[27]李赞明.工业工程在生产实践中的应用[J].工业工程.2000(第11期).
[28]刘颖,孔庆丽.仓库规划问题的研究[J].学术探讨.2008年(第12期).
[29] [日]今井正明,华经.现场改善——低成本管理方法[M].机械工业出版社,2000.
[30]刘正刚,姚冠.新设施布置设计的回顾现状与展望[J]江苏理工大学学报(社会科学版),2001,3(l):74一77.
[31]马汉武.设施规划与物流系统设计[M].北京:高等教育出版社,2005.
[32]计三有,钟华.物流中心规划与设计中的问题探讨[J].物流技术,2006,(3):93-95.全
[33]顾孝锋.现场改善实物.[M].广州:广东经济出版社,2005
[34]朱益颉.现场进阶管理技法.[M].广州:广东经济出版社,2002
[35]黄少坚.现场改善运营战略.[M].北京:经济科学出版社,2008
[36][美]戴伦多尔斯迈斯卡罗著,任建标,顾静怡.译.价值流管理面向全局供应链的精益方法[M].中国财政经济出版社,2008
[37]杨青,邱万华.项目精益价值管理及价值流分析方法研究[M].科学学研究,2006
[38]杨青,邱万华.精益价值管理的基本原理方法研究[M].科研管理,2007
[39]杨青,邱万华.精益项目研发过程中的非增值活动分析[M].工业工程与管理,2007
[40]董海,梁迪.设施规划与物流分析[M].北京:机械工业出版社,2005.
[41]Don Tapping,Tom luyster,Tom Shuker.价值流管理:计划、描绘及保持精益化革新的八个步骤[M].大连:东北财经大学出版社,2005,5:3-5.
[42] Tompkins J A. Facility Planning[M].2nd edition, New York: John Wiley,1996.
[43] Jaydeep Balakrishnan, Chun-Hung Cheng, Kam-Fai Wong. FACOPT: a user friendly FACility layout OPTimization system[J].Computers & Research ,2003,(30):1625-1641.
[44] S Sofianopoulou. Application of simulated annealing to a liner model for the formulation of machine cells in group technology [J].INT J prod RES,1997,35(2):501-511.
[45] PANAGIOTIS,WEN-CHYUAN CHIANG.A simulated annealing procedure for single row layout problems in flexible manufacturing systems [J].INT J prod RES,1992,30(4):717-732.
[46]Won You-Dong. Linear programming approach to linear machine layout problem [J].Industrial Mathematics, 1997,47(2):59-68.
[47] Ha,S.H.,&Krishnan,R.. A hybrid approach to supplier selection for the maintenance of a competitive supply chain .Expert System with Application,2008,34(2):1303-1311.
[48]Yang Y, Chute C G.An example-based mapping method for textcategorization and retrieval[J] .ACM Transaction on Information Systems(TOIS),1994,12(3):252-277.
[49]Ponnambalam S G.,Aravindan P.,MogileeswarNaiduG. A Comparative Evalution of Assembly Line Balancing Heuristics.The International Journal of Advanced Manufacturing Technology ,1999,15:577-586.
[50]Hadi Gokcen,Faruk Baykoc O.A New Line Remedial Policy for the Paced Line with Stochastic Task Times.International Journal of Ptoduction Economics,1999,58:191-197.
[51]Subhash C Sarin, Erdal Erel,Ezey M.Dar-EI.A Methodology for Solving Single-model,Stochastic Assembly Line Balancing Problem Omega,The international journal of man agement sience,1999,27:525-535.
[52]Michalewicz Z,et .al.A Modified Genetic Algorithm for Optimal Contro.Problems.Computers Math.Applcation,1992,23(12):83-94.