超声换能器生产线规划及优化
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摘要
结合公司发展战略需求,公司将从国外转移一种新的换能器产品到国内进行生产,本人作为这个项目的负责人,运用工业工程的知识,对新产品生产线进行规划以保证项目的正常运行。
本论文主要研究的是生产线规划理论、生产线平衡理论以及物流工程理论在超声换能器装配生产线上的综合应用。
本论文的核心内容是,应用SLP(系统布置设计法),在分析收集了有关产品,生产工艺,生产物流的基础数据后,结合新设施的有关约束条件,对换能器生产线进行布局;随后,应用生产线平衡理论和物流工程理论的有关分析方法,对已建立换能器装配生产线进行优化,利用工序同期化和动作分析法提高生产线平衡率。重新调整生产线布局来缩短物料搬运距离,有效降低物料搬运成本,提高生产线效率。根据生产物流的组织形式确定工序间物料搬运批量,有效解决各工序负荷不均匀性,减少在制品数量,使得生产物流有效、平稳的运转。
本文并非纯理论研究,旨在探讨生产线规划理论、生产线平衡以及物流工程理论在换能器生产线的应用与实施,从理论上和实际应用上突破定性分析与个人经验相结合的传统设计方法,代之以定量分析与系统规划与设计的先进方法,完善理论与实践的关系,同时,通过生产线平衡与生产物流的分析,将先进的生产管理理念与生产线规划结合起来,促进公司的生产管理水平提升,解决本企业的实际问题。文中的方案与措施不仅对本企业有指导作用,同时对换能器行业也有参考价值。
Given the stratagem of company, a new transducer is transferred into domestic site. As the principal for this project, apply IE knowledge to new transducer product line layout to ensure this project stable operation.
This thesis aims at studying the integrated application of the production line layout theory, product line balance theory and material flow engineering theory in ultrasonic transducer assembly line.
The core of this thesis is to adopt the SLP (System Layout Plan) to analyze the collected data of relevant products, manufacturing process and production material flow, combined with constrained conditions related of the new facility to plan the process layout of the ultrasonic transducer assembly line. Then by adopting relevant analysis methods from production line balance theory and material flow project theory to improve layout of built production line. Apply work procedure synchronization and assembly motion analysis to improve the production line balance rate. Readjust layout of production line to shorten the material transit distance, then reduce the cost for material transit and improve the production line balance rate. According to production line material flow organization form, work out material transit batch in each working procedure. Solve the asymmetry load of each working procedure and reduce the quantity of goods working in process. Make the material efficient and steady in production line finally.
This thesis is not purely for theory study but also for studying the production line layout implementation and ichnography design theory's application and in untrasonic transducer factories. Breakthrough the traditional design method of the combination of qualitative analysis and personal experience both theoretically and practically by adopting the advanced method for the combination of qualitative analysis and systematical layout and design instead.To solve the practical problems of this company, the relationship between theory and practice must be improved also. The plan and method narrated in this thesis not only act as guidance to this company but also as reference for other relevant companies especially for those untrasonic transducer companies.
本论文主要研究的是生产线规划理论、生产线平衡理论以及物流工程理论在超声换能器装配生产线上的综合应用。
本论文的核心内容是,应用SLP(系统布置设计法),在分析收集了有关产品,生产工艺,生产物流的基础数据后,结合新设施的有关约束条件,对换能器生产线进行布局;随后,应用生产线平衡理论和物流工程理论的有关分析方法,对已建立换能器装配生产线进行优化,利用工序同期化和动作分析法提高生产线平衡率。重新调整生产线布局来缩短物料搬运距离,有效降低物料搬运成本,提高生产线效率。根据生产物流的组织形式确定工序间物料搬运批量,有效解决各工序负荷不均匀性,减少在制品数量,使得生产物流有效、平稳的运转。
本文并非纯理论研究,旨在探讨生产线规划理论、生产线平衡以及物流工程理论在换能器生产线的应用与实施,从理论上和实际应用上突破定性分析与个人经验相结合的传统设计方法,代之以定量分析与系统规划与设计的先进方法,完善理论与实践的关系,同时,通过生产线平衡与生产物流的分析,将先进的生产管理理念与生产线规划结合起来,促进公司的生产管理水平提升,解决本企业的实际问题。文中的方案与措施不仅对本企业有指导作用,同时对换能器行业也有参考价值。
Given the stratagem of company, a new transducer is transferred into domestic site. As the principal for this project, apply IE knowledge to new transducer product line layout to ensure this project stable operation.
This thesis aims at studying the integrated application of the production line layout theory, product line balance theory and material flow engineering theory in ultrasonic transducer assembly line.
The core of this thesis is to adopt the SLP (System Layout Plan) to analyze the collected data of relevant products, manufacturing process and production material flow, combined with constrained conditions related of the new facility to plan the process layout of the ultrasonic transducer assembly line. Then by adopting relevant analysis methods from production line balance theory and material flow project theory to improve layout of built production line. Apply work procedure synchronization and assembly motion analysis to improve the production line balance rate. Readjust layout of production line to shorten the material transit distance, then reduce the cost for material transit and improve the production line balance rate. According to production line material flow organization form, work out material transit batch in each working procedure. Solve the asymmetry load of each working procedure and reduce the quantity of goods working in process. Make the material efficient and steady in production line finally.
This thesis is not purely for theory study but also for studying the production line layout implementation and ichnography design theory's application and in untrasonic transducer factories. Breakthrough the traditional design method of the combination of qualitative analysis and personal experience both theoretically and practically by adopting the advanced method for the combination of qualitative analysis and systematical layout and design instead.To solve the practical problems of this company, the relationship between theory and practice must be improved also. The plan and method narrated in this thesis not only act as guidance to this company but also as reference for other relevant companies especially for those untrasonic transducer companies.
引文
[1]林立千,设施规划与物流中心设计[M],北京,清华大学出版社,2003
[2]高广章,生产线的平衡及优化方法研究,[D],吉林,吉林大学,2004
[3]王家善,设施规划与设计[J],工业工程1(1): 11-14
[4]罗锐韧,曾繁正,生产与作业管理[M],红旗出版社,1997
[5]邓静,系统布置设计理论在涡轮精密铸造车间的应用[D],上海,上海交通大学, 2006
[6]李云月,小型空压机车间精益设施规划[D],上海,上海交通大学, 2006
[7]俞静等,半导体制造车间设施规划浅析[J],半导体技术,2003,28(6):22-25
[8]岑昊,蔡三发,装配线平衡的改善[J],上海管理科学,2005(5):16-17
[9]迟胜超,高玉致,利用工序同期化方法评测工艺布局[J],中国理论期刊出版社, 2003, 39(3):39～41
[10]张伟, IE与精益生产在产品衰退期的应用研究[D],天津,天津大学,2005
[11]楼应侯等,机械制造中的综合自动化物流技术[J],机械制造,1998 (7): 4-6
[12]韩天渊,沈阳机床齿轮厂物流分析与设施规划[D],沈阳,沈阳工业大学,2004
[13]王守海,制造车间绿色生产物流决策模型及其仿真研究[D],武汉,武汉科技大学,2007
[14]李必强,现代生产管理的理论与方法[M] ,武汉:华中理工大学出版社,1988 ,176–178
[15]张毕西,离散型生产系统物流批量最优化分析[J],华南理工大学学报,1999 ,8 (27) :77– 82
[16]张毕西,基于按运输批转移的生产系统物流优化方法[J],控制与理论,2000 ,4 (17) :609– 613
[17]黄卫伟,生产与作业管理[M],北京,中国人民大学出版, 2001
[18]王国化,丰田制造真经[M].北京,北京工业大学出版社,2006
[19] Moore, J.M., Plant Layout and Design.New York:The Macmillan Company, 1955
[20] Richard L. Francis, Facility Layout And Location An Analytical Approach. New Jersey: Prentice-Hall, Inc. ,1974
[21] James P. Womack, Daniel T. Jones, Daniel Roos. The machine that changed the world. New York: Rawson Associates, 1990
[22]朱道立,龚国华,罗齐,物流和供应链管理[M],上海,复旦大学出版社,2001
[23]胡锐,同步供货在神龙公司的应用[J],工业工程与管理,2001,(3):54一57.
[24]刘正刚等,设施布置设计的回顾、现状与展望[J],江苏理工大学学报, 2001,3(1):74-75
[25]王云华等,大规模定制生产的业务流程浅析[J],江苏大学学报, 2005, 17(7):90-94
[26]王家善,设施规划与设计[J],工业工程1(1):11-14
[27]胡锐,同步供货在神龙公司的应用[J],工业工程与管理,2001,(3):54一57
[28]陈军,工业设施系统规划[D],西安,西安建筑科技大学,2001
[29]倪伟英,精益生产管理系统的研究[D],北京航空航天大学,2003
[2]高广章,生产线的平衡及优化方法研究,[D],吉林,吉林大学,2004
[3]王家善,设施规划与设计[J],工业工程1(1): 11-14
[4]罗锐韧,曾繁正,生产与作业管理[M],红旗出版社,1997
[5]邓静,系统布置设计理论在涡轮精密铸造车间的应用[D],上海,上海交通大学, 2006
[6]李云月,小型空压机车间精益设施规划[D],上海,上海交通大学, 2006
[7]俞静等,半导体制造车间设施规划浅析[J],半导体技术,2003,28(6):22-25
[8]岑昊,蔡三发,装配线平衡的改善[J],上海管理科学,2005(5):16-17
[9]迟胜超,高玉致,利用工序同期化方法评测工艺布局[J],中国理论期刊出版社, 2003, 39(3):39～41
[10]张伟, IE与精益生产在产品衰退期的应用研究[D],天津,天津大学,2005
[11]楼应侯等,机械制造中的综合自动化物流技术[J],机械制造,1998 (7): 4-6
[12]韩天渊,沈阳机床齿轮厂物流分析与设施规划[D],沈阳,沈阳工业大学,2004
[13]王守海,制造车间绿色生产物流决策模型及其仿真研究[D],武汉,武汉科技大学,2007
[14]李必强,现代生产管理的理论与方法[M] ,武汉:华中理工大学出版社,1988 ,176–178
[15]张毕西,离散型生产系统物流批量最优化分析[J],华南理工大学学报,1999 ,8 (27) :77– 82
[16]张毕西,基于按运输批转移的生产系统物流优化方法[J],控制与理论,2000 ,4 (17) :609– 613
[17]黄卫伟,生产与作业管理[M],北京,中国人民大学出版, 2001
[18]王国化,丰田制造真经[M].北京,北京工业大学出版社,2006
[19] Moore, J.M., Plant Layout and Design.New York:The Macmillan Company, 1955
[20] Richard L. Francis, Facility Layout And Location An Analytical Approach. New Jersey: Prentice-Hall, Inc. ,1974
[21] James P. Womack, Daniel T. Jones, Daniel Roos. The machine that changed the world. New York: Rawson Associates, 1990
[22]朱道立,龚国华,罗齐,物流和供应链管理[M],上海,复旦大学出版社,2001
[23]胡锐,同步供货在神龙公司的应用[J],工业工程与管理,2001,(3):54一57.
[24]刘正刚等,设施布置设计的回顾、现状与展望[J],江苏理工大学学报, 2001,3(1):74-75
[25]王云华等,大规模定制生产的业务流程浅析[J],江苏大学学报, 2005, 17(7):90-94
[26]王家善,设施规划与设计[J],工业工程1(1):11-14
[27]胡锐,同步供货在神龙公司的应用[J],工业工程与管理,2001,(3):54一57
[28]陈军,工业设施系统规划[D],西安,西安建筑科技大学,2001
[29]倪伟英,精益生产管理系统的研究[D],北京航空航天大学,2003