汽车总装车间SPS实施运行探讨

在使用流水线作业方式进行整车大批量生产的汽车总装车间,为提高生产线的利用率,主机厂一般采用多车型混线生产的形式,一条生产线通常可生产5-6种车型,甚至更多,由于车型多、配置多和准时制生产要求,导致生产线线边物料存储面积不足。SPS物料配送方式能够有效解决线边物料存储空间不足的问题,并能提高装配效率,是一种先进的物流输送方式。     

汽车工厂总装车间混合动力汽车混线生产机运系统规划方案研究

本文以某合资汽车公司全新工厂的总装车间项目为例,针对现代化汽车工厂总装车间普通车型与混合动力车型混线生产的情况,对底盘机运系统的规划设计进行讨论,探讨了常规车型与混合动力车型混线生产的几种不同方案,并对本次项目中实际采用的方案,即针对混合动力车型采用专用Loop、专用吊架的方案进行了建模及软件仿真分析,研究如何在给定条件下使混合动力汽车产能达到最大。     

汽车涂装线机械运输设备故障分析与处理研究

涂装技术作为汽车生产的四大工艺（冲压、焊装、涂装、总装）之一，近年来也得到了很快的发展，但同时由于汽车涂装线设备较多，种类杂，给设备的维修和故障诊断带来了一定困难。本文对汽车涂装线机械运输设备故障的处理措施进行了研究。     

通用汽车公司北美工厂新建轿车涂装线参观小结

介绍了通用汽车公司北美汽车工厂新建涂装车间的情况,并对该车间的涂装工艺、设备和机械化输送系统进行了阐述.     

建阳市双富龙强车辆制造有限公司

建阳市双富龙强车辆制造有限公司座落在中国十大名山之一、秀丽的旅游风景区武夷山下建阳市。公司于2001年10月由建阳市龙强运输机械制造有限公司和福建汽车改装厂组建而成,现有厂区面积50000平方米,建筑面积20000多平方米,设有焊接车间、车架车间、车厢车间、涂装车间、总装车间及试车工段,各种机械、焊接、检测设备200多台,拥有员工400     

AVI系统在总装车间的应用

本文以某公司总装车间BDC为例,详细介绍了AVI自动车体识别系统的网络架构和组成,主要介绍了AVI系统在帮助汽车企业提高生产自动化水平和优化质量管理、计划排产管理和物流管理等方面发挥的积极效用。     

浅谈汽车柔性化生产线

在汽车生产的四大工艺（冲压装焊涂装总装）中,装焊工艺是不可缺少的工艺流程,也是最不易共用生产线。为了满足汽车市场多元化的需求,装焊生产线的趋势必然是柔性化生产线,满足不同车型的生产需求。     

汽车总装车间HPV降低方法及应用探讨

随着我国经济的迅速发展,人们的生活水平有所提高,对于汽车的需求在逐年增高,促进了汽车行业的发展。如何有效地控制生产过程中的成本,提升汽车企业的竞争力是目前各个汽车企业需要考虑的问题。HPV指生产一台车所消耗的人工时,从本质上测定生产性管理水准的全球共同使用的指标,它反映汽车生产厂家的管理效率及劳动生产性等主要指标指标,为了降低汽车的制造成本,需要采用合理的方法降低HPV值。本文将从汽车总装车间HPV简介和降低HPV主要方法及应用两个方面进行深入的探讨,以最终降低企业的成本。     

汽车涂装生产线的优化与仿真

介绍了汽车涂装生产线及其生产仿真的意义。在对某工厂汽车涂装生产线优化的基础上,利用Flexsim软件对其建立生产线仿真模型,并对该涂装生产线的两种不同方案进行仿真,为生产线的设计、规划和实施提供了依据。最后对计算机仿真的特点进行了阐述。     

综合信息

全球最大涂装机械商落户中山从2006年起,全球奔驰车的内饰配件将有一部分产自中山市小榄镇。2005年5月26日,专门为法拉利、保时捷、劳斯莱斯、林保坚尼、奔驰、宝马、奥迪、标致等欧洲知名汽车品牌生产汽车内饰配件及提供汽车表面涂装处理的德国万佳科(中山)涂装机械有限公司正式落户小榄镇。有着40多年历史的德国万佳科是全球最大的涂装机械制造商,生产范围涉及塑料、金属木材、玻璃等多个领域,是全球涂装机械制造业及表面处理行业的领先企业,他们生产制造的汽车表面涂装生产线目前已装备在欧洲所有的知名品牌的汽车生产车间,并同时为欧洲…     

Kitting in multi-echelon,multi-product assembly systems with parts substitutable

The kitting problem in multi-echelon, multi-product assembly systems with parts substitutable is to allocate on-hand stock and expected future deliveries to kits to minimize total cost including job earliness, job tardiness, and in-process holding cost while considering shop capacity and subassembly precedence restrictions, and parts being substitutable. This class of problem is NP-hard. When dealing with a large instance encountered in industry, in the worst case, it may not be possible to obtain an optimal solution in a reasonable time. In this paper, rules for using part substitutes along with heuristic procedure are presented. Computational results demonstrate that the proposed heuristic outperforms others tested. It is expected that the new heuristic can be applied in resolving largescale kitting problems encountered in industry to allocate available resources near optimality to enhance schedule performance and to lower the total cost of operating multi-echelon, multi-product assembly systems.     

Integrated scheduling and self-reconfiguration for assembly job shop in knowledgeable manufacturing

The problems of integrated assembly job shop (AJS) scheduling and self-reconfiguration in knowledgeable manufacturing are studied with the objective of minimising the weighted sum of completion cost of products, the earliness penalty of operations and the training cost of workers. In AJS, each workstation consists of a certain number of teams of workers. A product is assumed to have a tree structure consisting of components and subassemblies. The assembly of components, subassemblies and final products are optimised with the capacity of workstations simultaneously. A heuristic algorithm is developed to solve the problem. Dominance relations of operations are derived and applied in the development of the heuristic. A backward insertion search strategy is designed to locally optimise the operation sequence. Once the optimal schedule is acquired, the teams are reconfigured by transferring them from workstations of lower utilisation to those of higher utilisation. Effectiveness of the proposed algorithm is tested by a number of numerical experiments. The results show that the proposed algorithm promises lower total cost and desirable simultaneous self-reconfiguration in accordance with scheduling.     

Sustainable operator assignment in an assembly line using genetic algorithm

This paper addresses the operator assignment in predefined workstations of an assembly line to get a sustainable result of fitness function of cycle time, total idle time and output where genetic algorithm is used as a solving tool. A proper operator assignment is important to get a sustainable balanced line. To improve the efficiency and meet the desired target output within the time limit, a balanced assembly line is a must. Real world lines consist of a large number of tasks and it is very time consuming and crucial to choose the most suitable operator for a particular workstation. In addition, it is very important to assign the suitable operator at the right place as his skill of operating machines finally reflects in productivity or in the cost of production. To verify better assignments of workers, a genetic algorithm is adopted here. A heuristic is proposed to find out the sustainable assignment of operators in the predefined workstations.     

考虑效率差异和流动分配的混流装配线工人优化

本文研究了考虑工人装配水平差异、不同工位之间可以流动分配的装配线工人优化调度，在确定混流装配线的排序后，装配工人在其最擅长的工位工作，在完成本工位的工作后参与其他工位的装配工作，定义相关的优化因素变量和约束条件，建立了考虑工人工位效率差异且可流动分配的混流装配线工人优化数学模型。采用削峰填谷算法和多种群移民算法进行工人的调整和均衡优化，利用一个三层神经网络对削峰填谷的工位进行评估选择，得到工人的最优分配方案，最后通过Matlab对举例进行了验证。算例优化后，减少了2名装配工人，并提高了装配线的平衡率。     

Stochastic assembly line balancing using beam search

This paper presents a beam search-based method for the stochastic assembly line balancing problem in U-lines. The proposed method minimizes total expected cost comprised of total labour cost and total expected incompletion cost. A beam search is an approximate branch and bound method that operates on a search tree. Even though beam search has been used in various problem domains, this is the first application to the assembly line balancing problem. The performance of the proposed method is measured on various test problems. The results of the computational experiments indicate that the average performance of the proposed method is better than the best-known heuristic in the literature for the traditional straight-line problem. Since the proposed method is the first heuristic for the stochastic U-type problem with the total expected cost criterion, we only report its results on the benchmark problems. Future research directions and the related bibliography are also provided in the paper.     

A study of the design of a lot production system.

A lot production system is, generally, adopted in the fabrication shop, which supplies the components for the following assembly line. In such a shop, it is required to supply the components for the following assembly lino without tardiness and to reduce the in-process inventory

In this paper, we analyse the relations between the number of set-ups, the lead time, the total elapsed time, the in-process waiting time and the tardiness time on two-stage multi-item models, and propose a procedure to determine the number of set-ups and the lead time.     

Integrated assembly line balancing with resource restrictions

This paper documents a study carried out on the problem of designing an integrated assembly line when many workers with a variety of skills are employed. This study addresses the problem of selecting multi-functional workers with different salaries to match their skills and of assigning tasks to work stations when there are precedence restrictions among the tasks. The objective of this study is to minimise the total annual work station costs and the annual salary of the assigned workers within a predetermined cycle time. A mixed integer linear program is developed with a genetic algorithm in order to address the problem of resource restrictions related to integrated assembly line balancing. Numerical examples demonstrate the efficiency of the developed genetic algorithm.     

Impact of lot-sizing on the financial performance of dispatching techniques in an MRP-planned fabrication and assembly environment

By simulation analysis of a hypothetical MRP-controlled fabrication and assembly shop, the financial performance of six dispatching techniques are compared under four lot-sizing techniques, two levels of demand and two levels of nervousness. For each lot-sizing technique under low nervousness and low demand the choice of dispatching technique did not substantially affect financial performance. The choice of lot-sizing technique was much more critical. Under increased nervousness, period order quantity and least total cost generated enough setups to deplete excess capacity at the most heavily loaded workcentre. The choice of dispatching technique became critical.     

A priority rule-based constructive heuristic and an improvement method for balancing assembly lines with parallel multi-manned workstations

Assembly lines of big-size products such as buses, trucks and helicopters are very different from the lines studied in the literature. These products’ manufacturing processes have a lot of tasks most of which have long task times. Since traditional assembly line models including only one worker in each station (i.e. simple assembly lines) or at most two workers (two-sided assembly lines) may not be suitable for manufacturing these type of products, they need much larger shop floor for a number of stations and long product flow times. In this study, an assembly line balancing problem (ALBP) with parallel multi-manned stations is considered. Following the problem definition, a mixed integer programming formulation is developed. A detailed study of priority rules for simple ALBPs is also presented, and a new efficient constructive heuristic algorithm based on priority rules is proposed. In order to improve solutions found by the constructive heuristic, a genetic algorithm-based solution procedure is also presented. Benchmark instances in the literature are solved by using the proposed mathematical programming formulation. It has been seen that only some of the small-size instances can be solved optimally by this way. So the efficiency of the proposed heuristic method is verified in small-size instances whose optimal solutions are found. For medium- and big-size instances, heuristics’ results and CPU times are demonstrated. A comparative evaluation with a branch and bound algorithm that can be found in the literature is also carried out, and results are presented.     

Minimising total cost for training and assigning multiskilled workers in seru production systems

This paper investigates the multiskilled worker training and assignment (MWT&A) problem of the seru production system (SPS), which is a new type of assembly line configured as multiple assembly cells, or so-called serus. The configuration of the SPS emphasises production efficiency and flexibility, achieved by multiskilled workers (MWs) able to cope with the demand of high-variety and low-volume manufacturing. Well-arranged and trained MWs are viewed as a critical factor when it comes to enhancing the performance of SPSs. This paper studies the MWT&A problem in the SPS with the aim of minimising the total cost, specifically, the workers’ training cost and the balance cost of processing times of the MWs in serus. This study provides an applicable mathematical programming model and designs a two-phase heuristic, named the SAIG algorithm, to effectively and efficiently solve this problem. The performance of the proposed algorithm is demonstrated by a comparison with the state-of-the-art heuristic through a series of computational experiments.