新能源汽车电池包装配生产技术

在新能源汽车上,电池系统发挥着重要的作用。随着新能源汽车的市场需求日益增大,电池包的研发工作和装配生产技术越来越受关注。电池包装配线多布置在单独的车间内,按功能划分为不同生产区,根据产品装配工艺的要求,配备装配、充电、试验、输送等设备,完成合格电池包的装配任务。     

基于标准作业时间和仿真的装配线规划

在分析装配线规划内容的基础上,提出了基于标准作业时间及系统仿真的装配线规划方法并开发了相应的原型系统。通过建立装配操作树,定义装配操作约束,规划合理平衡的装配工位,同时生成装配作业表。以此作业表为输入,建立装配线的仿真模型,为装配线系统布置中的流参数等优化提供环境。通过这些工作,为企业制定工时定额合理的装配线,提高自主规划生产系统的能力提供途径。     

考虑转换约束的汽车混流装配线投产排序研究

讨论了有生产线线边替补人员协助完成超载工作量的情况下,汽车混流装配线投产排序的问题,并且考虑工作人员行走占用的时间。通过对某整车厂进行实地调研,将汽车装配生产中的优化问题从以往文献中只考虑的总装车间向前延伸到涂装车间,给出连续喷涂某种颜色的车辆数的上界s。在此基础上,并考虑总装线线边物料消耗速率波动均衡和子装配工负荷均衡的约束条件,建立涂装切换成本和总装车间人工成本最小化的数学模型。最后,用CPLEX对模型进行优化求解,并分析得出生产节拍和工作站长度等参数与总成本之间的变化关系。     

混流汽车液压电子制动控制单元装配线平衡问题设计与研究

为了有效解决混流汽车液压电子制动控制单元装配线平衡问题,提出了基于优化遗传算法的求解方法。首先对于复杂的液压电子制动控制单元装配线的工艺装配过程进行设计与计算,分析液压电子制动控制单元的生产工艺步序、工作站数、生产节拍、以最小化生产节拍、最小化工作站数以及均衡各工作站的加权平均负荷进行多目标优化。同时构建液压制动控制单元装配工艺平衡问题的测量模型,并进行案例分析,利用模型求解。最后,以某独资汽车零部件工厂的汽车液压电子制动控制单元装配线为例,对工艺过程进行数学建模,采用优化遗传算法进行求解。结果表明,所提方法与测量模型可为汽车液压电子制动控制单元装配线平衡问题提供可行的解决方案。     

地面高机动雷达整机装配工艺的研究

针对某地面高机动雷达Ⅰ号单元的结构特点,结合图片分析对比两种总装方案和装配工艺难点.通过采取相应的工艺措施解决产品装配安全性和装配精度问题,制定整体装配工艺流程,提高了装配效率和装配质量.简述了电子设备整机装配的基本顺序和安装的基本要求,以及电缆布线原则、顺序和方法.     

应用基础工业工程理论提高装配线的生产效率

结合手工装配线的改善实例,详细阐述了应用基础工业工程中的流程分析、单元设计、装配线平衡等理论,结合柏拉图分析法,探讨改善手工装配线效率和管理水平的方法.改善前后的定性和定量对比分析说明结合柏拉图分析的基础工业工程理论和方法对提高企业生产效率的显著作用.     

改进启发式方法下的轻型车底盘装配线平衡分析

对于轻型车而言,其装配工艺较为复杂,为了有效提升装配效率就需要对装配线平衡问题进行分析。本文就改进启发式方法下的轻型车底盘装配线平衡分析作简要阐述。     

基于工作研究的点钞机装配线平衡改善

以某点钞机企业装配线为研究对象,运用秒表测时法测定出装配线各工位工时,识别瓶颈工位.制作标准作业指导书对瓶颈工位进行初步改善.进一步绘制双手作业分析图,分析装配线上的装配工艺过程、工人操作方法与内容以及工位布局等方面存在的问题,结合ECRS原则、山积图以及流水线平衡化中工位作业内容的重新分配等理论,重新设计装配线.经过两次改善,装配线平衡率总体提升8.1%,日产量提升43.9%,企业日产量达到了订单要求.     

基于车型相似度的装配线排序

通过总结混流装配线排序问题,提出了一种新的装配线排序模型.根据装配车型的关键件不同,引入车型相似度的概念,应用遗传算法解决以最大化相似度总和为目标的混流装配线优化排序问题.经实践中应用,关键件装配更换次数减少了70%.     

应用基础工业工程理论改善手工装配线布置方式

认识到基础工业工程理论对提高设备密集和人员密集型企业管理水平的重要性。结合手工装配线的布置实例,详细阐述了如何巧妙集成工作研究、设施布置和物流规划领域的实用方法改善企业的装配线布置。改善前后的定性和定量对比分析说明了基础工业工程的理论和方法对提高企业生产效率和系统的灵活性以及对市场的适应能力等方面的显著作用。     

Cellular manufacturing: its impact on the total factory

This paper compares a factory structured as a traditional job shop with the same factory structured as a hybrid factory containing a cellular manufacturing unit. The comparison is based on job shop simulation using differing combinations of capacities, allocations of jobs between the cell and the rest of the factory and levels of productivity improvements achieved in the cell. Performance is evaluated in terms of flow times and delays for the cell, the non-cell remainder of the factory and for the normal functional factory. The simulation model was designed to eliminate possible confounding issues of machine reliability, operator skill, unique manufacturer specific part characteristics, factory layout and different scheduling techniques. The result is a systematic evaluation of cellular manufacturing, some general conclusions as to the particular circumstances that favour the use of cells and a set of implications for management practice.     

氦气检漏工位的作业仿真与改善

某压缩机装配线中氦气检漏工位的工作效率不高，而且操作者疲劳度较大，改进的需求迫切。应用人因工程学的原理和方法，通过实地考察和录像分析，进行了氦气检漏工位的工作研究，分析了影响劳动强度的原因。采用了改变工作台面高度、增加设备和简化手工作业动作等方法，提高生产节拍和改善劳动强度，并利用JACK软件进行了作业方案改进前后的仿真和比较分析，对企业的生产装配线改造提供了一些积极的建议.     

A practical method for design of hybrid-type production facilities

A comprehensive method for the design of hybrid-type production shops, which comprise both manufacturing cells and individual workcentres, is presented. The method targets the minimization of the material handling effort within the shop and includes four basic steps: (1) identification of candidate manufacturing cells, (2) evaluation and selection of the cells to be implemented, (3) determination of the intra-cell layout, and (4) determination of the shop layout. For the cell formation step the 1CTMM technique has been enhanced to cater for important practical issues. The layout of each significant cell is determined by a simulated annealing (SA)-based algorithm. Once the sizes and shapes of the selected cells are known the shop layout is determined by a similar algorithm. The resulting hybrid shop consists of the selected cells and the remaining machines. The methodology has been implemented in an integrated software system and has been applied to redesign the shop of a large manufacturer of radar antennas.     

Simulation-based optimisation of logistics distribution system for an assembly line with path constraints

The design of logistics distribution system for an assembly line with given layout is usually constrained by various factors such as the vehicles for the distribution of assembly components and the paths on the shop floor for the vehicle movement. Since design optimisation of these production systems with such constraints is hard to solve by mathematic approaches, simulation-based approach is mostly used. In this paper, simulation-based analysis and optimisation of a logistic distribution system is performed combined with a heuristic algorithm to obtain a solution that most suits the practical requirements of an assembly line. The proposed simulation-based method builds a model that satisfied various complicated real-world problems at the work site of an investigated factory. Meanwhile, a dynamic dispatching method for vehicle movement is also presented which can adjust the control strategy and decision parameters dynamically in the process of simulation and contributes significantly to form a more fruitful design scheme. Experimental results show that proposed method performs better than the analytical model-based approach and some other methods, and the dynamic vehicle dispatching method presented performs better than some existing common strategies used in literature.     

Improved design of CMS by considering operators decision-making styles

Cell formation is one of the oldest problems in cellular manufacturing systems (CMS) including assigning parts, machines and operators to cells. Cell manufacturing contains a number of cells where each cell is responsible for processing the family of similar parts. Another important aspect of cell formation is worker assignment to cells. Since operators work together in long periods, it is suggested to consider operators’ personal characteristics to increase their satisfaction and the productivity of system. This paper considers decision-making styles of operators (as an index of operator’s personal characteristics) and presents a new mathematical programming model for clustering parts, machines and workers simultaneously. The model includes two objectives; (1) minimization of intracellular movements and cell establishment costs, (2) minimization of decision-making style inconsistency among operators in each cell. The paper applies ε-constraint method for solving the problem and gathering non-dominated solutions such as Pareto optimal solutions. Furthermore, this paper uses common weighted multicriteria decision analysis (MCDA)-data envelopment analysis method to choose the best solution from the candidate Pareto optimal solutions that have been achieved by solving the mathematical model. A real case study is investigated to show the capability of the proposed model to design CMS in the assembly unit. The proposed design assists decision-makers to develop cellular systems with more operators’ satisfaction and productivity.     

DFT的装配车间生产物流策略仿真与研究

针对某汽车部件的实际装配生产,运用离散事件仿真的方法对基于需求流动技术(DFT)的装配生产物流策略进行了研究.在分析该汽车部件装配生产流程的基础上,确定eM-Plant仿真软件中的建模对象与装配生产系统中实体对象的对应关系,使用面向对象的方法建立了相应的离散事件仿真模型.在模型中分别实施基于推式生产方式的物流策略和基于DFT的物流策略,以该汽车部件的平均日产量为绩效指标,比较了两种物流策略对装配生产的影响.     

Assembly systems layout design model for delayed products differentiation

Frequently changing customers’ needs and market pressures motivate manufacturers to offer a wide variety of their products. Poor demand prediction and increased manufacturing complexities and managerial burdens are just a few symptoms of products variety proliferation. Applying a postponement strategy is an effective method for mitigating the complexities arising due to increased products variety and customisation. Delayed product differentiation (DPD) is a prerequisite for applying form postponement strategies, where the unique features that distinguish each product are added at the final stages of production. This paper introduces an innovative design methodology to derive and represent an assembly line schematic layout for delayed products differentiation. The proposed methodology incorporates product commonality analysis and feasible assembly sequences to synthesise the assembly line layout in a single integrated logical design framework, without pre-defining either the number or the positions of differentiation points along the line. Products commonality analysis is performed using cladistics techniques commonly used for biological classification. The classical cladistics was modified to take into consideration the precedence constraints, which are required to ensure the feasibility of assembly sequences. Real product variants are used to validate the proposed DPD assembly line layout design methodology and demonstrate its merits.     

工作研究在组合开关装配线平衡改善中的应用

针对温州汽配企业遭遇的效率低下、人力成本上升困境,以某汽配企业组合开关装配线为研究对象,在运用秒表测时法测定装配线各工位作业时间的基础上,通过双手作业分析、工装夹具设计、工作台布局设计、工位重划分等方法,以及流水线平衡设计理论对原有流水线进行了平衡改善设计.通过改善,单件作业时间降低了14.6%,生产线平衡率提升了13.6%,人均产量提升了39.3%,同时作业环境及员工工作疲劳度也得到了很大的改善.     

Local scheduling problems submitted to global FIFO processing constraints

This paper deals with local scheduling problems as part of a global process management policy. The industrial context is an automotive assembly plant. An automobile manufacturing process creates a list that schedules orders so as to optimize production costs. Such a list must respect the vast majority of shop-related constraints, notably those of the assembly shop, which are the hardest to schedule. This list also allows one to provide information to suppliers regarding the parts they are required to deliver to the assembly plant. PSA Peugeot-Citroën has set the ambitious objective of ensuring compliance with all list entries upon arrival at the assembly plant. This objective is equivalent to instituting a global first-in, first-out (FIFO) management policy for all operations upstream of the assembly line (i.e. body shop, paint shop) and in particular it enables one to make significant reductions in component inventories.

However, FIFO-based flows are difficult to achieve. They first require setting up local production scheduling in the plant in order to satisfy constraints specific to each shop (body shop, paint shop, assembly line); this step will be referred to as ‘local scheduling’. Moreover, a number of disturbances intervene to change the initial order.

The aim of our work is to lay out a new policy for managing flows (called ‘reorderable scheduling’). The premise is to define the maximum scheduling level allowed upon input into each shop so as to guarantee restoration of the initial list order (i.e. reordering) at the assembly entrance.

We will start by studying, from a theoretical perspective, a very general base case and then we will characterize the maximum authorized local scheduling disturbance that enables us to fulfil the global management objective (i.e. FIFO). We will also show the implementation of this method in our industrial case within the context of an automotive assembly plant and finally perform the validation step by means of simulation.