结构件分厂工艺改善、布局规划及价值流分析研究
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摘要
通过对A企业结构件生产线的分析,发现了该生产线的诸多问题,作者从物流、信息流、人因三方面对该结构件生产线进行分析,利用传统流程分析法对该生产线工艺进行全面的改善。并运用现代的价值流分析法,直观的分析了结构件生产中存在的问题,基于对价值流图的分析,对该结构件生产线进行了持续改进,使生产线更加精益。
本文研究重点是:布局改善和对工位的重新划分。通过对整个生产线的工位进行重新划分,使生产线整体布局得到全方位的改善,进而缩短了生产线的搬运时间,增加了整个生产线的平衡率,尽最大可能减少了线上半成品的堆积,并达到一个流生产的目的,使整个车间的生产状况得到根本的改观。
另外,根据精益的思想,把生产线上的物料流、信息流都全面的绘制到价值流图上,把生产中的浪费直观地呈现出来,从而更便捷的缩短传递的路径,提高传递的效率,更完整系统的描述生产流程。
本文的研究结果使结构件生产线的有效作业时间比重大幅提升,多余走动大幅减少,生产效率、产能以及结构件的质量得到大幅提升。
Many problems have been found in the production line based on an analysis of the course of structural components production. A study about the line is done from logistics, information flow, and human factors by using traditional production circuit analysis to achieve the comprehensive improvement towards technology process. Based on the modern value-stream analysis, the present problems in structural component productions are studied intuitively. Structural parts of the production line are improved continuously, which makes the line finer and more efficient.
This paper focuses on layout improvements and working state re-divisions, which improve the overall layout of the production line all-roundly, shorten the production line handling time, increase the equilibrium rate of the entire production line, reduce the accumulation of semi-finished products in the line as possible, and achieve the purpose of the stream producing. Finally, status of the entire plant's production is changed fundamentally.
According to the fine and efficient thought, the production line material flow and information flow are entirely mapped on the value stream, so that the production of waste is presented visually. This reduces the transmission path, improves transfer efficiency, and completely depicts the system production process.
These study results that the proportion of working time of the effective structural parts production line is improved significantly, useless walking is reduced obviously, and the production efficiency, productivity and quality of structural components are enhanced greatly.
本文研究重点是:布局改善和对工位的重新划分。通过对整个生产线的工位进行重新划分,使生产线整体布局得到全方位的改善,进而缩短了生产线的搬运时间,增加了整个生产线的平衡率,尽最大可能减少了线上半成品的堆积,并达到一个流生产的目的,使整个车间的生产状况得到根本的改观。
另外,根据精益的思想,把生产线上的物料流、信息流都全面的绘制到价值流图上,把生产中的浪费直观地呈现出来,从而更便捷的缩短传递的路径,提高传递的效率,更完整系统的描述生产流程。
本文的研究结果使结构件生产线的有效作业时间比重大幅提升,多余走动大幅减少,生产效率、产能以及结构件的质量得到大幅提升。
Many problems have been found in the production line based on an analysis of the course of structural components production. A study about the line is done from logistics, information flow, and human factors by using traditional production circuit analysis to achieve the comprehensive improvement towards technology process. Based on the modern value-stream analysis, the present problems in structural component productions are studied intuitively. Structural parts of the production line are improved continuously, which makes the line finer and more efficient.
This paper focuses on layout improvements and working state re-divisions, which improve the overall layout of the production line all-roundly, shorten the production line handling time, increase the equilibrium rate of the entire production line, reduce the accumulation of semi-finished products in the line as possible, and achieve the purpose of the stream producing. Finally, status of the entire plant's production is changed fundamentally.
According to the fine and efficient thought, the production line material flow and information flow are entirely mapped on the value stream, so that the production of waste is presented visually. This reduces the transmission path, improves transfer efficiency, and completely depicts the system production process.
These study results that the proportion of working time of the effective structural parts production line is improved significantly, useless walking is reduced obviously, and the production efficiency, productivity and quality of structural components are enhanced greatly.
引文
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[6] Frizelle, G., E. Woodcock. Measuring complexity as an aid to developing operational strategy[J]. International Journal of Operation and Production Management, 1995, 15(5):26-39.
[7]Calinescu.,A, J.Efstathion,J. Bermejo. Applying and assessing two methods for measuring complexity in manufacturing[J]. Journal of Operational Research Society, 1998,49(7):723-733.
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[10]朱传军,常沿斌.制造车间不确定信息研究现状及趋势[J].机床与液压,2008,36(5):182-186.
[11] Helmut Gegenheimer.精加工工艺改善成型和冲压刀的质量.现代制造.现代模具, 2007(02):38-40.
[12]胡正国,李海燕,陈炳森,基于价值流的物料管理策略研究.机械工业自动化, 19(4): 9-11,26.
[13]李云,阚树林,朱妍.多品种混合装配流水线规划的仿真方法,上海大学学报(自然科学版), 2003, 9(4): 338-345.
[14]张俊芝.价值流与业务协同机制在能源企业固定资产管理中的应用研究.经济研究, 2011.05: 35-37.
[15]王秉刚.价值流图析技术—实现精益生产的工具,世界汽车, 2000, 7:28-31.
[16]于忠洋.出钢机轨道梁加工工艺的改善,机械工程师, 2010, 7:137-138.
[17]刘义乐,李红广,梁斌.价值流分析在精益维修中的应用[J].国防技术基础, 2007(1): 54-57.
[18]牛占文,何桢.实施精益生产提升企业核心竞争力[J].工程机械, 2006(6): 66-70.
[19] Won You-Dong. Linear programming approach to linear machine layout problem [J]. Industrial Mathematics, 1997,47(2):59-68.
[20] 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.
[21] Yang Y, Chute C G. An example-based mapping method for text categorization and retrieval[J] . ACM Transaction on Information Systems(TOIS), 1994, 12(3): 252-277.
[22] 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.
[23] 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.
[24]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.
[25]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.
[26] Israel David, Moshe Eben-Chaime. How far should JIT vendor–buyer relationships go. International Journal of Production Economics. 2003,1: 361~368.
[27] Barratt M,Oliveira A,Exploring the experiences of collaborative Planning initiatives. International Journal of Physical Distribution & Logistics Management. 2001,31(4):266~289.
[28] Whybark, D.C. and Williams,J.G. Material Requirements planning Under Uncertainty[J],Decision Sciences,1976,7(4):595-606.
[29] De Bodt,M.A.and Wassenhove L.V.Lot sizes and safety stoeks in MRP: a case study[J].Production and Inventory Management ,1983FirstQuarter,1-16.
[30] Blackburn,J.D. Kro,D.H.,and Millen,R.A.,A. Comparison of Strategies to Dampen Nervousness in MRP Systems[J].Management Science,1986,32(4):413-429.
[31]庄薇,陈勇,阮幸聪,方秋军,胡婷婷.基于价值流的电动工具生产线的分析与改善,工业工程, 2011, 14(2):122-126.
[32]商层,王少宇,平衡块深孔加工工艺改善,精密成形工程, 2010, 2(4): 86-88.
[33]席玉明.搅拌槽工艺改善过滤效果的应用,矿业工程, 2011, 9(4): 41-43.
[34]杨青,乔黎黎.基于价值流图析技术的精益改进研究,金属世界, 2009:145-148
[35]刘义乐,李红广,梁斌.价值流分析在精益维修中的应用,国防技术基础, 2007, 1: 54-57.
[36]曹伟华,梁艳.精益持续改善理论在纵梁钻模板制造工艺改善中的应用,汽车工艺与材料, 2008, 9: 12-18.
[37] Gallego,G. Scheduling the Production of several items with random demands in a single facility[J].Management Science.1990,36(12),1579-1592.
[38] Kelle,P.,Clendenen,G,Dardeau,P. Economic lot scheduling heuristic for random demands[J].International Journal of Production Economics1994,35,337-342.
[39] Karl Inderfurth,Stefan Minner. Safety stocks in multi-stage inventory systems under different service measures [J]. European Journal and Operational Researeh. 1998,106,57-73.
[40]牟德一,陈秋双.基于安全库存的二级库存系统的优化方法[J].系统工程,2003(3):83-87.
[41]林勇,马士华.基于提前期的通用件安全库存管理[J].系统工程,2003(l):7l-75.
[42]张慧颖,寇纪淞.基于δ/Q的库存控制中安全库存的优选策略[J].管理科学学报,2004(12):46-51.
[43]韩宇鑫,刘晓伟.基于时间优化的安全库存管理[J]商业研究,2004,(12):71-73.
[44]徐春迎,阮文彪.供应链不确定性与安全库存研究[JJ.商业研究,2005(l3):65-67.
[45] Jing-Sheng Song.The dffect of lead-time uneertainty in a Simple Stochastic inventory model[J].Management Seience,1994,40(5):603-613.
[46] Yingdong Lu,Jing-Sheng Song,David.D.Yao.Order fill rate,lead time variability and advance demand information in an assemble-to-order system[J].Operations Research,2003,51(2):292-342.
[47] Yano,Candace Arai.Stoehastic lead times in two-level assembly systems[J].IIE Transactions,1987,19(4):371-378.
[48]郜振廷.海尔物流创新模式.中国时代经济出版社. 2003: 67~82.
[49]黄培清,揭晖.供应链库存管理的几项措施.工业工程与管理. 1998,5: 14~17.
[50]徐贤浩,马士华.供应链网络状结构模型中的多级库存控制模型.华中理工大学学报. 1998, 26(7): 68~70.
[2]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.
[3] Kotha, S., D. Orne. Generic manufacturing strategies: A conceptual synthesis[J]. Strategic Management Journal, 1989(10):211-231.
[4] Cooper,W.W., K.K.Sinha, R.S.Sullivan. Measuring complexity in high-technology manufacturing: indexes for evaluation [J]. Interfaces, 1992, 22(4): 38-48.
[5] Frizelle, G. Getting the measure of complexity[J]. Manufacturing Engineer, 1996, 75(6):268-270.
[6] Frizelle, G., E. Woodcock. Measuring complexity as an aid to developing operational strategy[J]. International Journal of Operation and Production Management, 1995, 15(5):26-39.
[7]Calinescu.,A, J.Efstathion,J. Bermejo. Applying and assessing two methods for measuring complexity in manufacturing[J]. Journal of Operational Research Society, 1998,49(7):723-733.
[8]Khurana,A. Managing complex production processes[J].Sloan Management Review, 1999, 40(2):85-97.
[9]姚锡凡,张毅,董绍强等.不确定信息的度量及其在制造中的应用示例[J].计算机集成制造系统,2004,10(11):1466-1470.
[10]朱传军,常沿斌.制造车间不确定信息研究现状及趋势[J].机床与液压,2008,36(5):182-186.
[11] Helmut Gegenheimer.精加工工艺改善成型和冲压刀的质量.现代制造.现代模具, 2007(02):38-40.
[12]胡正国,李海燕,陈炳森,基于价值流的物料管理策略研究.机械工业自动化, 19(4): 9-11,26.
[13]李云,阚树林,朱妍.多品种混合装配流水线规划的仿真方法,上海大学学报(自然科学版), 2003, 9(4): 338-345.
[14]张俊芝.价值流与业务协同机制在能源企业固定资产管理中的应用研究.经济研究, 2011.05: 35-37.
[15]王秉刚.价值流图析技术—实现精益生产的工具,世界汽车, 2000, 7:28-31.
[16]于忠洋.出钢机轨道梁加工工艺的改善,机械工程师, 2010, 7:137-138.
[17]刘义乐,李红广,梁斌.价值流分析在精益维修中的应用[J].国防技术基础, 2007(1): 54-57.
[18]牛占文,何桢.实施精益生产提升企业核心竞争力[J].工程机械, 2006(6): 66-70.
[19] Won You-Dong. Linear programming approach to linear machine layout problem [J]. Industrial Mathematics, 1997,47(2):59-68.
[20] 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.
[21] Yang Y, Chute C G. An example-based mapping method for text categorization and retrieval[J] . ACM Transaction on Information Systems(TOIS), 1994, 12(3): 252-277.
[22] 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.
[23] 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.
[24]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.
[25]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.
[26] Israel David, Moshe Eben-Chaime. How far should JIT vendor–buyer relationships go. International Journal of Production Economics. 2003,1: 361~368.
[27] Barratt M,Oliveira A,Exploring the experiences of collaborative Planning initiatives. International Journal of Physical Distribution & Logistics Management. 2001,31(4):266~289.
[28] Whybark, D.C. and Williams,J.G. Material Requirements planning Under Uncertainty[J],Decision Sciences,1976,7(4):595-606.
[29] De Bodt,M.A.and Wassenhove L.V.Lot sizes and safety stoeks in MRP: a case study[J].Production and Inventory Management ,1983FirstQuarter,1-16.
[30] Blackburn,J.D. Kro,D.H.,and Millen,R.A.,A. Comparison of Strategies to Dampen Nervousness in MRP Systems[J].Management Science,1986,32(4):413-429.
[31]庄薇,陈勇,阮幸聪,方秋军,胡婷婷.基于价值流的电动工具生产线的分析与改善,工业工程, 2011, 14(2):122-126.
[32]商层,王少宇,平衡块深孔加工工艺改善,精密成形工程, 2010, 2(4): 86-88.
[33]席玉明.搅拌槽工艺改善过滤效果的应用,矿业工程, 2011, 9(4): 41-43.
[34]杨青,乔黎黎.基于价值流图析技术的精益改进研究,金属世界, 2009:145-148
[35]刘义乐,李红广,梁斌.价值流分析在精益维修中的应用,国防技术基础, 2007, 1: 54-57.
[36]曹伟华,梁艳.精益持续改善理论在纵梁钻模板制造工艺改善中的应用,汽车工艺与材料, 2008, 9: 12-18.
[37] Gallego,G. Scheduling the Production of several items with random demands in a single facility[J].Management Science.1990,36(12),1579-1592.
[38] Kelle,P.,Clendenen,G,Dardeau,P. Economic lot scheduling heuristic for random demands[J].International Journal of Production Economics1994,35,337-342.
[39] Karl Inderfurth,Stefan Minner. Safety stocks in multi-stage inventory systems under different service measures [J]. European Journal and Operational Researeh. 1998,106,57-73.
[40]牟德一,陈秋双.基于安全库存的二级库存系统的优化方法[J].系统工程,2003(3):83-87.
[41]林勇,马士华.基于提前期的通用件安全库存管理[J].系统工程,2003(l):7l-75.
[42]张慧颖,寇纪淞.基于δ/Q的库存控制中安全库存的优选策略[J].管理科学学报,2004(12):46-51.
[43]韩宇鑫,刘晓伟.基于时间优化的安全库存管理[J]商业研究,2004,(12):71-73.
[44]徐春迎,阮文彪.供应链不确定性与安全库存研究[JJ.商业研究,2005(l3):65-67.
[45] Jing-Sheng Song.The dffect of lead-time uneertainty in a Simple Stochastic inventory model[J].Management Seience,1994,40(5):603-613.
[46] Yingdong Lu,Jing-Sheng Song,David.D.Yao.Order fill rate,lead time variability and advance demand information in an assemble-to-order system[J].Operations Research,2003,51(2):292-342.
[47] Yano,Candace Arai.Stoehastic lead times in two-level assembly systems[J].IIE Transactions,1987,19(4):371-378.
[48]郜振廷.海尔物流创新模式.中国时代经济出版社. 2003: 67~82.
[49]黄培清,揭晖.供应链库存管理的几项措施.工业工程与管理. 1998,5: 14~17.
[50]徐贤浩,马士华.供应链网络状结构模型中的多级库存控制模型.华中理工大学学报. 1998, 26(7): 68~70.
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