Optimizing a Production Line with a Simulation Analysis

摘要

山东博特精工股份有限公司生产精密滚珠丝杠副、精密滚动直线导轨副、高速精密电主轴、动静压主轴、数控机床主轴、X-Y精密双坐标工作台、精密梯形丝杠等各种精密轴类零件。该公司希望有一条具有更高生产能力的生产线，生产线可以通过现有的设备获得。本文创建了一个精密主轴生产线的仿真模型，且本文的重点是对该生产线进行优化。　　为了优化精密主轴生产线，本文首先在最低加工速度下观察生产线来检测瓶颈；而本文使用的另一种瓶颈检测方法是通过查看在制品在各个工序的滞留时间，而这并不能提供准确的信息。随后，本文利用约束理论进行了一次迭代来消除生产线的瓶颈。在消除瓶颈的过程中，本文使用了生产线优化技术之一的缓冲技术。　　在了解了生产线以及生产线优化技术后，本文使用FlexSim软件建立了仿真模型，利用每台机器的加工时间进行了9个不同的实验。　　在第一次实验中仿真模型表明，生产过程的最后阶段锥孔磨床是生产线的瓶颈。但是需要进行更多的实验来验证这一观点，于是本文使用了每台机器所处的状态、处理状态、空闲状态和阻塞状态来进行验证。在进行9次重复实验后，结果表明，具有较高处理时间的工序是生产线的瓶颈。其次，在第9次实验中，生产线的产量开始下降，所以最合理的生产线是第八条生产线，它的生产率为88.7%，而第一次实验的生产率78.2%。因此，本文建议公司使用这条生产线作为公司车间布局的基础。　　最后，本文建议当车间目前的生产线有更完整的数据时，对本文的仿真模型进行更新。同时，为了提高车间生产的整体产品的整体生产线的效率，建议公司收集所有必要的数据，再做一个仿真模型同时对现有模型进行更新。一个更精确的仿真模型将对生产线优化提供更有效的帮助，而这有助于提高整个生产线的性能。

目录

声明

1 Introduction

1.1 Company Profile

1.2 Background of study

1.3 The choice for conducting a simulation analysis

1.4 Objectives of the study

1.5 Problem statement

1.6 Organization of thesis

1.7 Scope of the study

2 Literature Review

2.1 Effectiveness, Productivity, and Efficiency

2.1.1 Overall Equipment Efficiency (OEE)

2.1.2 Overall Line Efficiency (OLE)

2.2 Single Minute Exchange of Die - SMED

2.3 Production line inefficiency

2.3.1 Machine efficiency

2.3.2 Manpower utilization

2.3.3 Supporting department

2.3.4 Operators or workers

2.4 Job Shop Manufacturing

2.4.1 Characteristics of Job Shop production

2.5 Production Line Simulation

2.6 Production line optimization techniques

2.6.1 Bottleneck detection

2.6.2 Effects of a standstill of the bottleneck

2.6.3 Production line optimization methodologies

2.6.4 Production line optimization techniques

2.6.5 Production Line Layout

2.7 FlexSim Software

3 Information about the production line

3.1 Products to be produced on the production line

3.2 Workstations in the production line

3.2.1 List of workstations in the production line

3.2.2 Processes in the production line

3.3 KPIs that will be optimized in the simulation study

4 Research Methodology

4.1 Implementation of the simulation model

4.1.1 Presentation of the simulation model

4.1.2 How the simulation model works in general

4.2 Verification and validation of the simulation model

4.2.1 Explanation on verification and white-box validation

4.2.2 Explanation of black-box validation

4.2.3 Verification and white-box validation of the simulation model

4.3 Choices regarding the optimization of the production line

4.3.1 Integration of theories

4.3.2 Experiments with production line optimization techniques

4.4 Conceptual model of the production line

4.4.1 Simplifications in the simulation model

4.4.2 Input data for the simulation model

4.4.3 Production line layout

4.4.4 Output variables of the simulation model

4.5 Summary

5 Experiments with the simulation model

5.1 Preparations for the experiments

5.1.1 The nature of the simulation model and simulation output

5.1.2 Issues in obtaining accurate simulation results

5.2 Experiments with the production line optimization techniques

5.2.1 Bottleneck detection

5.2.2 Buffering

5.2.3 V-curve

Conclusion, recommendations, and discussion

Conclusion

Recommendations

Discussion

参考文献

致谢