CN102402722A - Method for improving assembly line efficiency of project machine products - Google Patents
Method for improving assembly line efficiency of project machine products Download PDFInfo
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- CN102402722A CN102402722A CN2011102987673A CN201110298767A CN102402722A CN 102402722 A CN102402722 A CN 102402722A CN 2011102987673 A CN2011102987673 A CN 2011102987673A CN 201110298767 A CN201110298767 A CN 201110298767A CN 102402722 A CN102402722 A CN 102402722A
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Abstract
The invention discloses a method for improving assembly line efficiency of project machine products. The method comprises the following steps of: measuring the operating time of each assembly task by using a standard time general analysis method, and exporting the assembly process of the products from a product data management system and a computer aid assembly process planning system; and calculating the preorder and post-order number of each assembly task, decomposing a large-scale assembly task distribution problem of the project machine products into small-scale sub problems, solving the optimal distribution schemes of the sub problems by using a branch and bound method, combining and regulating the optimal distribution schemes of the sub problems to acquire preferable distribution of the original assembly task distribution problem, and estimating errors produced by decomposition. According to the method, restraints of cycle time, process sequence and assembly task operating margins and the like can be comprehensively considered; and under the requirement of given cycle time or yield, the errors are effectively controlled, and the shortest assembly line is planned, so that the utilization rate of manufacturing resources is improved and the manufacturing cost of the products is reduced.
Description
Technical field
What
the present invention relates to is a kind of method that improves assembly line efficient, specifically is a kind of method that improves the assembly line efficient of construction machinery product.
Background technology
engineering machinery is one of core of Chinese equipment manufacture, and development in recent years is rapid, but faces many difficulties and challenge simultaneously, and it is low with the manufacturing resource utilization mainly to show as production efficiency.Planning, the high efficiency assembly line of construction are to improve to make resource utilization, reduce one of effective way of cost of goods manifactured and raising product competitiveness.Because the construction machinery product weight and volume is huge, the difficulty that carrying in the assembling process, locate and clamp etc. is operated is bigger, therefore extensively adopts novel bilateral assembly line.Compare with traditional monolateral assembly line, it is shorter that it has assembly line length, instrument public with reduce carrying, clamp advantage such as number of times.Structure, the complex process of single construction machinery product, fittage quantity is more, and planning process need satisfy constraints such as productive temp, process sequence, and the difficulty of assembly line planning is big.If relatively poor programme can seriously reduce the efficient and the product quality of assembly line, thereby influences competitiveness of product.
Through literature search discovery to prior art,
Deng the people at " International Journal of Production Research " (2010; 48, " Balancing parallel two-sided assembly lines " (the bilateral assembly line balancing) delivered on 4767-4784), this article is under the prerequisite that satisfies constraints such as beat, process sequence, fittage working edge; Through adjusting the distribution of each fittage on station; The load of each station of balance reduces station quantity, thereby improves the efficient of assembly line.The technology that this article relates to mainly exists this method of following defective and deficiency: ⑴ can only try to achieve feasible fittage allocative decision, is difficult to try to achieve optimum scheme; ⑵ the uncontrollable error of this method may obtain the lower assembly line of efficient; ⑶ it is measurement index that this article has been continued to use monolateral assembly line " station quantity ", may try to achieve monolateral assembly line by error.
Summary of the invention
the present invention is directed to the above-mentioned deficiency that prior art exists; A kind of method that improves the bilateral assembly line efficient of construction machinery product is provided, can takes all factors into consideration constraints such as beat, process sequence and fittage operation limit, under the requirement of given beat or output; Effective departure; Plan the shortest assembly line, make resource utilization, reduce cost of goods manifactured thereby improve.
the present invention realize through following technical scheme; Method of the present invention can be used for the bilateral assembly line planning of construction machinery product; Comprise the running time of adding up each fittage, set up the first preface restriction relation of fittage, calculate all the first prefaces of each fittage and the quantity of postorder; The fittage assignment problem of construction machinery product is decomposed into several relevant subproblems; Utilize exact method to try to achieve the optimal distributing scheme of subproblem then, according to the relation between the subproblem, thereby the optimal distributing scheme of combination, adjustment subproblem obtains the more excellent scheme of former assembling Task Distribution problem.
Specifically be divided into following several steps:
(1) utilizes the time measurement method to obtain the running time of each fittage.According to MTM-UAS (time standard-Gneral analysis system) method each fittage is decomposed into the action of standard, measures each standard operation and accomplish required time, addition obtains the running time of each assembling then.
The assembly technology of product is derived in
from PDM (product data management system) and CAPP (area of computer aided assembly process planning system), set up the first preface restriction relation between each fittage.
Calculate all first prefaces of each fittage iAP
i , postorderAS
i , corresponding quantity NAP i , NAS i , if NAP i , NAS i Any one greater than 0, then calculate RNPS i ,
RNPS
i
Expression fittage i elder generation's sequence task quantity and follow-up work quantity are near the degree that equates.For the purpose of standardization, be as the criterion RNPS divided by higher value with the smaller value among both
i
≤1, more approaching equal near 1 first sequence task of explanation and postorder task quantity more.
Mission critical is selected in
, is to have the subproblem of restriction relation successively with the Task Distribution PROBLEM DECOMPOSITION of former assembly line.According to NAP i + NAS i Order from big to small, judge whether following condition satisfies:
RNPS
i
>;0.5 (2)
NAP
i ≤40，NAS i ≤40 (3)
If satisfy, then task i is a mission critical, its all first prefacesAP
i With task i be subproblem G1, its all postordersAS
i Be subproblem G2, other remaining tasks then are subproblem G3.
Utilize the branch-and-bound method, the constraint according to first preface constraint, beat constraint and assembly station limit is assigned to the fittage among G1 and the G2 on the station of assembly line;
The Task Distribution scheme OS1 and the OS2 of
(6) connexon problem obtain main allocative decision.All idle time windows on the assembly line station among the calculating OS1, and arrange sequentially; Under the prerequisite that satisfies first preface constraint, beat constraint and operative orientation constraint, the task of being distributed among the scanning OS2, according to the principle of " task is preferential on-stream time the earliest ", searching can move on to task in the idle time window or task combination among the OS1; After task moves, upgrade other task on-stream times and OS1 free time window among the OS2 successively, and continue to seek the task that can move, the task in having scanned all OS2.From OS1, choose next free time window, repetitive cycling is inserted up to the task of accomplishing all window free time.
The error E M that OS1 is connected with OS2 is calculated in
.If OS1 is with after OS2 is connected, the minimizing of assembly line length 1 position, then error E L=0; Otherwise, error E L=1.
The free time that to main allocative decision is added the task among the subproblem G3 in
is in the window.Calculate the free time window on the station in the main allocative decision, and arrange sequentially; Under the prerequisite that satisfies first preface constraint, beat constraint and operative orientation constraint; Fittage among the scanning subproblem G3; Calculate running time summation TPL, the TPR of L type (left side operation) task and R type (the right operation) task; According to following rule, searching can be added task in the idle time window or task combination among the OS1;
Rule one: if TPL is greater than assembling beat, then the priority of task of L type is in E type (left and right limit all can be operated) task;
Rule two: if TPR is greater than assembling beat, then the priority of task of R type is in E type task;
rule three: if TPL and TPR be greater than beat, perhaps TPL and TPR then preferentially select the task of " load maximum " to make up less than beat.
utilize the branch-and-bound method to find the solution the optimal distributing scheme OS3 of subproblem G3 residue task, and the assembly line length of subproblem is PNR.
according to the first preface constraint of fittage, with OS3 be inserted into main distribution can in, thereby the assembly line that obtains construction machinery product is than optimal sorting prescription case.
The maximum possible error PME of step 10) gained assembly line length,
PME=EL+PNR (4)
maximum rigging error shows the degree of assembly line near optimal case, thereby the quality of control assembly line planning is guaranteed the raising of assembly line efficient.
can be learnt by above-mentioned steps, the running time that the present invention measures each fittage with standard time Gneral analysis method, and from product data management system and area of computer aided assembly process planning system the assembly technology of derivation product; Then, calculate the first preface and the postorder quantity of each fittage, the extensive fittage assignment problem of construction machinery product is decomposed into small-scale subproblem; Utilize the branch-and-bound method to find the solution the optimal distributing scheme of subproblem; The optimal distributing scheme of combination, adjustment subproblem obtains joining than optimal sorting of former assembling Task Distribution problem, and the error that produces is decomposed in estimation; Guarantee to optimize the distribution of fittage, thereby improve the efficient of construction machinery product assembly line.
compared with prior art; The present invention has outstanding substantive distinguishing features and marked improvement; The present invention solves the problem that exists in the assembly line efficiency method of present raising construction machinery product; A kind of method of the bilateral assembly line efficient of raising mould based on PROBLEM DECOMPOSITION, combined strategy is provided: 1. this method is a target to optimize assembly line length, has avoided the assembly line of final planning to deteriorate to monolateral assembly line; 2. this method can solve the extensive assembly line planning problem of actual construction machinery product; 3. this method quality of can the effective evaluation fittage distributing guarantees to obtain more excellent fittage allocative decision, improves the efficient of assembly line.
Description of drawings
The process flow diagram of Fig. 1 embodiment of the invention;
The fittage instance graph that Fig. 2 the present invention implements.
Embodiment
elaborate in the face of part embodiment of the present invention down; Present embodiment is being to implement under the prerequisite with technical scheme of the present invention; Provided detailed embodiment and concrete operating process, but protection scope of the present invention is not limited to following embodiment.
are as shown in Figure 1; Process flow diagram for the embodiment of the invention; Comprise the running time of adding up each fittage, set up the first preface restriction relation of fittage, calculate all the first prefaces of each fittage and the quantity of postorder; The fittage assignment problem of construction machinery product is decomposed into several relevant subproblems; Utilize exact method to try to achieve the optimal distributing scheme of subproblem then, according to the relation between the subproblem, thereby the optimal distributing scheme of combination, adjustment subproblem obtains the more excellent scheme of former assembling Task Distribution problem.
In
present embodiment, the assembly line of shovel loader adopts bilateral assembly line, and by 8 positions, 16 stations are formed, and have 59 fittages and are assigned to each assembly station.After the car body of shovel loader was reached the standard grade, the workman on the assembly line was according to the requirement of assembly technology, and operation tool is installed to product component or assembly on the car body of shovel loader.The transmission system of assembly line moves to next position with product from a position according to the beat of setting, up to accomplishing final assembling.The Task Distribution of assembly line receives technology, the constraint of facility or tool configuration etc.
Present embodiment improves the method for the assembly line efficient of construction machinery product, and practical implementation is following:
1) according to the MTM-UAS method each fittage is decomposed into the action of standard, utilizes stopwatch to measure each standard operation and accomplish required time, addition obtains accomplishing the running time of each assembling then, and converts the standard time to.
The assembly technology of product is derived in
from PDM (product data management system) and CAPP (area of computer aided assembly process planning system), set up the first preface restriction relation between each fittage, and is as shown in Figure 2.Numbering in the circle is represented fittage, the numeral operation required standard time of fittage in the bracket; Character L or R represent that task can only on the left side or the right operation, and E representes that any one side of the right and left can operate this fittage; Arrow is represented first preface constraint, and shown in Fig. 2, task 4 is first prefaces of task 6, and the distribution of fittage must be followed following rule: after the first preface of all of current task is distributed, could distribute current task.
Calculate all first prefaces of each fittage iAP
i , postorderAS
i , corresponding quantity NAP i , NAS i , if NAP i , NAS i Any one greater than 0, then calculate RNPS i
4) according to NAP i + NAS i Order from big to small is according to RNPS 29 =0.93, NAP
29 =28≤40, NAS i =30≤40,
Utilize the branch-and-bound method, the constraint according to first preface constraint, beat constraint and assembly station limit is assigned to the fittage among G1 and the G2 on the station of assembly line;
6) the Task Distribution scheme OS1 and the OS2 of connexon problem obtain main allocative decision.In this instance, do not have task can adjust on the station of OS1 among the OS2, directly connection promptly obtains the final assignment scheme.
with after OS2 is connected, assembly line length does not reduce, then error E L=1.
) there is not the subproblem of G3 in this instance, so OS1 with promptly accomplish fittage side after OS2 is connected and fit over the distribution on the assembly line.As shown in the table.
The maximum possible error PME=1 of
gained assembly line length.
can obtain fittage side as shown in the table and join through after the above-mentioned practical implementation step, and the maximum station manipulation time is the left side station of position 6, and the running time is 660 seconds, then assembles beat and can be made as 660 seconds.Originally the beat of assembly line is 750 seconds, calculates in 8 hours to work every day, brings up to 43.6/day from original 38.4/day, improves about 5.2 of production capacity.Being illustrated in does not increase under the prerequisite of making resource and manufacturing cost, and this method can effectively be raised the efficiency and production capacity.
What provide more than
only is one embodiment of the present of invention; The present invention can also be applicable to the assembly line of other situations, through taking all factors into consideration constraints such as beat, process sequence and fittage operation limit, under the requirement of given beat or output; Effective departure; Plan the shortest assembly line, make resource utilization, reduce cost of goods manifactured thereby improve.
will be appreciated that above-mentioned description should not be considered to limitation of the present invention although content of the present invention has been done detailed introduction through above-mentioned preferred embodiment.After those skilled in the art have read foregoing, for multiple modification of the present invention with to substitute all will be conspicuous.Therefore, protection scope of the present invention should be limited appended claim.
Claims (3)
1. a method that improves the assembly line efficient of construction machinery product is characterized in that comprising the steps:
1) utilize the time measurement method to obtain the running time of each fittage;
2) assembly technology of derivation product from product data management system PDM and area of computer aided assembly process planning system CAPP is set up the first preface restriction relation between each fittage;
3) calculate all first preface AP of each fittage i
i, postorder AS
i, corresponding quantity NAP
i, NAS
i, if NAP
i, NAS
iAny one greater than 0, then calculate RNPS
i,
RNPS
iExpression fittage i elder generation's sequence task quantity and follow-up work quantity are as the criterion RNPS near the degree that equates divided by higher value with the smaller value among both
i≤1, more approaching equal near 1 first sequence task of explanation and postorder task quantity more;
4) selecting mission critical, is to have the subproblem of restriction relation successively with the Task Distribution PROBLEM DECOMPOSITION of former assembly line, according to NAP
i+ NAS
iOrder from big to small, judge whether following condition satisfies:
RNPS
i>0.5
NAP
i≤40，NAS
i≤40
If satisfy, then task i is a mission critical, its all first preface AP
iWith task i be subproblem G1, its all postorder AS
iBe subproblem G2, other remaining tasks then are subproblem G3;
5) utilize the branch-and-bound method, the constraint according to first preface constraint, beat constraint and assembly station limit is assigned to the fittage among G1 and the G2 on the station of assembly line;
6) the Task Distribution scheme OS1 and the OS2 of connexon problem obtain main allocative decision, all idle time windows on the assembly line station among the calculating OS1, and arrange sequentially; Under the prerequisite that satisfies first preface constraint, beat constraint and operative orientation constraint, the task of being distributed among the scanning OS2, according to the principle of " task is preferential on-stream time the earliest ", searching can move on to task in the idle time window or task combination among the OS1; After task moves, upgrade other task on-stream times and OS1 free time window among the OS2 successively, and continue to seek the task that can move; Task in having scanned all OS2; From OS1, choose next free time window, repetitive cycling is inserted up to the task of accomplishing all window free time;
7) calculate the error E M that OS1 is connected with OS2, as if OS1 with after OS2 is connected, the minimizing of assembly line length 1 position, then error E L=0; Otherwise, error E L=1;
The free time of 8) adding the task among the subproblem G3 to main allocative decision is in the window; Calculate the free time window on the station in the main allocative decision, and arrange sequentially; Under the prerequisite that satisfies first preface constraint, beat constraint and operative orientation constraint; Fittage among the scanning subproblem G3; Calculating the L type is that left side operation task and R type are running time summation TPL, the TPR of the right operation task; According to following rule, searching can be added task in the idle time window or task combination among the OS1;
Rule one: if TPL is greater than the assembling beat, but then the priority of task of L type is all operation tasks of left and right limit in the E type;
Rule two: if TPR is greater than assembling beat, then the priority of task of R type is in E type task;
Rule three: if TPL and TPR be greater than beat, perhaps TPL and TPR then preferentially select the task of " load maximum " to make up less than beat;
9) utilize the branch-and-bound method to find the solution the optimal distributing scheme OS3 of subproblem G3 residue task, the assembly line length of subproblem is PNR;
10) according to the first preface constraint of fittage, with OS3 be inserted into main distribution can in, thereby the assembly line that obtains construction machinery product is than optimal sorting prescription case.
2. the method for the assembly line efficient of raising construction machinery product according to claim 1; It is characterized in that: in the step 1); Each fittage is decomposed into the action of standard according to time standard-Gneral analysis system MTM-UAS method; Measure each standard operation and accomplish the required time, addition obtains the running time of each assembling then.
3. the method for the assembly line efficient of raising construction machinery product according to claim 1; It is characterized in that: the maximum possible error PME of step 10) gained assembly line length; PME=EL+PNR, the maximum possible error shows the degree of assembly line near optimal case.
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Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN105117094A (en) * | 2014-04-02 | 2015-12-02 | 英飞凌科技股份有限公司 | Process support system and method |
| CN106155016A (en) * | 2016-07-05 | 2016-11-23 | 上海交通大学 | A kind of project type Product Assembly process management and control system |
| CN107317872A (en) * | 2017-07-20 | 2017-11-03 | 河海大学 | The dispatching method of polymorphic type task in a kind of space mass-rent |
| CN107570430A (en) * | 2017-10-26 | 2018-01-12 | 中国人民解放军国防科技大学 | Intelligent robot-based part sorting method in mechanical equipment maintenance process |
| CN109426898A (en) * | 2017-08-24 | 2019-03-05 | 阿里巴巴集团控股有限公司 | Job task distribution method, device and computer system |
| CN112308450A (en) * | 2020-11-12 | 2021-02-02 | 深圳市华博创新科技有限公司 | Manual process productivity determination method |
| CN115619082A (en) * | 2022-12-02 | 2023-01-17 | 天津大学 | Method and device for solving balance problem of man-machine cooperation mixed flow assembly line |
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Cited By (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105117094A (en) * | 2014-04-02 | 2015-12-02 | 英飞凌科技股份有限公司 | Process support system and method |
| CN106155016A (en) * | 2016-07-05 | 2016-11-23 | 上海交通大学 | A kind of project type Product Assembly process management and control system |
| CN106155016B (en) * | 2016-07-05 | 2019-05-24 | 上海交通大学 | A kind of project type Product Assembly process management and control system |
| CN107317872A (en) * | 2017-07-20 | 2017-11-03 | 河海大学 | The dispatching method of polymorphic type task in a kind of space mass-rent |
| CN107317872B (en) * | 2017-07-20 | 2020-05-05 | 河海大学 | Scheduling method of multi-type tasks in space crowdsourcing |
| CN109426898A (en) * | 2017-08-24 | 2019-03-05 | 阿里巴巴集团控股有限公司 | Job task distribution method, device and computer system |
| CN109426898B (en) * | 2017-08-24 | 2022-04-12 | 阿里巴巴集团控股有限公司 | Job task allocation method and device and computer system |
| CN107570430A (en) * | 2017-10-26 | 2018-01-12 | 中国人民解放军国防科技大学 | Intelligent robot-based part sorting method in mechanical equipment maintenance process |
| CN107570430B (en) * | 2017-10-26 | 2018-07-31 | 中国人民解放军国防科技大学 | Intelligent robot-based part sorting method in mechanical equipment maintenance process |
| CN112308450A (en) * | 2020-11-12 | 2021-02-02 | 深圳市华博创新科技有限公司 | Manual process productivity determination method |
| CN115619082A (en) * | 2022-12-02 | 2023-01-17 | 天津大学 | Method and device for solving balance problem of man-machine cooperation mixed flow assembly line |
| CN115619082B (en) * | 2022-12-02 | 2023-03-28 | 天津大学 | Method and device for solving balance problem of man-machine cooperation mixed flow assembly line |
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