CN113256061A - Production scheduling evaluation method for casting process - Google Patents
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 93
- 238000005266 casting Methods 0.000 title claims abstract description 22
- 238000011156 evaluation Methods 0.000 title claims abstract description 15
- 238000000034 method Methods 0.000 claims abstract description 67
- 239000000047 product Substances 0.000 claims description 40
- 238000000465 moulding Methods 0.000 claims description 13
- 238000003723 Smelting Methods 0.000 claims description 10
- 238000007517 polishing process Methods 0.000 claims description 9
- 238000002360 preparation method Methods 0.000 claims description 9
- 239000011265 semifinished product Substances 0.000 claims description 9
- 238000005498 polishing Methods 0.000 claims description 5
- 239000002184 metal Substances 0.000 claims description 4
- 229910052751 metal Inorganic materials 0.000 claims description 4
- 239000004576 sand Substances 0.000 claims description 4
- 238000003754 machining Methods 0.000 description 8
- 238000002844 melting Methods 0.000 description 7
- 230000008018 melting Effects 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
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- 230000009286 beneficial effect Effects 0.000 description 1
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Abstract
A production scheduling assessment method for a casting process belongs to the technical field of casting and is used for solving the problems of production continuity and production beat length of an automatic production line. The scheduling evaluation method comprises the steps of setting a set of scheme for evaluating the rated capacity of the production process, and evaluating the rated capacity of each process according to the rated capacity scheme; setting a set of scheme for evaluating the planned capacity of the production process, and evaluating the planned capacity of each process according to the planned capacity scheme; obtaining the capacity utilization rate by multiplying the planned capacity/the rated capacity by 100 percent, and if the capacity utilization rate is more than 100 percent, indicating that the planned capacity exceeds the rated capacity; and if the capacity utilization rate is less than 100%, indicating that the planned capacity is less than the rated capacity and has surplus. By evaluating the production capacity of the production line, bottleneck production nodes of the production line are found out, and an achievable mode is provided for full production and maximum production so as to improve the production capacity of the production line.
Description
Technical Field
The invention relates to the technical field of casting, in particular to a production scheduling method of a casting process.
Background
The automatic production lines of a horizontal molding line, a vertical molding line, a static pressure molding line, an iron mold sand-covering line and the like are mainly used for producing large-batch small products, the production process comprises core making, molding, smelting, pouring, polishing and processing, and the production line equipment has high automation degree and strong continuity, but is limited by the current production scheduling mode, so that the production line cannot continuously produce or the production takt is too long. Therefore, it is necessary to provide a method for evaluating the scheduling of casting processes in accordance with an automatic production line for large-scale and small-scale parts.
Disclosure of Invention
In view of the above problems of poor continuity and long production cycle of the automatic production line, there is a need for a method for evaluating the production schedule for casting processes.
A method for evaluating the scheduling of production for casting technology includes setting a set of scheme for evaluating the rated capacity of production process, and evaluating the rated capacity of each process according to the rated capacity scheme; secondly, a set of plan for evaluating the planned capacity of the production process is set, and the planned capacity of each process is evaluated by the plan capacity scheme; thirdly, obtaining the capacity utilization rate by multiplying the planned capacity/the rated capacity by 100 percent, and if the capacity utilization rate is more than 100 percent, indicating that the planned capacity exceeds the rated capacity; and if the capacity utilization rate is less than 100%, indicating that the planned capacity is less than the rated capacity and has surplus.
Specifically, the scheme for evaluating the rated capacity of the production process specifically includes:
s001, selecting basic data for evaluating the rated production capacity;
and S002, calculating the rated capacity according to the set evaluation rule.
Specifically, the scheme for evaluating the planned capacity of the production process specifically includes:
s101, determining the required working hours for producing single products or semi-finished products;
s102, determining equipment working hours needing equipment participation in the required working hours for producing the single product or the semi-finished product;
and S103, determining the planned capacity of the corresponding production process according to the equipment depending on the corresponding production process.
The technical scheme of the invention has the beneficial effects that: by evaluating the production capacity of the production line, bottleneck production nodes of the production line are found out, and an achievable mode is provided for full production and maximum production so as to improve the production capacity of the production line; meanwhile, the utilization rate of each production device can be well obtained, so that an information basis is provided for efficient utilization of the devices.
Drawings
FIG. 1 is a graph of the man-hour calculation required for core making of a single sand core;
FIG. 2 is a chart of the man-hours required for the apparatus in producing a single piece core;
FIG. 3 is a monthly capacity evaluation table for a product.
Detailed Description
In order to illustrate the technical solutions of the present invention more clearly, the following detailed description of the technical solutions of the present invention is provided, and it is obvious that the following descriptions are some exemplary embodiments of the present invention, and it is obvious for those skilled in the art that other solutions can be obtained according to the embodiments without creative efforts.
In order to improve the productivity of an automatic production line, a set of scheduling method for casting process is established on the existing automatic production line, so that the rated productivity of the automatic production can be evaluated, the planned productivity can be evaluated according to the scheduling quantity, the productivity utilization rate of the automatic production line is obtained, and an improvement scheme is provided for improving the productivity or the maximum production of the automatic production line.
The method for evaluating the scheduling production for the casting process comprises the steps of firstly, setting a set of scheme for evaluating the rated capacity of a production process, and evaluating the rated capacity of each process according to the rated capacity scheme; secondly, a set of plan for evaluating the planned capacity of the production process is set, and the planned capacity of each process is evaluated by the plan capacity scheme; thirdly, obtaining the capacity utilization rate by multiplying the planned capacity/the rated capacity by 100 percent, and if the capacity utilization rate is more than 100 percent, indicating that the planned capacity exceeds the rated capacity and cannot be produced completely; and if the capacity utilization rate is less than 100%, indicating that the planned capacity is less than the rated capacity and has surplus.
In the core-shooting casting process, the production process is divided into a core making process, a molding process, a core assembling process, a smelting process, a pouring process, a polishing process, a machining process and the like.
A scheduling evaluation method for core shooting process comprises the following contents:
firstly, a set of scheme for evaluating the rated capacity of the production process is set, and the rated capacity of each process is evaluated by the rated capacity scheme.
Specifically, the scheme for evaluating the rated capacity of the core making process comprises the following steps:
1) the rated capacity of the core making process is evaluated in time unit minutes, the core making process adopts a core shooter to complete core making operation, and the basic data to be acquired for evaluating the rated capacity of the core making process comprises the model of the core shooter, the number of the core shooters, the design starting rate of the core shooter, the daily working time (unit: hour), day preparation time (unit: minutes), monthly hours of operation;
2) calculating the rated capacity of a core making procedure under the core shooting process, wherein the rated capacity is the core shooting machine planning starting rate multiplied by the daily working time multiplied by 60 multiplied by the number of core shooting machines multiplied by the number of monthly working days, the daily production preparation time multiplied by the number of core shooting machines multiplied by the monthly working days; for example, when the core shooter a20 and the core shooter plan starting rate is 0.9, the daily operating time is 22h, the daily production preparation time is 120min, and the monthly operating days are 30 days, the monthly rated capacity of the core shooting line is 0.9 × 22 × 60 × 20 × 30-120 × 20 × 30-640800 min, that is, 640800min can be put into production within one month of the core shooting line, or the full capacity of the core shooting line is 640800 min.
Similarly, the maximum monthly rated capacity of the molding line in the molding process, i.e., the design start rate of the sand drift machines × the daily operating time × 60 × the number of sand drift machines × the number of month operating days — the daily production preparation time × the number of sand drift machines × the number of month operating days, is 32040min, i.e., the maximum production time that the molding line can be put into one month is 32040 min.
Similarly, if the facility used in the melting step is a melting furnace, or may be an electric furnace, the monthly rated capacity of the melting line is 0.99 × 22 × 60 × 4 × 30-0 × 1 × 30, which is 150480min, that is, the maximum production time that can be put into the melting line in one month is 150480min, where the melting furnace plan start rate × daily operating time × 60 × the number of melting furnaces × monthly operating days — daily production preparation time × the number of melting furnaces × monthly operating days.
Similarly, the grinding process belongs to a process of pure manual operation, and the monthly rated capacity is the manual efficiency × daily operating time × 60 × the number of people × monthly operating days — the daily production preparation time × the number of people × monthly operating days is 0.9 × 8 × 60 × 5 × 30-60 × 5 × 30 ═ 55800min, that is, the grinding process has a maximum production time of 55800min which can be put into a month under the condition of single-shift operation of five people.
Similarly, the maximum production time that can be put into a month in the case where one lathe is used for the machining process is 33840min, which means that the maximum production time that can be put into a month is 33840min, when the equipment used for the machining process is a lathe, the rated monthly capacity is 0.9 × 22 × 60 × the number of lathes × the number of days of the month × the preparation time for daily production × the number of lathes × the number of days of the month.
And step two, setting a set of plan for evaluating the planned capacity of the production process, and evaluating the planned capacity of each process according to the plan for capacity.
Specifically, the scheme for evaluating the planned capacity of the core making process is as follows:
1) calculating the required working hours for producing the single sand core according to the required core making working hours of the single mould, the number of the sand cores which can be made by the single mould, the number of the matched sand cores, the model of the core shooter, the serial number of the core making mould and the number of the single box modeling, wherein the required working hours of the single sand core is the required mould number for making the core multiplied by the required core making working hours of the single mould, the required mould number for making the core is the required sand core number/the number of the sand cores which can be made by the single mould, the required sand core number is the required moulding box number multiplied by the number of the matched sand cores, and the required moulding box number is the number of products to be produced/the number of the single box modeling; in the embodiment, 9 sand cores are designed, and specific calculation can be shown in fig. 1;
2) calculating the required working hours of the single product, namely the required core-making working hours of the single product is the sum of the required working hours of all the single sand cores forming the single product, wherein the required working hours of the core shooter are the required working hours of any single sand core, and the required working hours of the core shooter are shown in figure 2 when the single sand core is produced. For example, as can be seen from fig. 1 and 2, the required labor hour of the C equipment is the sum of the required labor hours of the 3# sand core and the 8# sand core, that is, the required labor hour of the C equipment is 4.75 min; for another example, the required working hours for producing the product by the equipment A are the sum of the required working hours for producing the product by the equipment A, namely the 1# sand core, the 5# sand core and the 6# sand core are produced in the same mould, namely the required working hours for producing any one of the three sand cores at one time are required, and the required working hours for producing the product by the equipment A are 9.5 min;
3) based on the core shooting process, the equipment required by the core making process is a core shooting machine, that is, the capacity of the core making process is limited by the core shooting machine or the sand blasting equipment, for example, in fig. 1, when the equipment a is used to produce a product, the monthly planned capacity of the equipment a is equal to the monthly planned yield × the man-hour required by the equipment a to produce the product.
Similarly, the planned productivity assessment method for the modeling process is to calculate the monthly planned productivity of the modeling process based on one box or one model as a production unit, the man-hours required for single-box production, and the number of single boxes, wherein the monthly planned productivity of the modeling process is the monthly planned yield/the number of single boxes × the man-hours required for single-box production, and the unit is minutes.
Similarly, the planned capacity evaluation scheme of the smelting process is to calculate the monthly planned capacity of the smelting process by taking one smelting furnace as a production unit and taking the total weight of the molten metal required for pouring a single product as a basis, wherein the monthly planned capacity of the smelting process is the monthly planned capacity multiplied by the total weight of the molten metal required for the single product, and the unit is ton.
Similarly, the planned productivity evaluation scheme of the polishing process is to calculate the planned productivity of the polishing process by taking a single product as a production unit and the required working hours of polishing the single product, wherein the planned productivity of the polishing process is the monthly planned yield multiplied by the required working hours of polishing the single product, and the unit is minutes.
Similarly, the planned productivity evaluation scheme of the machining process is to calculate the planned productivity of the machining process by taking a single product as a production unit and the required working hours for machining the single product, wherein the planned productivity of the machining process is the monthly planned yield/the required working hours for machining the single product, and the unit is minutes.
Thirdly, setting a certain number of products to be scheduled, wherein the planned capacity/rated capacity multiplied by 100% is equal to the capacity utilization rate, and when the capacity utilization rate is more than 100%, the planned capacity is excessive, or the planned capacity exceeds the rated capacity, so that the products cannot be produced in time; when the productivity utilization rate is less than 100%, the scheduling is insufficient and the system is idle. Specifically, the production quantity is order quantity-stock quantity, and the monthly planned yield is production quantity x (1+ rejection rate). For example, fig. 3 shows a monthly capacity evaluation table of a certain product, and it can be seen from fig. 3 that the capacity utilization rate of the polishing process exceeds 100%, that is, the planned capacity of the polishing process exceeds the rated capacity, and all scheduling tasks cannot be completed. For another example, if the capacity utilization rate of the modeling process exceeds 100%, the planned capacity needs to be reduced to the rated capacity because the fixed assets cannot be increased due to the limitation of the number of devices.
The above embodiment is only a description of a typical application of the technical solution of the present invention, and may be reasonably expanded without creative efforts.
Claims (10)
1. A method for evaluating a yield for a casting process, the method comprising:
setting a set of scheme for evaluating the rated capacity of the production process, and evaluating the rated capacity of each process by using the rated capacity scheme, wherein the scheme for evaluating the rated capacity of the production process comprises the following steps of,
selecting base data for evaluating the rated capacity,
calculating rated capacity according to a set evaluation rule;
setting a set of scheme for evaluating the planned capacity of the production process, and evaluating the planned capacity of each process according to the planned capacity scheme, wherein the scheme for evaluating the planned capacity of the production process comprises the following steps of,
the man-hours required for producing the single piece or semi-finished product are determined,
determining the equipment working hours needing equipment participation in the required working hours for producing the single product or the semi-finished product, and determining the planned capacity of the corresponding production process according to the equipment depending on the corresponding production process;
the capacity utilization rate is obtained by planning capacity/rated capacity multiplied by 100%.
2. The method for evaluating the scheduling of casting process according to claim 1, wherein the capacity utilization rate is used for evaluating the capacity of each process, and if the capacity utilization rate is greater than 100%, the planned capacity exceeds the rated capacity; and if the capacity utilization rate is less than 100%, indicating that the planned capacity is less than the rated capacity and has surplus.
3. The method for estimating the scheduling of casting process according to claim 1, wherein the basic data for estimating the rated capacity includes equipment used for a corresponding process, the number of the equipment, a planned starting rate of the equipment, a daily operating time, a daily production preparation time, and a monthly operating day.
4. The method for estimating the scheduling yield for the casting process according to claim 3, wherein the estimation rule in calculating the rated capacity according to the set estimation rule is that the rated capacity is core shooter design starting rate x daily operating time x 60 x number of core shooters x number of months operating days-daily production preparation time x number of core shooters x number of months operating days.
5. The method for evaluating the scheduling of the casting process according to claim 1, wherein the determination of the man-hours required for the production of the single piece or semi-finished product is in particular:
the required working hours of the single sand core are equal to the number of the moulds needed for core making multiplied by the required working hours of the single mould for core making;
the number of the moulds required for making the cores is equal to the required number of the sand cores/the number of the sand cores which can be made by a single mould;
the required quantity of the sand cores is equal to the quantity of the molding boxes multiplied by the quantity of the matched sand cores;
the number of the molding boxes is equal to the number of products to be produced/the number of the single box moldings.
6. The method for evaluating the production schedule for casting process according to claim 5, wherein the core-making required man-hours of a single product are the sum of the required man-hours of each of said single sand cores constituting the single product.
7. The method for evaluating the scheduling of the casting process according to claim 6, wherein the determination of the man-hours required for the production of the single product or semi-finished product is carried out by:
the planned productivity evaluation plan of the modeling process is to calculate the monthly planned productivity of the modeling process based on the number of single boxes and the number of single boxes, wherein the monthly planned productivity of the modeling process is the monthly planned productivity/the number of single boxes multiplied by the number of single boxes.
8. The method for evaluating the scheduling of the casting process according to claim 6, wherein the determination of the man-hours required for the production of the single product or semi-finished product is carried out by:
the planned capacity evaluation scheme of the smelting process is to calculate the monthly planned capacity of the smelting process by taking one smelting furnace as a production unit and taking the total weight of the molten metal required by pouring a single product as a basis, wherein the monthly planned capacity of the smelting process is the monthly planned output multiplied by the total weight of the molten metal required by the single product.
9. The method for evaluating the scheduling of the casting process according to claim 6, wherein the determination of the man-hours required for the production of the single product or semi-finished product is carried out by:
the planned productivity evaluation scheme of the polishing process is that a single product is taken as a production unit, the planned productivity of the polishing process is calculated according to the required working hours of polishing the single product, and the planned productivity of the polishing process is equal to the monthly planned yield multiplied by the required working hours of polishing the single product.
10. The method for evaluating the scheduling of the casting process according to claim 6, wherein the determination of the man-hours required for the production of the single product or semi-finished product is carried out by:
the planned capacity evaluation scheme of the processing procedure is that a single product is taken as a production unit, the planned capacity of the processing procedure is calculated according to the required working hours of processing the single product, and the planned capacity of the processing procedure is monthly planned yield/required working hours of processing the single product.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115809794A (en) * | 2023-02-02 | 2023-03-17 | 浪潮通用软件有限公司 | Production plan management method, equipment and medium based on bottleneck equipment capability evaluation |
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| CN110059842A (en) * | 2018-01-19 | 2019-07-26 | 武汉十傅科技有限公司 | A kind of foundry's production planning optimization method considering smelting furnace and sand mold size |
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