Lean Evaluation And Optimization Method For Green Production Process Of Aluminum Alloy Die Casting Workshop

With the continuous and rapid development of automobiles,home appliances,equipment manufacturing,communications infrastructure and other industries,the number of die casting products in China has increased year by year,and the die casting industry has entered a new normal of steady growth.At the same time,people are paying more and more attention to energy conservation and environmental protection,and some industries are showing the trend of replacing steel and iron with aluminum.Aluminum alloy die casting is an increasingly important category in the die casting industry.Its competitive environment is becoming increasingly fierce.The market’s production requirements for aluminum alloy castings are gradually developing towards high efficiency,high quality and low energy consumption.Under this background,many aluminum alloy die casting workshops have implemented lean production to improve the workshop management level and reduce energy waste,but without a systematic and objective lean evaluation system.Most workshops only implement lean production management methods and production methods on the surface,resulting in the existence of low lean management level,serious energy waste and other problems in the workshop.In this paper,based on the fuzzy BP neural network,a lean evaluation model for the green production process of aluminum alloy die casting workshops was established and an improved value stream mapping method to optimize the workshop production process from the perspective of energy management was proposed,lean evaluation and optimization prototype system for green production process of die casting workshop were designed and developed.Firstly,the green production process of the aluminum alloy die casting workshop was analyzed,and a lean evaluation system for the green production process of the aluminum alloy die casting workshop according to the departmental responsibility system and the principles of lean index selection was established.According to the theory of fuzzy BP neural network,a reasonable neural network structure was constructed,and through the training of sample data,a lean evaluation model for the green production process of aluminum alloy die casting workshop was established.By taking the green production process of an aluminum alloy die casting workshop as an example,the validity of the evaluation model was verified,and the relationship between product unit consumption and lean level was analyzed.Secondly,a lean optimization method for green production process of aluminum alloy die casting workshop was proposed based on modified stream mapping,which expands the Current State Map in the traditional value stream map to an energy value stream map.The method classifies production events based on lean thinking,emphasizes the optimization potential of non-value-added events,model energy consumption in the production process through energy block methods,and establishes Current State Map and Future State Map to realize the identification of energy waste in the production process,and optimizes product unit consumption and lean level through lean technology.By taking the green production process of an aluminum alloy die casting workshop as an example,the validity of the modified stream mapping was verified.Finally,on the basis of the above lean evaluation model based on fuzzy BP neural network and modified stream mapping method,a lean evaluation and optimization prototype system for the green production process of the aluminum alloy die casting workshop was designed and developed,the function modules of which include lean evaluation,lean optimization,production management,quality management,energy management,etc.