Research On Optimization Of Gearbox Assembly Line Balance In Company A

The production line occupies a place in the development of enterprise competitiveness.For a modern manufacturing system,the balance of production line is directly related to output.Therefore,how to improve the balance of the production line has become an urgent problem in the current production line management.With the rise of environmental protection industry,the order quantity of gearbox of A company continues to rise substantially,which is difficult to meet the increasing order quantity due to its current production situation.Therefore,this paper takes the gearbox assembly line of A company(hereinafter referred to as the assembly line)as the research object,through the use of industrial engineering methods and genetic algorithm to optimize the balance of the assembly line,so that the work time of each workstation of the assembly line is evenly distributed,so as to improve the balance rate of the assembly line and improve the production capacity.Based on the actual production situation on site,this paper makes clear the problems existing in the gearbox assembly line,including the poor balance of the assembly line,the large inventory of work in progress,and the inability to respond to customer demand in time.Through the analysis of human procedure and combining with the four principles of ECRS,the preliminary improvement can effectively eliminate the waste in the assembly process,initially improve the balance rate of the assembly line and increase the production capacity to a certain extent.Considering the limitations of traditional industrial engineering optimization methods,then,according to the characteristics of the actual problems of the assembly line,the mathematical balance model is established.Based on MATLAB design genetic algorithm,the model is simulated and optimized,and four optimization schemes are obtained.Through the analysis and comparison of the improvement effect of these four optimization schemes,the optimal scheme is obtained,and the scheme is carried out according to the actual situation Fine tuning.The final plan further improves the assembly line balance rate and production capacity,reduces the waste phenomenon in the assembly process,achieves the goal of meeting customer demand,and improves enterprise efficiency.After improving the gearbox assembly line of A company,the balance rate,smoothness index,production beat and production capacity of the assembly line have been effectively improved.Before the improvement,the balance rate of the assembly line was62.79%,after the improvement,the balance rate was 92.21%,and the increase range of the balance rate was 29.42%.The smoothness index of the improved assembly line is 43.02,and the smoothness index of the improved assembly line is 6.08,with a decrease of 85.87%.The production beat of the assembly line before the improvement is 6087 seconds,and after the improvement is 3420 seconds.The production beat is reduced by 2667 seconds,with a decrease of 43.84%.The production capacity of the assembly line also increased from2763.9 units before improvement to 3660.3 units,and the production capacity increased by1593.6 units,up 77.11%.Fully meet the demand of customer orders.The research results of this paper can be used for reference and guidance in solving the production line balance problem of similar manufacturing enterprises.