Research On Thin Sheet Production Line Optimization Of C Company Based On Lean Production

For a long time,small and medium-sized manufacturing enterprises have generally faced the problem of operating difficulties.Under the influence of COVID-19,the overall environment of manufacturing industry is in a slump,and the reduction of orders and the price rise of raw materials make the operation of small and medium-sized enterprises more difficult.Only by continuously improving the production process and improving the production efficiency,can the enterprise solve the production difficulties for a long time.This paper takes lean production as the guiding ideology and takes the sheet production line of C company as the object.On the basis of full on-site investigation,the operation time measurement is used to understand the balance state of the production line,and the production line is analyzed from five aspects: processing technology,process,inventory management,workshop environment and personnel training.Then,aiming at the problems of on-line WIP inventory backlog,lack of effective warehouse management,imbalance of production line and low automation level of production line,the optimization of buffer area configuration,warehouse management.The main research contents are as follows:(1)The simulated annealing algorithm is used to optimize the capacity configuration of the buffer,which is verified by constructing the Flexsim simulation model;By analyzing the operation data of the simulation model,the number of buffer areas is adjusted to simplify the process flow of the thin plate production line.After configuration optimization,the number of buffers is reduced to 4,and the online WIP inventory is reduced from 116 to 93.The optimization effect is obvious;(2)The cold rolled coil warehouse is replanned by grid method,the coordinate system of stack position is established,and the warehousing process and stack position management of steel coil are optimized by combining visual management.(3)Through the man-machine operation analysis of the bottleneck unit,the operation content and personnel allocation of the unit are readjusted according to the ECRs principle.Through the use of dual unit production,the average time of cold rolling operation is reduced from 3813 s to2423s,and the bottleneck problem is improved;(4)Through the introduction of palletizing robot and self-designed end effector,the automatic improvement of cross shear unit is realized.When the sheet with specification of1.2*1000*1100 is cut twice,1162.9s can be saved per roll;(5)The optimized production line simulation model and optimization scheme evaluation system are constructed,and the comprehensive effect of the optimization scheme is evaluated by using the correlation matrix method.Comparing the operation data of the production line simulation model before and after optimization,it is found that the average unit occupancy rate of the optimized production line increases from 69.65% to 85.66%,and the inventory in the buffer area decreases from 116 to 72;Through the comprehensive evaluation of the production line before and after optimization by the incidence matrix method,it is found that the comprehensive score of the optimized production line is 1.7 times higher than that before optimization.The above results strongly prove the feasibility and superiority of the optimization scheme and technical improvement measures proposed in this paper.