| The model of car is updated faster and faster, so is engine. There is at least one updated productin the life cycle of an engine series to maintain its competitive force. It’s common question of howto retool a production line to have the flexibility of multi-type production.In this paper, aluminium alloy cylinder block line made up of flexible machine centers isstudied on how to allocate new process of LDK/LAF block to available machine centers makingcycle time as balance as possible, when updated product LDK/LAF block and the old oneLE5/LTD block needs to be machined on one line without new machines. Aluminium alloycylinder block is widely used in engines now. The practice in balance and retool of varies kind ofaluminium alloy cylinder block is useful to automobile industry of China for rapid growth.At first we analyse the similarities and differences of cylinder block process between turbo、SIDI engine and naturally aspirated engine, then we collect data of cycle time in detail ofLE5/LTD block on site and convert it into PERT Chart. A preliminary retool solution can be madeby allocating new process with heuristic method according to constraint condition established byinformation of clamper in each machine center. Optimum load factor of mixed line and retoolsolution can be archieved along with batch size、cycle time and continuous improvement andbalance on process flow in test production verification and mass production, during which thequality issues of milling surface and aluminium chips are closed and cycle time increased, theadvantage of PCD tool cutting speed of aluminium alloy are used to decrease the cycle time ofhard metal tools and rebalance the cycle time of production line. |
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