Sequence Reconstruction And Simulation And Optimization Of A Vehicle’s Painting Line

With the increasing competition occurred in the global automotive market，thedemands of automotive consumer are presenting individualized features. Productionpattern of automobile enterprise is changing from large-scale production to smallbatches and multi-species production. In the process of enterprise transformation,improving the production line and optimizing resource assignment are playing moreand more important roles.First，according to the actual production condition of a car body plant in Hubeiprovince, we try to find the main reasons of paint guns replaced and flushed so manytimes, aim at reducing the number of painting gun replaced, production cost andburden on the environment, and improving production efficiency. Based on thesplitting critical points and merging critical points in painting line buffer regions, weestablish a splitting point mathematical model and a merging point mathematicalmodel as to reduce the times of painting gun replaced and flushed. Then we solve theoptimization models by GAMS/Cplex software under the actual production vehiclesequence data, and test the optimization results of mathematical models.Then, according to the status of painting shop, two kinds of vehicle sequencesimulation models of painting line based on actual production and heuristic rules areestablished respectively. After running the simulation models several times, thesimulation results are obtained and compared.At last, the results of restructuring model optimization method and the simulationoptimization method based on heuristic rules and the actual production data arecompared, to verify the effectiveness and superiority of the established restructuringmathematical model. Under the guidance of this model, a suitable and cost-effectivepainting sequence reconstruction method for real application is explored.