Research On Aircraft Assembly Line Layout Based On Lean 3P Activity

In aviation manufacturing industry, thecomplicated product structure, enormous BOM and complex assembly process result in long production cycle, difficult assembling resource coordination and large quantity of WIP. This brings great challenge for the aviation manufacturing enterprise facing rigorous market competition. A reasonable assembly line layout can save factory space, smooth the production flow, reduce logistics cost and improve production efficiency.With the urgent demand to increase capacity, traditional layout methods mainly based on experience easily lead to subsequent modification and rework. This study suggestsan aircraft assembly production line layout method based on lean 3P(Production Preparation Process) activity after complete analysis of previous studies.Firstly, this study analyzes the differences between traditional layout and lean layout line.A process for assembly line layout of airplane product is established based on 3P lean concept.Also, the one-piece flow method is suggested based on the analysis of assembly 7 flow and continuous flow.Secondly,the assembly line layout was created using the 3P Lean concepts and lean tools. The optimal layout was selected with AHP method. Also, there use the QUEST software to build up the logistics simulation model to evaluate and optimize the layout.Finally, using the Moonshine method, the assembly production line was simulated in 1:1 and made lean improvements.The one-piece flow production line constructed with those methods greatly improves the utilization rate of the tooling and meet the capacity requirements.