| In this paper, a optimize program is made to increase the balance rate of a engine cylinder head assembly line, in order to improve the productivity and reduce the cost.The production line of engine will be analyzed, then the process of the cylinder head sub-assembly line is counted about 39 percent of the total assembly line, which is the main assembly line of the whole line, and each process in it is a little representative. After analyzing the situation of the cylinder head sub-assembly line, the layout and the histogram for each process can be obtained, which can display the low balance rate of the cylinder head sub-assembly line. On the base of this analysis, the balance problem of cylinder head sub-assembly line can be found from the process, equipment and the workers, and then a method can be got to solve this problem.First, a genetic algorithm is used and some priority restrictions will be added into this general frame of genetic algorithm in order to rearrange and reorganize the process of the assembly line. Then the methods of industrial engineering is used based on the genetic algorithm optimized result from macro to micro, and go to a deep research from the general to the specific process. The specific content is following. The key points can be found by using program analysis. Man-machine operation diagram can be made, and study the emergence of idle time by using the job analysis, and rearrange operation order, then eliminate the waiting time. Then go to the operation analysis, disintegrate the operation into subtle action, then combine two-handed operation to one-handed operation. At last, the optimized process proposal is modeled and simulated by the simulation software, and use the simulation result to evaluate the reliability and the effectiveness of the process proposal. This process proposal can get a improvement about 14.3% of the balance rate of the cylinder head sub-assembly line, furthermore, the cost of it can be reduced 600 yuan per 10 hours. |
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