The Research On Self-organizing Production Line With Considering Staff's Learning-forgetting And Fatigue

Global competition has a huge impact on the market environment, it compels manufacturing enterprises to deliver products with competitive price and high quality continuously, to do this, they must have the characteristics of fast response, high efficiency and flexibility. To deal with the pressure from market and competitors, manufacturing enterprises throng to seek more flexibility and high efficiency production operation mode while they make the improvement of the product itself. Self-organizing production line is the only successful application for self-organization theory in the field of manufacturing, and have been widely used in America and Japan by taking advantage of its high efficiency, flexibility and low management cost.For three main factors which affect the production efficiency in human factor: Learning, forgotten and fatigue, taking self-organizing production line as the research object, build the corresponding discrete learning-forgetting curve and fatigue function based on the characteristics of the staff. We design simulation model for the initial self organizing production line, considering the factor of learning and forgotten, and considering the factor of fatigue respectively by using the simulation software called Tecnomatix Plant Simulation(?). We know that the changes of production efficiency and the dynamic characteristics of self-organization production line when considering different human factors by study of the statistical analysis of data obtained from simulation. We give an analysis from the following aspects:(1) On the basis of theory analysis on the traditional assembly line and the self-organization production line from the aspects of utilization rate of staff, utilization rate of work station and productivity respectively, we have made the numerical analysis by establishing simulation model of this two kinds of production mode for assembly line which the number of staff is less than work station. We also analyzed the pros and cons of this two kinds of production mode combined with the current order features with more varieties and little batch, and come to the conclusion that the self-organization production line conform to the requirements of the production for characteristics of more flexible, efficient, and humanize.(2) We study dynamic characteristics and production efficiency of self-organization production line when the staffs work efficiency is in a constant state of flux because of being affected by the factor of learning and forgetting and changing. Combined with the feature of staff on self-organizing production line, we build simulation model on self-organization production line considering the factors of learning and forgetting by Tecnomatix Plant Simulation(?) software. After the analysis of simulation results we get that self-organization production line has a strong robustness, namely it can also keep self-organizing when staffs work efficiency and production line production efficiency are improved under the influence of learning. While, although staffs work efficiency and production efficiency of production line are downward trend under the influence of forgetting, it still has self-organizition.(3) we studied the dynamic characteristic of self-organization production line when staff are affected by fatigue factors. We can get the maximum work hours of staff without fatigue according to the physical parameters and working load, staffs work efficiency is decreased with the increase of the work hours when staff is into the state of fatigue. By theoretical analysis and simulation we get that, if there are differences for staffs initial work efficiency, self-organization of production line is worse if ordering staff by work efficiency when staff is into the state of fatigue, while self-organization of production line is better if ordering staff by fatigue characteristic when staff is into the state of fatigue.