Research On Production Logistics Simulation And Optimization Of ZY Company A Workshop Oriented Green Manufacturing

The manufacturing industry is the pillar of the national economy,and it is also a major source of energy consumption and pollution emissions.Under the general trend of manufacturing transformation and upgrading and green manufacturing,significant research results have been achieved at the technical level and even at the management level.However,the production logistics management and optimization is still focusing on traditional economic indicators represented by production capacity,equipment utilization,quantity of WIP and transportation distance and ignoring the key factor of green manufacturing.This thesis proposes to comprehensively optimize the production logistics system by taking the green manufacturing as one of the optimization target.The aim is to ensure and even improve the traditional indicators of the production system economy,reduce production energy consumption,and provide more detailed and intuitive suggestions for enterprises to implement green manufacturing.The workshop A of company ZY is a production workshop with the Metallic process and heat treatment of excavator parts.The complicated process,chaotic material transportation route and large difference among equipment utilization ratio are features of the production system,the amount of energy consumed in the production process is large,and the energy consumption of the heat treatment equipment in the idle process accounts for a large proportion of the total production energy consumption,which has become a major factor that can hinder the company’s implementation of green manufacturing.Therefore,aiming at reducing production energy consumption while improving the traditional economic indicators and finding the best alternative as a reference for the future improvement of the workshop,the energy consumption index is took into consideration in the research of production logistics simulation optimization.The specific research contents are as follows:1.Summarizes the relevant theoretical results of green manufacturing and production logistics,introduces two representative modeling methods in the IDEF modeling method family,and the functions and features of Flexsim simulation software.2.Analyzes the current status of production logistics of ZY Company A workshop,including the current situation of facility layout,production capacity and energy consumption,introduces method of calculating energy consumption during every phase,and simply explained how will the green manufacturing may influence production logistics.3.Using the IDEF modeling method to establish the functional model and process model of production logistics of workshop A,based on the two models,use simulation software Flexsim to build and run the simulation model of the production system,in according to the simulation reports,calculating and analyzing the balance rate between the devices,the number of products in the temporary storage area,the energy consumption of processing equipment,and the utilization and energy consumption of forklifts and then identifies key issues.4.Initially optimize the original production system by increasing the amount of resources and simply adjusting the equipment layout,and then take the two variables of material transportation batch size between equipment and downtime of heat treatment equipment into consideration,optimizing and select the best alternative from the two perspectives of traditional production logistics optimization and production logistics optimization oriented green manufacturing,and compares and analyzes the two options from several important indexes.This research method is applicable to the production system of general discrete manufacturing enterprises,and can be used as an effective reference for implementing green manufacturing in discrete production systems.This study eventually developed an optimization strategy by 21 batches of inter-process transportation and 3 hours of downtime for heat treatment equipment.The comparison of simulation results verified that the optimization scheme can not only effectively improve system output,ensure balance ratio between equipment but also can save a lot of energy consumption and promote green manufacturing.