Study On Automobile Exhaust System Assembly Line Balance

Due to poor project manufacture planning,serious waste is found in Faurecia’s production line.Through study of assembly line balance and optimizing line design,the waste and manufacturing cost can be greatly reduced.Input of the study includes product manufacturing process and time parameters related to the first type of line balance questions.The way to analyze the product manufacturing process is to define related process according to the product design at the first step,then generate the process flow chart,and then build the initial frame of the assembly line.The time parameters include target cycle time,auto run time of machines,and manual operation time.The main content of the study includes following steps,firstly distribute the welding work elements with heuristic algorithm,however,the result is not so satisfying;secondly search the optimized solution with genetic algorithm,using combined roulette method and best Chromosome retained method;at last,build assembly line using in software of flexsim.Output of the study is a newly designed assembly line.With flexsim simulation,assembly line can be continuously improved according to the trail run report,lien layout can be optimized comparing with Faurecia’s 16 lean principles,and operators can be distributed according to the principle workers serve equipment.After comparison,the newly designed assembly line has saved about three million yuan of equipment and tool investment,36 square meters of site area,and one operator.