The Analysis And Implementation Of Flexible Transformation Of Automatic Transmission Production Line

The world's first pre-drive automatic transmission in China is quite mature in terms of assembly technology,production line layout,workstation layout,staffing,tooling and abrasives,etc.However,with the input of more and more new products and the structural differences of products due to the difference of the whole vehicle factory,the original automatic transmission production line can neither meet the market demand nor realize multi-variety co-production.Flexible upgrading and transformation has gradually become the primary task of automatic transmission company.This paper takes the production line of one Automatic Transmission Company as the research object.Firstly,taking the flexible transformation of automatic transmission production line as the research direction,using the theory of production line balance,production capacity,rapid switching tooling,rapid switching system and ECRS and other related theories and methods,the status quo of the original automatic transmission production line is preliminarily obtained.Through the detailed analysis of the requirements of automatic transmission and the flexible target of production line,it is concluded that the current production line can not meet the requirements of automatic transmission.Based on production line balance theory,production capacity theory,rapid switching tooling,rapid switching system and ECRS theory,combined with production capacity and balance,process and production rhythm,tooling replacement,system switching and other aspects of analysis and research,the production line transformation program is obtained.Secondly,this paper analyzes the effect of the automatic transmission production line before and after the transformation from the aspects of production capacity balance,automatic transmission production line personnel configuration optimization,tooling replacement,system switching and so on.The production capacity of the automatic transmission line has been increased from about 100,000 to 204,000 sets before the transformation.The production rhythm has been reduced from 162 s before the transformation to 90 s after the transformation.The production capacity has been doubled and the rhythm has been reduced by 44.44%.The production line balance rate increased to about 80%from about 40%before upgrading,nearly doubled.The allocation of operator was reduced from 99 to 80 after transformation,which was reduced by nearly 20 and 20%.Tool replacement time was reduced from 3.5 hours before transformation to 0.1 hours after transformation,system switching time was reduced from 0.3 hours before transformation to 115 seconds after transformation,and the equipment after transformation can automatically realize tool and system switching,saving a lot of manpower and material resources.Finally,using the payback period method and NPV method,the paper evaluates and analyzes the flexible transformation scheme of automatic transmission production line from static and dynamic aspects.The results show that the flexible transformation scheme of automatic transmission production line is feasible with the investment payback period of 0.436 years<the base investment payback period of 9 years and the NPV>0.