Research On Human-Machine Reliability From Assembly Line Production To Japanese Seru Production Conversion

With the continuous advancement of society and the development of technology,in this environment,the manufacturing system of the enterprise has been put forward higher requirements.The production line model used by most companies in the past has gradually revealed a drawback:as the customer’s demand for products becomes more and more personalized,the market demand is changed from a large number of small varieties to a small batch and multiple varieties,which requires a high flexibility of the production line.However,rigid traditional assembly line production no longer meets the needs of contemporary manufacturing companies.Enterprises are looking for new manufacturing methods and models.Under the guidance of lean thinking,Japanese companies have proposed a production method of seru with both mass production economy and flexible production of one piece,gradually replacing the traditional production line and realizing the transformation of production mode.However,in today’s fierce market competition,companies often overlook an important factor in the pursuit of production efficiency and profit maximization-the reliability of production systems.The problem of re-evaluating the reliability of production systems is highlighted by the problem of people changing from single work to multi-functional work,and the removal and replacement of equipment.Moreover,in the in-depth study of the reliability of the production system,it is found that in the research on the reliability of the production line system,most of the importance of the reliability of the machine equipment,with the "respect for people" idea is more and more accepted by enterprises,human reliability has gradually been valued by scholars.Therefore,in the study of the reliability of production systems,human reliability and equipment reliability,that is,human-machine system reliability,should be considered.Therefore,in such a large background,the problem to be solved urgently is the research on the reliability of the production system(human-machine system)in the process of converting the production mode of production line to the production mode of seru unit.And because of the rise of the seru production model in the electronic component industry,this topic is based on the TX electronic information manufacturing company.By comparing the differences between the seru unit production and the traditional assembly line production,the characteristics of the seru production model are clarified.By constructing mathematical models and VBA programming,the assembly line of the company’s production X products is converted into the production mode of the seru unit;reliability analysis is performed from the human and machine equipment systems.Establish the fault mode of the human system,the fault factor index,the PSFs,and the reliability calculation method.Establish the failure mode,reliability index system,maintenance model,maintenance cycle and reliability calculation method of the machine system;determine the analysis and evaluation method of the production line and the reliability of the seru production system.Through the comparison of reliability,it provides a theoretical basis for enterprises to change production lines.The main innovations of this article:(1)As the production model of seru is gradually known to enterprises and scholars,many literatures have studied how to transform from the production mode to the seru production mode,but ignore the change in reliability during the conversion process.In this paper,the reliability of human-machine system in the conversion process of the production system of the seru unit is studied and calculated,and the change of reliability is analyzed to supplement the theoretical basis for the conversion.(2)In the analysis of human reliability,considering the process of conversion of production line to production mode of seru unit,the change of PSFs,such as the learning ability becomes stronger,the work pressure becomes larger,and the operator does not feel boring.Etc.These factors all affect human reliability,which will be quantified in this paper and will be considered when analyzing human reliability.Through the research results,it is found that:(1)The human factor(the PSFs)that affects the production mode of the assembly line is different from the seru production mode.In the traditional production mode,responsibility,stress and age are the main factors affecting the behavior of operators,and also an important factor affecting the reliability of human factors.In the seru unit production model,supervision,cooperation capabilities,age,work space and work environment are the main factors affecting operator behavior.Therefore,by adjusting these factors,human reliability can be improved.(2)After the production mode of the assembly line was changed to the production mode of the seru unit,the reliability of the entire production system was not reduced and slightly improved.Explain that the converted seru unit production mode system is reliable.