| With the new generation of information technology and manufacturing depth integration,manufacturing is leading to far-reaching changing and forming the new production form.Represented by the German industry 4.0,the American Advanced Manufacturing Strategic Plan,and the China manufacturing 2025,many countries are actively planning the new advantages of manufacturing.Intelligent manufacturing,such as smart devices,smart factories,and other smart products based on the cyber-physical system(CPS),are leading the way in manufacturing.With the development of the society,the requirements of furniture have been increasing,and requirements for furniture styles have become more and more high.With this background furniture manufacturing becomes more flexible to meet the customers need,which need unification of mess production and customization.The intelligent manufacturing of furniture is a new mode,combined with the manufacturing characteristics of the Chinese customize wardrobe industry,to plan and design a line with a daily production of 6000 sets wardrobes.Focusing on the goal of the customized wardrobe factory with advanced manufacturing mode,high efficiency and good economic efficiency,the overall layout of the customize wardrobe factory was designed from the aspects of layout,functional division,logistics,production mode and national laws and regulations.Based on the materials,combination,positional relationship,hardware and connection methods,the structural characteristics,production process and processing technology of each component are studied.On this basis,the software and machines planning,equipment selection and information system management system of the customized wardrobe production line are realized.The main results and findings are as follows:(1)To realize a customized wardrobe factory with advanced manufacturing mode,it should be according to five principles,high efficiency and good economic efficiency,the factory planning should follow the separation principle of production area and living area,meet the principle of related functions,the convenience of different workshop logistics,and coordinate the main and auxiliary workshops,and overall aesthetic principles.Five principles,including principles and overall aesthetic principles.(2)The daily 6000 sets wardrobe factory project covers an area of 400 mu,of which 350mu is used for production and 50 mu is used for office and living area.The production area mainly includes 38127m~2,sliding door,decorative plates,finishing laminate workshop,narrow parts and special-shaped workshop A 11800m~2,narrow parts and special-shaped workshop B7919.5m~2,wardrobe workshop A 23400m~2,workshop B 17200m~2,wardrobe workshop C17200m~2,vertical warehouse 7020m~2 and press line workshop 12600m~2.(3)The main materials of the customized wardrobe are MDF and particleboard.The main processes of the production process are cabinet body,cabinet door and plastic.The main production process is panel saw cutting,automatic edge banding and drilling.According to the production organization process,the line is divided into batch flexible automated production lines and special-shaped production lines.The production process of the cabinet body including cutting,boring/grooving,edge banding,drilling,inspection,sorting and packaging.The door production process is aluminum profile material/louver specification material/MDF specification material/glass,combination assembly and packaging.The blister production process is the front panel of drawer cutting,milling,sanding,door paneling,door panel assembly,door panel sanding,machined door reaming,glue injection,inspection,blistering,inspection and packaging.(4)Considering of the capacity matching,the principle of process conformity,advanced equipment selection,equipment investment cost performance,the service and maintenance,the daily 6000 sets production line includes a third-generation line,which capacity is daily 3000 sets and locate at the plant C,and a fourth-generation line of capacity is 3000 sets which locate at plant F and plant G.(5)The flexible production line consists of the following main equipment,the vertical warehouse has 1000 shelves,which crane capacity is 500 stacks.The design capacity of cutting saw is 47.5 pieces/minute.The panel saw,model type is HPL300,efficiency is 3.67pieces/minute,and the equipment requirements 13 sets.The design capacity of edge banding is47.5 pieces/minute.The edge banding machine,model type is IMA Novimat,efficiency is 20pieces/minute,and the equipment requirements 3 sets.The design capacity of drilling section is41.59 pieces/minute for single side parts and 9.60 pieces/minute for double sides parts.The single side drilling machines,model type is WEEKE ABL220,efficiency is 4.7 pieces/minute,and the equipment requirements 9 sets.The double sides drilling machines,model type is WEEKE ABH100,efficiency is 2.4 pieces/minute,and the equipment requirements 4 sets.(6)Intelligent production line is divided into two workshops,which consists of the following main equipment,the vertical warehouse has 1000 shelves,which crane capacity is 500stacks.The design capacity of cutting saw is 56 pieces/minute.The panel saw,model type is HPS320,efficiency is 3.5 pieces/minute,and the equipment requirements 16 sets.The design capacity of edge banding is 56 pieces/minute.The edge banding machine,model type is IMA Novimat,efficiency is 14 pieces/minute,and the equipment requirements 4 sets.The design capacity of drilling section is 37.6 pieces/minute for single side parts and 19.2 pieces/minute for double sides parts.The single side drilling machines,model type is WEEKE ABL220,efficiency is 4.7 pieces/minute,and the equipment requirements 8 sets.The double sides drilling machines,model type is WEEKE ABH100,efficiency is 2.4 pieces/minute,and the equipment requirements 8 sets.Each vertical buffer has 280 storage capacity and requires 4 units;Baumer surface quality inspection equipment requires 4 units.The system sorting processing efficiency is 56 pieces/min,the robot processing efficiency is 5 pieces/min,and 12 robots need to be configured.(7)Manufacturing Execution System MES interfaces with the ERP and WMS,including scheduling management,work calendar,process management,production equipment management,system management and report analysis.The MES system consists of a data layer,a line control layer,an acquisition layer,an operation monitoring layer,and an infrastructure management layer. |
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