Material Distribution Optimization Of Engine Mixed Model Assembly Line

With the diversified customer demand and increasing market competition,traditionally single and large-scale production modes have been gradually replaced by multi-variety and small-batch mixed-model production modes,which significantly increase the complexity of material distribution in the workshop.Material distribution management acts as a bridge and bond to maintain each link of production.On the basis of the punctuality and accuracy,how to improve the efficiency of material distribution and reduce the logistics cost has become an urgent problem to be solved.Taking an engine enterprise as the background,some key issues such as production logistics system simulation,distribution method design,distribution path planning,and distribution system development were investigated to optimize the material distribution of mixed-model assembly line in this study.Based on the actual layout of engine assembly workshop and material distribution process,a simulation model of cylinder head assembly line production logistics system was established based on FlexSim software.The entity parameters of the model were set by collecting field data such as production beat and distribution cycle,and the simulation results showed an unreasonable operation condition of forklift.Thus,an optimization scheme was put forward from two aspects of adjusting distribution path and changing channel layout.The average no-load walking time and transportation distance were reduced by 16.73%and 15.8km,respectively,which improve the current situation of logistics.In order to improve the pertinence of the material distribution management of the mixed-model assembly line,three evaluation indexes involving material value,package volume,and universality were selected.K-means algorithm was adopted to improve the traditional ABC classification method,and the material classification matrix was obtained by combining the coefficient of demand variation.Through the analysis of the whole distribution process,a total distribution cost model was established to solve the optimal distribution quantity interval of materials.Based on the real-time production and material consumption,a material distribution method was designed containing dynamic distribution time and quantity.Compared with the traditional method,the average inventory capacity of key materials and the cost of holding inventory were reduced by 23.91%and 23.96%through simulation,respectively.Taking the distribution cycle as a unit and considering the constraints such as fuzzy time window and load capacity,a path planning model was established to minimize the total distribution distance and the minimum number of delivery vehicles based on the dynamic distribution tasks with material demand time and quantity.An improved genetic algorithm was designed to solve the optimal distribution path for each cycle,and the effectiveness of the model and algorithm was verified by an instance.According to the actual logistics situation of an engine mixed-model assembly workshop,the material distribution system was designed and developed to realize the dynamic and information distribution process.The system mainly includes system management,basic information management,real-time data acquisition,material distribution management,distribution report management,visual management,and other functional modules,which can effectively solve the problem that the material distribution is non-timely and inaccurate in response to the line production,and improve the accuracy of material distribution.