Research On Optimization Of Crankshaft Production Line Of D Company Based On Genetic Algorithm

With the continuous improvement of automobile demand,people put forward higher and more stringent requirements for the product quality and production capacity of automobile manufacturing enterprises.Therefore,the production,assembly,sales and other aspects of automobile parts are facing severe challenges.At the same time,China issued the "made in China 2025" strategic document in 2015,which further clarified that the development of China’s automobile manufacturing industry should adhere to the concept of quality first and green development.In order to comply with the trend of social development,managers gradually realize that they must apply advanced scientific management and optimization methods to the actual production of enterprises to improve their comprehensive competitiveness.Company D’s main business is to produce engine crankshafts for large commercial vehicles.Its crankshaft production line is a mixed model production line for three different types of products.At present,the company is facing the problem of non-standard production capacity.Therefore,it is necessary to study the optimization of crankshaft production line in D company.Based on the above research background,this paper takes the crankshaft production line of D company as the research object.Firstly,it introduces the crankshaft production process,operation time,workstation delimitation and personnel allocation;Then the Flexsim simulation software is used to establish the crankshaft production line model and simulate it.The production capacity of the workshop and the comprehensive utilization rate of all the machine tools are obtained.The balance rate of the production line is calculated.The three problems of the production capacity is not up to the standard,the equipment utilization rate is low,and the balance rate of the production line is low are analyzed;Then,the 5M1 E analysis method is used to analyze the problems existing in the production line in detail,and three main reasons are summarized: bottleneck process,unreasonable equipment layout and chaotic crankshaft production sequence;Then,we use program analysis method,action research method,ECRS analysis method and other basic industrial engineering methods and tools to optimize the above three aspects.In order to minimize the idle and load costs of mixed model crankshafts,the mathematical model of multi variety crankshafts production scheduling optimization problem is established.The genetic algorithm program is written with MATLAB software to solve the problem,and the optimal production scheduling scheme and idle and load costs are obtained;Finally,the Flexsim software is used to establish the optimized production line model and carry out simulation analysis to get the optimized capacity and equipment utilization index value.Then,the comparative induction method is used to evaluate the relevant indexes and comprehensive effect of the crankshaft production line of D company before and after optimization,and the prospect is put forward for the deficiencies of the paper.This paper combines industrial engineering theory,intelligent algorithm,simulation technology and other scientific optimization methods,and achieves remarkable results: the whole production cycle is reduced from 5923 seconds to 5460 seconds,and the production rhythm is optimized from 327 seconds to 280 seconds;The number of production processes was reduced from 26 to 23,a total of 3 processes were reduced,and the processing sequence of 2 processes was rearranged;The production line balance rate increased from 62% to 85%,and the average equipment utilization rate increased from 55% to 81%;JPH increased from 9.0 to 12.7 Sticks / hour,and daily production increased from 180 sticks before optimization to 254 sticks;The idle and load cost of crankshafts reduced from 401000 yuan to 183000 yuan,a decrease of218000 yuan,a decrease of 54.36%;The production environment is more clean and tidy,the work fatigue intensity of employees is reduced,and the job satisfaction is continuously improved,so that the comprehensive competitiveness of enterprises is greatly improved.This paper has 41 picture,23 tables and 77 references.