Research On Balance Optimization Of Post-Press Flexible Production Line Based On Production System Simulation

With the increase in market demand for small-scale production,there is a growing need for flexibility in post-press production.More complex production systems composed of workers and equipment are required to meet production needs.The uneven production capacity and bottlenecks caused by this production mode are urgent issues to be addressed in the development process of intelligent printing factories.On the one hand,without accurate production labor hours,production decisions cannot fully leverage the effective value of data.Secondly,there is no ability to identify production bottlenecks through multidimensional data analysis,and the effectiveness of production system optimization solutions cannot be validated.Finally,the production line planning method relies too heavily on manual experience,resulting in inconsistencies between the planned and actual production,leading to a decline in production continuity and low line balancing rate.The following is a proposed method for optimizing post-press flexible production lines based on digital factory modeling and simulation technology,which is validated using a production example from L company.The main research contents are as follows:(1)Combined with the requirements of intelligent factory,this paper analyzes the problems of post-press flexible production lines and proposes to optimize the production process through digital factory modeling and simulation technology.To address the issue of studying production line problems under fixed working hours which do not reflect actual production scenarios,a work-hour random processing method based on discrete empirical distributions is proposed.Taking actual production as a case,the man-hour data was evaluated and cleaned to provide a data basis for bottleneck identification and optimization research of production line.(2)In this paper,the bottleneck analysis method of the post-press flexible production line was studied,the concepts of blocking time and waiting time were introduced to define the bottleneck process,and the model of the post-press flexible production line was established based on Plant Simulation.The multi-dimensional operation data of each station was obtained by simulation,and the bottleneck process of the production line was accurately identified through data analysis.(3)In this paper,the optimization of the production system is studied,and the optimization scheme is formulated from the perspective of optimal capacity allocation,and the simulation experiment is designed to verify the effectiveness of the scheme.Taking the production line of Company L as an example,the research results provided specific production line improvement plans for the company,which increased the production capacity per shift by 21.5%and the balance rate of the production line by 20.9%.(4)In this paper,a dynamic production line planning method based on simulation verification is proposed to solve the problem of post-press flexible production line planning.Based on DDE(Dynamic Data Exchange),A visualization data interaction system for post-press flexible production line was developed to realize the data interaction function between the external data table and the simulation system.In this paper,the digital factory modeling and simulation technology is applied to solve the actual production problems,solve the bottleneck analysis and optimization of production line in the development process of intelligent printing factory,and provide systematic technical solutions for digital management and optimization of post-press flexible production line.