Research On Optimization Of W Model Flange Production Line In Company Z

With a thriving national economy,the government has been investing more in high-end equipment manufacturing and key basic components,leading China’s forging industry develops rapidly and market demands becomes more and more diverse.Company Z,a professional manufacturer of forged flanges,faces the situation of an insufficiency of production capacity and a shortage of supply due to poor balance of production lines,uneven loading of work stations and insufficient on-site management.To increase production capacity,this thesis conducts in-depth analysis and evaluation of the production line to improve its balance condition and increase the production efficiency of the enterprises with the W model flange production line in Company Z as the research object.Firstly,this thesis elaborates the theories related to lean production and production line balancing,and then makes a sort summary of the current research of production line balancing optimization and lean production at home and abroad.Secondly,this thesis introduces the current situation of W model flange production line.The standard working time of each station is obtained by program analysis and operation measurement.After analyzing and calculating the data,it can be found that the balance rate of the production line is 70.81% and the smoothing index is 21.83.Besides,Modeling analysis is performed with Flexsim simulation software to derive the current load condition of each workstation and identify the overloaded workstations of the line.Combined with the results from the field research,the current problems in the production site of W model flange are analyzed and described.Thirdly,the production line is optimized integrally with the industrial engineering methods such as process analysis,5W1 H questioning techniques and ECRS principles.Based on the results of IE optimization,a 0-1 integer planning model is established and the optimal solution is obtained with Lingo software.Then the equipment layout and management system of the production site will be adjusted and improved.Finally Flexsim simulations are carried out again to verify the effectiveness of the optimized production line and to compare and evaluate the situation before and after improving the site management.According to the overall optimization results,the production capacity of the W model flange production line is increased by 16.81%,the balance rate of the production line is eventually increased to 89.19%,the smoothing index is reduced to7.37,the number of work stations is reduced from 25 to 22.Thus the work load of each station is more balanced,the layout of the production site is more reasonable and the production management system is perfect,having comprehensively improved its production efficiency and market competitiveness.