First, the assembly line balance introduced The balance of the assembly line has always been a long-term concern in the production organization and has played a key role in the normal operation of the company's production order. The imbalance of the assembly line not only directly affects the production efficiency of the assembly line but also affects the quality of the product. This is due to the inconsistent labor intensity of the assembly workers caused by the imbalance of the production line, and the labor intensity of the operator often has to be in order to catch up with the operating cycle of the assembly line. Neglecting the quality of assembly, according to statistics from the United States, an average of 5% 10% of assembly time in assembly production in an industrially developed country like the United States is wasted in the balance of delay. Therefore, the balance of the assembly line is an important issue in the organization of the production process. Second, assembly line balance parameters Beat refers to the time between successive completions of the same two products (or two services, or two batches of products). The tempo of the assembly line is mainly determined by the work assigned to it by each work site until the work can be carried out down to the maximum time allowed, and the tempo determines the output of a production line within a certain period of time. The longest working time of the current assembly line is 36S, so Shanghai Yanfeng Johnson Controls Seating Yancheng Branch set its assembly line beat to 36S. After the improvement, the maximum working time is only 30S. We will change the assembly line beat to 30S. After that, we can perform a balanced analysis of the assembly line: A. Daily output = OT/CT type, OT is the daily operating time, CT is the beat; B. Idle rate = idle time per beat / (number of process steps) 100% C. Production line balance rate. W = Ti S i /(T 0 S i) 100% W is the line balance rate, T i is the ith station standard time, S i is the number of ith stations, T o is the line beat. Three, JBC seat assembly line status analysis and improvement measures Currently, manual and semi-automated assembly lines account for the majority of manufacturing industries in China. These assembly lines have problems with unscientific and unreasonable designs to varying degrees. Therefore, in order to improve the competitiveness of enterprises, it is a matter of balancing the assembly line. Important and arduous task. The analysis of process procedures is the basis for assembly flow balance. A. Comparison of time. Shanghai Yanfeng Johnson Controls Seating Co., Ltd. analyzes the process procedures of the first 39 processes (omitted). Shanghai Yanfeng Johnson Controls Seating Co., Ltd. analysis of process procedures after 29 major assembly time (slightly). Prior to the quantitative analysis before and after the improvement, the analysis and comparison of workers' wide relaxation time is conducted to determine whether the improvement plan is feasible. The calculation is as follows: a. The multiplication method, that is, how much wide time is given in the unit net time. Wide spread rate = wide release time / net working time 100% b. Ratio of internal multiplication, wide release time to total working time, ie how much to give in a complete working time (including work and wide time) The wide release rate. Wide Releasing Rate = Wide Releasing Time/(Net Working Time + Wide Releasing Time) Current Plan: Daily Business Hours: 480 minutes, Leadership Instructions: 10 minutes, Going to the Bathroom: 10 minutes, Chat: 25 minutes, Thinking about how to process: 10 Minutes, breaks: 40 minutes. Net working time is: 480-( 10+ 10+ 25+ 10+ 40) = 385 minutes and wide time is 10+ 10+ 40= 60 minutes Chat and think how to process is a delay and cannot be counted in wide time Inside. External multiplication wide open rate = wide release time / net working time = 60/385 = 15. 58% multiplication wide open rate = wide release time / (net working time + wide time) = 60 / (60 + 385) = 13. 48% improvement plan: Daily working hours: 480 minutes, leadership instructions: 5 minutes, going to the bathroom: 8 minutes, chatting: 10 minutes, thinking about how to process: 5 minutes, middle rest time: 40 minutes net working time: 480-( 5+ 8+ 10+ 5+ 40) = 412 minutes and wide-release time is 5+ 8+ 40= 53-minute multiplication wide open-rate = wide release time/net working time = 53/412 = 12. 86 % multiplication wide open rate within % = wide release time / (net working time + wide time) = 53/(53 + 412) = 11. After 40% improvement, the outer multiplication wide release rate is 12.86%, inner multiplication wide The rate of release of 11.40% does not cause workers to become fatigued. Because of this, the plan is feasible. B. Calculate the time parameters and compare a. Daily output = OT/CT type, OT is daily operation time, CT is beat; current plan: daily output = 8 3600/36 = 800 improvement plan: daily output = 8 3600/ 30 = 960 b. Idle rate = Idle time per beat / (number of process cycles) 100% Current solution: Idle rate = (2+ 3+ + 2+ 2) / ( 39 39) = 81/1521 100% = 5. 3% improvement plan: idle rate = (2+ 3+ + 2+ 1) / (29 30) = 43/870 100% = 4. 9% c. Line balance. W = TiSi / (T0S i) 100% current solution: W = (12 1+ 15 1+ + 17 1+ 12 1) / (39 42) 100% = 604 / 1638 100% = 36. 9% improvement scheme: W = (12 1+ 15 1+ + 28 1+ 12 1) / (30 34) 100% = 567 /1020 100% = 55. 6% Summary Analysis The above data can be obtained from the following table: Total number of workers / s daily output / station idling rate of production before the analysis of the balance of the program 45 823 800 5. 3% 36. 9% of the post-analysis program 37 700 960 4. 9% 55. 6% comparison by the above table, we It can be clearly seen that prior to the analysis of the process flow, the current assembly line production rate was 36.9%, and the idle rate was relatively high, which confirmed that the balance of the flow was indeed problematic. This production line under the assembly line, the equipment of the assembly line, and the use of space are not sufficient, which seriously restricts the output of the assembly line. However, after analyzing through the process procedures, the balance rate has increased significantly to more than 55.6%, and the idle rate has also decreased by nearly 0.4%. Obviously, there are the following advantages: a. Decrease the cycle time of the production line and increase the Assembly line production capacity. The start of the assembly line beats 36S, and the analysis of the assembly line after the beat dropped to 30S. This led to a significant increase in daily production capacity, the theoretical value rose to more than 160 seats per day, production capacity increased by 20%. B. Reduced direct investment. After the analysis, the direct reduction of 8 staff members will not only not affect the assembly line operation, but will also expand the assembly line space and ensure the continuity of the assembly line. At the same time, the reduction in personnel, in terms of investment in the shop, directly reduced the salaries of eight employees. c. Through the transformation, the production line will be smoother, the process will be more reasonable, the line balance rate will be greatly improved, and the idle rate will be reduced. This will reduce the impact of bottlenecks on the assembly line and increase the utilization of equipment and space. Through the above analysis, we can find that it is indispensable to perform process program analysis in the assembly line balancing process. It is the premise of other analysis. After the analysis of the process procedures, a more comprehensive analysis of the problems existing in the assembly line was conducted. At the same time, using the 5W 1H questioning technology and the four principles of ECRS, combined with the principles of the economics of operation and the balance of the production line, the bottleneck station of the assembly line was again performed. The improvement will reduce the spare time to a minimum, re-arrange the production line after planning analysis, and greatly increase the production capacity of the assembly line. Power Plant Grinding Media,Rolling Forged Grinding Media,Grinding Media For Gold Mining,Grinding Media For Cement SHANDONG SHENGYE GRINDING BALL CO., LTD , https://www.sygrindingball.com