摘 要

随着时代的发展，自行车的产量逐渐增大，自行车的用途也越来越多样化。在自行车装配线的设计中，需要涉及到装配工艺、作业研究、工位划分、生产线平衡率和车间布局等问题。其中，生产线平衡率和切合实际且有效的工位划分是设计的关键。

本文在明确了自行车的零件需求后，结合生产实际，确定了自行车的装配顺序并用秒表测试法进行工作研究，确定标准作业流程与标准工时，同时对设备需求进行说明。根据年产200000辆自行车的要求计算生产节拍进而确定使用两班制。并依此进行工位的划分与平衡率的计算。然后结合实际情况对以上结果运用工业工程的方法进行分析和优化。通过优化前后方案的比较得到最终计算结果后，开始进行装配车间的设计，首先划分各个功能模块，然后根据实际情况运用SLP方法对装配车间进行布局并最终画出CAD图纸。

本设计根据生产实际的要求，通过对装配线的设计与优化，确定了相对合理的工位划分，生产线平衡率由90.2%提升至94.4%。通过SLP方法进行物流、非物流关系分析等，得到了相对合理的车间布局方案。在生产线稳定合理的前提下，为年产200000辆自行车的计划给出了一个相对高效的可行方案。

关键词:生产线平衡率、SLP方法、车间布局

Abstract

With the development of The Times, the output of bicycles is increasing and the use of bicycles is becoming more and more diversified. In the design of the bicycle assembly line, the assembly process, the work study, the station division, the balance rate of the production line and the layout of the workshop are involved. Among them, the balance rate of production line and practical and effective station division are the key points of design.  

In this paper, after the requirements of the bicycle parts are defined, combined with the actual production, the assembly order of the bicycle is determined and the stopwatch test method is used to conduct the work research, the standard operation process and standard working hours are determined, and the equipment requirements are explained. According to the requirement of 200,000 bicycles per year, the production beat is calculated and the two-shift system is determined. And carry on the division of the station and the calculation of the balance rate according to this. Then combined with the actual situation, the above results are analyzed and optimized by industrial engineering method. After the final calculation results are obtained through the comparison of schemes before and after optimization, the assembly shop is designed. First, each functional module is divided. Then, SLP method is used to layout the assembly shop according to the actual situation and finally CAD drawings are drawn.

This design according to the actual production requirements, through the design and optimization of the assembly line, to determine a relatively reasonable division of the station, the balance rate of the production line from 90.2% to 94.4%. Through the SLP method to carry on the logistics non-logistics relationship analysis and so on, obtains the relatively reasonable workshop layout scheme. On the premise of the stable and reasonable production line, a relatively efficient feasible scheme is proposed for the annual production of 200,000 bicycles.

Key words: FMEA, line balance ratio, SLP method, workshop layout

目录

第1章. 绪论 1

1.1 研究背景及意义 1

1.2 国内外发展现状 1

1.3 本文主要完成的任务 2

第2章. 零部件需求和装配工艺流程的确定 3

2.1 自行车零部件需求 3

2.2 自行车装配工艺流程的确定 4

2.2.1 装配工序的确定 4

2.2.2 装配工艺流程图 5

第3章. 工序分析与作业研究 6

3.1 作业研究 6

3.1.1 各工序的标准作业 6

3.1.2 制定标准工时 8

3.2 设备需求说明 12

第4章. 工位的划分与平衡率的计算 15

4.1 节拍的计算 15

4.2 基于韩格逊-伯尼法的流水线生产平衡计算 15

4.2.1 列出所有任务 15

4.2.2 画出先后顺序图 16

4.2.3 装配次序矩阵表和进行位置权重计算 16

4.2.4 工位的划分 16

4.2.5 生产线平衡率的计算 17

第5章. 装配线的优化 18

5.1 计算结果可行性分析 18

5.2 对调整的装配顺序的可行性说明 18

5.3 对几处装配工序的优化 19

5.4 优化后的结果 20

5.4.1 优化工序的标准作业与正常所需工时 20

5.4.2 优化后的标准工时表 21

5.4.3 优化后的工位划分与生产线平衡率计算 22

5.5 优化后的方案与原方案的比较 23

第6章. 生产的设计与布局 25

6.1 车间及车间中各个功能模块的说明 25

6.2 物流关系分析 25

6.3 非物流关系分析 28

6.4 功能模块关系综合分析 29

6.5 功能模块位置关系分析 30

6.6 生成面积相关图 31

6.7 生成车间布局图 31

第7章. 总结与展望 33

参考文献 34

致谢 37

绪论

研究背景及意义