| Within the mass production of the electronic products, assembly line is the most important part, whose balance status would directly affect the productivity and benefit of the whole manufacturing system. Research is carried out aiming at the problems of low balance rate and poor production capability etc on the assembly line. In order to improve efficiency and productivity of the assembly, industrial engineering technique and system simulation method have been comprehensive used.The paper researches on the assembly line of a large TV manufacturing factory. Drawing of the procedure and the assembly line is mapped out through on site investigation. The stopwatch time method is used to collect data of operation time at different assembly stations, and the treble standard derivation principle is used to exclude the outliers. In order to obtain the best fitting distribution function of the needed data needed for the TV assembly line modeling and simulation. Data fitting analysis of the work station time is done using quality statistical software Minitab and finds the best fitting function. The TV assembly line is modeled in Flexsim and simulation is done to obtain the rates of utilization, blocking and idle at each work station, and the bottle-neck position is found out. Two optimization schemes A and B are proposed according to the condition and simulation of them is also carried out in Flexsim to compare with the original scheme, the results shows that the two can both increase the balance rate and production capability of the assembly line, and B is superior to A after consideration. The production rate of qualified product increases from 179.86 set/hour to 243.63 set/hour, so a significant improve in production is presented. Besides the balance rate of B changes from 63.48% to 84.18% with an net incensement of 32.61%. From the above, the tool of system simulation can be used in the refinement research of TV assembly line and achieve satisfactory results. |
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