The Simulation And Work Study On TV Set Assembly Line

Within the batch production of the manufacturing industries, assembly line is the most important component during the production process, whose balance status would directly affect the productivity of the whole manufacturing system. This paper aims at the analysis of TV set assembly line, applying the modern system simulation technology and the work study theory to optimize and improve the assembly line.This paper takes CRT TV set assembly line of a large home appliance manufacturer as the research object. Through field investigation on the CRT TV set assembly line, both of the operation process chart and the assembly flow chart have been drawn. In order to guarantee the accuracy of the data collected and to lower down the cost of observation, the method of error limit has been applied to determine the observation times and the raw data of operation time at each station have been collected as well. With the data collected, statistical analysis and process have been conducted, thus the frequency distribution histogram has been drawn. With the identification of the normal distribution, the beta distribution and the weibull distribution on the time data, as well as the distribution parameter estimation and the identification of the goodness-of-fit tests between the distribution and actual date, then the distribution function of the input time data used in simulation has been determined. After that, a simulation model of the current CRT TV set assembly line has been established with the application of Arena. The model has been run and the results of simulation have been analyzed. With the analysis of the scheduled utilization of various resources in the reports, the bottleneck station in the current TV set assembly line has been found out. The bottleneck station has been analyzed and researched by the work study theory. With Double-E industrial engineering software, motion-time analysis of the operation has been conducted as well. After eliminating the otiose motions, the operation time of this station has been reduced by 12.14%. Based on the improved operation time of the bottleneck station, an optimized simulation model of the CRT TV set assembly line has been established. Through calculating the balance rate before and after improvement, the balance optimization scheme has been obtained. Comparison between the simulation model before and after optimization also has been conducted. By improving the operation time at the bottleneck station, the whole level of the scheduled utilization of resources in the TV set assembly line has been significantly improved. The balance rate of the CRT TV set assembly line has been increased by 10.70% and the productivity of qualified products has been increased by 11.06%. Hence, with the comprehensive application of the system simulation technology and the work study theory, the CRT TV set assembly line has been obtained overall optimization and improvement, and the production efficiency of the CRT TV set assembly line has been improved as well.