Mixed Production Line Manufacturing Process Modeling And Simulation

The mixed production line in Machine Manufacture enterprise has the characteristics of complicated process and equipment, diversity of product types, long production cycle, and the volume of work in process (WIP) great and uneven distribution, accordance of production logistics and strictly matched production rhythm. It is difficult to arrange production plan, debug new product processing and optimize the production process. Traditional production management has the difficulties in managing the whole production process, and what's more, it's hard to realize the whole optimization in both time and cost. Simulation can greatly shorten system research and development cycle, find out the problems in production, and save development cost, therefore provide an efficient way to solve above management problem.In this thesis, a mixed gear production line in a speed reducer enterprise is systematically simulated, in order to realize organization optimization, raised out optimization program of scheduling, the number of input, improve equipment efficiency, shorten the production cycle, reduce the average time of volume of WIP and finally improve the capacity of the whole line.Firstly, work study method of Industry Engineering has been applied to investigate the production logistics situation, equipment parameters, and product parameters. Input data of simulation model has been abstracted based on these real production data.Secondly, based on WITNESS simulation platform, object-oriented technology, the model of the main production equipment and main transport equipment in gear production line is set up. Then, the product processing model is developed by abstracting product data from real production line. Finally, the whole mixed gear production line is formulated by integrating equipment model and product model.Thirdly, dynamical running of the simulation model is realized by applying parameter dynamic simulation technology, mathematics statistics and numerical analysis, and visual reality technology. The production line's production capacity, key equipment's workload rate and the average of the time of WIP are analyzed during the running process. Finally, the problem of the production line is diagnosed by simulation and the model is rebuilt based on schedule optimized scheme, WIP optimized scheme, people optimized scheme. The final production process optimization scheme is worked out after several optimization simulations by comparing the optimized model with the former model at the aspects of average WIP time and key equipment's workload rate. The application practice of the simulation study in a speed reducer enterprise shows that the digital modeling and simulation of the mixed production line can analyze the production capacity and equipments, workload, and optimize the production running and scheduling process. Therefore, the work can effectively support the decision making of production management and scheduling.