Empirical Study And Spatial Layout Optimization On Wrapping Section Of American-style Sofa Production

During30years of reform and opening-up, Chinese furniture industry had achieved highspeed development. With the continuous expansion of the domestic furniture market demand, theexport-oriented furniture companies and domestic furniture enterprises have accelerated in thedomestic market expansion. At the same time, the expansion is proposed for a severe test to她the production capacity and management model of medium and small scale furniture enterprises.Industrial engineering technology is the direct pathway to improve the production efficiency.Especially the application of work study,you can keep continuous improvement with lessinvestment or no extra investment to the current production system.This paper takes the wrapping operations section in furniture company D with theAmerican-style sofa named Y608-2as the research object, through the production of field surveyand observation, and the use of industrial engineering, operations research methods of spatialdesign human engineering theory and production organization theories, we draw the followingconclusions:(1) Apply process chart for the four basic procedures of wrapping operation section for fieldrecording, and use "5W1H" questioning technique and" ECRS" principle of operation processanalysis. The number of "processing" is93before the improvement, and is81after theimprovement; The number of " checking" is14before the improvement, and is10after theimprovement. The improvement effect is reducing12"processing" and4"check".(2) Apply flow process chart to record the work flow and work time of backrest wrappingworker and frame wrapping worker, and use use "5W1H" questioning technique and" ECRS"principle to process the program analysis. Total moving distance is96.9m before theimprovement, and is61.7m after the improvement; Total operation time is4132.8s before theimprovement, and is3943s after the improvement. The total operation time of wrapping sectiondecreased189.8s, and transport distance reduced35.2m.(3) Apply plan of wiring to record the processing and delivery path of serpentine spring,hardware supplies, filling material and coating materials and other materials, to analyze thelayout and way. We got the recognition of problem that is the dispersed locations and presence ofsevere repetitive path after analysis of production system in material processing and transportprocesses. In view of the above problems, we found the Group A and Group B of sofa productionpreparation, Group A is responsible for filling materials and coating materials processingpreparation; Group B is responsible for hardware accessories and supplies processing. Totaloperation time is1129s before the improvement, and is697s after the improvement; Total moving distance is778.5m before the improvement, and is298m after the improvement. Thetotal operation time of wrapping section decreased432s, and transport distance reduced478.5m.(4) The backrest and seat frame wrapping workers completed a task time are respectively1144.8s and2615.8s. The total task time to wrapping a sofa is2615.8s. Through the jointoperation analysis, when the back pack is completed, this two workers take all other operationson sitting frame pack jointly, so that the seat frame pack shorten to1913.5s, The total task time towrapping a sofa reduced702.3s.(5) According to the operation process of American sofa wrapping, and fully consider thecoherence and similarity among different operations,we can divide wrapping operation into23operational units, and measure the standard operating time of each operational units with using ofMOD method.The standard operation time of wrapping operation measured is3250s.(6) In wrapping operation space design, for the space of work site, the study fully considerthe dynamic human body size of operation worker in production process and the data about thefrequency of materials used up in practical operation,obtaining the dimension of the space ofwork site is5000*4400mm,and inside the space of work site,it consist of materials shelf(designsize1550*900*2000mm), tools shelf(design size650*500*1125mm) and wrapping operationworktable(design size2600*1100*350mm),the other spaces to the table for center extension1200mm.(7) Through combing the product flow relationship among the four kinds of function space(operation space, semi-finished products space, space for temporary storage space of finishedproducts inspection and the cache storage space before finished products storage), combinedwith the space demand under assembly line production mode to divide and arrange the each zoneof packaging workshop. According to the standard operating time of23operation unit, the paperdetermine wrapping operation assembly line and set6workstations, and primordially identify thecycle time is617s.