| Motor industry, as a typical scale economy industry, flexibility contradicts withproductivity in this term of mass production. This is largely due to the fact that singlevariety, large batch, special equipment, stable technology and high efficiencyconstitute the economies of scale. On the contrary, any of these factors changes, underthe similar processing mode, will lead to the frequent adjustment of the clampingapparatus, which is sure to diminish the process stability and production efficiency. Inorder to meet the customers’ need for personality, the automakers at home and abroadare seeking to replace the traditional production line with the flexible productionsystem, which could adapt to high rhythm, high efficiency and high quality. It hasbeen an essential project about how to expand capacity.Starting from the work site of Company G’s assembly shop and hinging aroundthe goal of “achieving the compact workshop planning, orderly efficient and flexiblesystem,and reliable quality”， this paper applies the new notion of technology reformand advanced production techniques to every part of the capacity expanding program.There is a complete collinear production line that combines a motor consolidationsystem with a chassis assembly process, particularly for ZC and CR45, which are twodifferent platform models (bearing and non-bearing). Though the parametric vehiclemodels’ specification and the research, analysis and implementation of theinterference pattern, high-efficiency mixed production could be achieved in assemblyshop. What is worth mentioning is that this transformation adopts the project” bearingauto body and non-bearing auto body are put into completely one collinear assembleline””, which is called multi production platform models in a mixed line, greatlyenhances the input and output efficiency, and fully meet the changing marketrequirements. The new assembly shop allows for the mixed routing manufacturing ofbearing auto body and non-bearing auto body with multi chassis structure platform. Ifthe new production line is put into practice, the SUV type, such as ASX, Pejero Sportand Pejero-V73, which the company produces at present, can be easily compatible.The different bodies will put into distribution at one time during the construction oftransformation, so that the industry can produce1.3billion units every year on thefirst stage, then have the production capacity of2.6billion units on next stage. Thekey drive part of the new workshop’s conveyor line was already designed in the light of production capacity of2.6billion units, which was helpful for later productionexpansion.The line balancing rate of G Company’s new assembly shop could improvecontinuously and the production capacity promotes by means of the research andcalculation of process configuration, balanced wall smoothness index and thereduction of the worthless work in the production. It also continuously improves theefficiency of production line, reduces cost and makes zero waste. The balancingoptimization theory and the industrial engineering methodology under this study mayserve as a valuable reference for the design and optimization of assembly lines inmanufacturing enterprises.In order to improve quality assurance ability in assemble stage; this paperintroduces these statistical process control technology, which could make off-lineanalysis and on-line control for assemble line, and help to establish the Quality LifeCircle System, a quality management system of assembly process, which containsbasic support, technical service and implement application layer. It also containsnetwork technique and information superhighway, which networked the distributedcontrol system and adapt to the flexible production system’s need. Best practiceindicates that implements of process quality control not only greatly enhancing GCompany’s quality management level about elaboration, but also mightily support thework of quality management and bring more benefits to industry. |
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