Research On Simulation And Optimization Of Mixed-flow Assembly Line Balancing Problem Based On RPW

Assembly is the last part of the manufacturing process and it occupies an important position in the manufacturing system.The balance of the assembly line helps to ensure the stability of the product quality,reduce the in-process inventory,reduce the logistics cost of the enterprise,and increase the production efficiency.The operation of the assembly line is directly related to the level of competitiveness of the enterprise.Therefore,improving the balance of the assembly line plays an important role in improving the productivity and efficiency of the company.This paper first analyzes the research status and solution of Assembly Line Balance Problem,according to the assembly line of R company’s automobile dashboard,analyze its product structure and assembly process,then establish a mathematical model of single-model product assembly line.In order to improve the balance of the assembly line,use heuristic search algorithms and Ranked Positional Weight(RPW)to redistrict workplaces,compare and analyze the optimization results of the two methods.Then,base on the assembly process flow of the multi-type dashboard,and in the light of the joint assembly sequence,convert multi-model mixed-flow assembly lines into equivalent single-model product assembly lines,use RPW to redistrict workplaces to get a mixed-flow assembly solution.Next,use the eM-Plant simulation software to simulate and model the mixed-flow assembly line,analyze the optimal production sequence of the mixed line under certain conditions.Finally,simulate and model the mixed-flow assembly line of multi-model automobile dashboard under random conditions,and analyze the balance of all workplaces.Due to the optimization by heuristic search algorithm and RPW,the number of workplace has decreased,the average utilization of workplace has increased significantly,the balance delay rate has reduced,the line Smoothness Index(SI)has also significantly reduced,the balance of the assembly line has significantly improved,and the results prove that RPW is better than the heuristic search algorithm.This paper analyzes and designs mixed-flow assembly line for five different types of automobile dashboard.Due to the optimization by RPW,the balance of this mixed-flow assembly line has significantly improved.Then,use the eM-Plant simulation software to simulate and model this mixed-flow assembly line of five types of dashboard,and it is concluded the best production sequence when the total assembly time is the shortest.And under random conditions,the utilization of the workplaces of the mixed-flow assembly line is higher,the Smoothness Index is lower,the result of this optimization is good.This paper used static heuristic algorithm and dynamic simulation optimization methods to solve Assembly Line Balance Problem.The use of two methods combined with each other can reduce the deficiencies of a single solution method and make the results more realistic.At the same time,the mixed-flow assembly line designed in this papera chieved reasonable allocation of workplaces,it helps to shorten the production cycle of products,reduce inventory,increase productivity and provides guarantee for the stability of product quality.In addition,the relevant methods and conclusions used in this paper not only have the most direct reference value for this research subject,it will also provide reference for the study of other similar mixed-flow Assembly Line Balance Problem.