Optimize the workpiece processing process, use OEE to monitor the ratio of the actual production capacity of the production equipment to the theoretical capacity, and master the bottleneck of the production process, which is a useful exploration to achieve efficient and low-cost parts processing.
The cylinder block is an important part of the engine, and the basic shape is relatively complicated: the wall is thin, the box shape, the multi-cavity and the hole system. Under normal circumstances, the processing characteristics of the cylinder production line are: the first face and the back hole; the process of easily discovering the internal defects of the part; firstly, the deep hole processing is completed to avoid the large internal stress affecting the subsequent finishing; correct and reasonable arrangement of the seal Auxiliary processes such as testing, press fitting, and cleaning.
In the optimization of the cylinder production line of a domestic automobile company, the technicians adopted the method of beat optimization and utilized OEE management means to increase the production capacity and reduce the production cost.
Optimize cylinder processing beats
Taking the L4 gasoline engine cylinder production line as an example, the production line consists of 4 horizontal machining centers and 4 vertical machining centers made in China. The workpieces are manually clamped and transported using unpowered roller tables. Auxiliary machines (cleaning, leak testing, pressure) The machine is equipped with a special machine; the position is measured by a three-coordinate measuring machine, and the special measuring tools are used for the hole diameter, hole depth and threaded hole; the tool is mainly made of domestically produced carbide tools, and the key tools are well-known foreign brands; the design capacity is 80 sets/day.
First, analyze the line balance ratio of the production line, that is, the time balance of the operator who constitutes the production line body in the operation elements.
Line balance ratio = (sum of all process beats × 100%) / (bottleneck process beat × personnel)
Assuming that one operator is assigned to each machining center, the line balance ratio can be calculated to be 43.4% and the loss is 56.6%.
Usually the production cycle of the production line is determined by the longest production time in the entire line. By analyzing the process flow and the beat of the cylinder (Table 1), it can be seen that the OP60 has the longest processing cycle, followed by the OP30 and OP100.
The optimization process can be divided into single-process optimization and full-line beat balancing.
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