目录
摘要Abstract1 导论 3 1.1 选题内容和研究意义1.2 研究思路和方法1.3 主要内容
.7
1.4 主要创新点2 相关理论阐述2.1 生产过程管理理论^
2.2 生产设备布置优化原则2.3 精益六西格玛理论2.3.1精益生产理论2.3.2六西格玛理论2.3.3精益六西格玛理论2.4 仿真建模理论2.4.1生产物流系统仿真2.4.2仿真基本内容和过程2.4.3 SDZ公司DOSIM投-3仿真系统简介3 生产流程分析与优化方案研究
21
3.1 预精焊生产流程分析
21
3丄1 SLSP公司及预精焊分厂介绍
21山东大学硕±学位论文
3.1.2预精焊工艺生产流程
..22
3丄3生产流程中人员及设备现状
巧
3丄4生产流程中出现的主要问题
25
3.2 优化方案研巧
26
3.2.1优化方案的思路
%
3.2.2优化的原则
27
4. 生产线布置与仿真模型建立
28
4.1 预精挥工艺流水线布局
28
4.2 利用Dosimis-3建立生产流程模型
29
4.2.1 模型中模块选择
30
4,2.2入口(Source)螺旋焊管主机SPM
32
<
4.2.3钢管传输辕道及运管小车和梭车(Conveyor and Shuttle) ...33
4.2.4 工作站(Workstation)
35
4.2.5 节点合并分配模块(Combining and Distributor)
3i8
4.2.6 出曰(Sink)
38
4.2.7连接各模块建立模型
巧
5. 仿真模拟分析瓶颈工位
40
5.1 仿真模拟运行
40
5.2 模拟结果分析瓶颈点
43
5.3 瓶颈产生原因与判巧
46
6. 仿真优化过程与结果分析
50
6.1 优化瓶颈
51
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山东大学硕±学位论女
6.1.1两个准备站分开
5.1
6丄2提高操作技能和焊接生产质量
54
6.2 优化作业率
%
6.2.1精焊机组作业率分析
56
6.2.2螺旋焊管主机优化作业率
別
I
6.2.3模拟系统的最大产能
62
7. 结论与研究不足
66
7.1 结论
66
7.2 不足与局限
66
参考鋪
68
致谢 70
iii 山东大学硕±学位论文
Contents
Abstract in ChineseAbstract in English1 Introduction.1.1 Research significance1.2 Research ideas1.3 Research methodsg
1.4 Thesis innovation2 Relative theory and menthods2.1 Production process management2.2 Optimization of production equipment layout2.3 Le^ Six Sigma Theory2.3.1 Lean Production Theory2.3.2 Six Sigma Theory2.3.3 Lean Six Sigma Theory
16 ^
2.4 Simulation modeling theory2.4.1 Production Logistics System Simulation
‘.17
2.4.2 Basic content and process2.4.3 SDZ DOSIMIS-3 introduction3 Production process analysisand optimization research.
21
3.1 Production process analysis
21
3丄 1 I打troduction 化 SLSP and 2-step Weldi打g Plant
21
3.1.2 2-step welding process
22
3.1.3 The status of personnel and equipment
23
3.1.4 The main problems in the production process
,24
3.2 Optimization research
26
3.2.1 Ideas of the optimization
26
3.2.2 Principles of the optimization
27
4 Production line layout and simulatio打 model establishment
28
4,1 Spriral welded pipe production line
28
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山东大学硕±学位论文
4.2 Use Dosimis-3 化 build a production model
29
4.2.1 Module Selection
30
4.2.2 SoOTce Spiral pipe machine
32
4.2.3 Conveyor and Shuttle
33
4.2.4 Workstation
35
4.2.5 Combining and Distributor
38
4.2.6 Sink
38
k
4.2,7 Connect the modules to build the model
39
5 Simulation analysis of bottleneck
40
5.1 Simulation run
.40
5.2 Analysis of bottleneck
43
5.3 Caiises and judgments of bottleneck
45
6 Simulation optimization process and results analysis.....
49
6.1 Optimization of bottleneck..
50
6.1.1 Separation of two preparation stations
50
6.1.2 Improve operational skills and weld qu^ity
53
6.2 Optimize the operating rate
55
6.2.1 Analysis of Operation Rate of final welding machine
55
6.2.2 Spiral pipe machine optimization
.60
6.2.3 Maximum capacity of the simulation system
61
7 Conclusion and the deficiencies
65
7.1 Conclusion
66
7.2 Deficiencies
66
Reference documentation
67
Acknowledgements
69
V
山东大学硕±学位论文
摘要
生产流程是制造企业经营中的一个重要环节,是指在生产工艺中,从原料投
入到成品产出,通过一定的设备按顺序连续地进行加工的过程。也指产品从原材
料到成品的制作过程中要素的组合。生产流程优化是企业生产持续改善的一个重
要指标,企业通过生产流程优化,可W提高生产效率、减少浪费、降低库存、提
高产能,进而提高对市场变化的适应度,増强企业的核屯、竞争力

本文目的是根据SLSP有限公司预精焊分厂螺旋焊管生产线的实际情况,对
生产线流程的现状进行详细的分析,最终提出生产流程优化的方案,并寻求优化
后的最大产能。本文从生产优化的理论和仿真模拟的理论出发,结合预精焊螺旋
焊管生产线的特性与实际情况,确定了生产流程优化的主要研究内容。在分析
预精焊螺旋焊管生产线时,首先分析了此类产品线的特点,同时对生产线的具体
、 工艺流程做了分析,另外,还对该生产线中人员和设备状况,及在生产流程中
出现的主要问题进行了分析。在生产设备布置与仿真模型建立中,根据预精焊生
产设备特点,分别介绍了各个生产部分的主要工作,和根据工作特点选取了不同
的仿真模块来构建基于Dosimis-3软件1下的整个生产系统的仿真模型。在产能瓶
颈问题的分析中,根据运行仿真模型的结论和数据分析,找出瓶颈工位,找出造
成瓶颈的原因,并提出解决瓶颈的方法。在仿真优化过程与分析中,通过改变钢
管流向的策略,和提高技能及产品合格率的方法优化了系统中的瓶颈,并通过系
统再运行加W验证。另外,通过仿真系统分析了系统中关键工位的作业率,并且
提出整套方法来优化作业率。最终通过系统的再次运巧找出优化后的系统最大产
量

关键词:生产流程优化仿真模型,Dosimis-3,生产瓶颈,优化作业率
I ◎巧94-2013 SDZ GmbH德国SDZ公司软件
I
山东大学硕±学位论文
乂 bs 化 act
Productio打 process is an important part of the manufacturing i打dustry. It refers to
the production,which flows from raw materials to 打nished product output,through a
certain continuous processing sequence. It also refers to 1:he product from raw materials
to finished products in the process of elements combination. Optimizatio打 of a
production process is an important indicator of continuous production improvement.
The optimization of production process can improve the productio打 efficiency,reduce
the waste, reduce the inventory, increase the production capacity and improve the
adaptability to the market change. Enhance the core competitive打ess of enterprises.
The purpose of this paper is to analyze the present situation of the production line
process in detail according to the actual situation of the 2-steps spiral welded pipe
production line of SLSP Co.,Ltd. And seek the optimized maximum productio打
capacity. Based on 化e theory of production optimization and tihe simulation of
production, this paper combined with the characteristics and actual situation of the pipe
productio打ne, and determined the main research contents of production process
optimization. In the analysis of 2-step spiral welded pipe production line,the first step
is to study the characteristics of such product lines and the 1:echnical process. I打
＊
additional,this paper also state 化e personnel and equipment conditio打s,as well as 也e
problems in the production. In the establishment of the simulation model, this paper
respectively introduced the mai打 work of the various productio打 parts, accordi打g to the
characteristics of the equipment, and selected different simulation modules to build the
entire productio打 system based o打 the simulatio打 software Dosimis-3. I
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