随着中国国民经济的快速发展，人民的收入不断增加，对生活质量的要求也产生了快速的 变化。汽车的出现极大地促进了人们的生活质量的提升，促进了人员资源的快速流通。早期， 只有政府、大公司或者富裕家庭才能消费起的汽车近年来在中国的销量呈爆发式增长，中国的 汽车生产和销售多年来一直位居世界第一，并且仍在高速发展，汽车制造业已成为中国国民经 济的重要支柱产业。随着中国汽车消费市场的快速发展，全球各汽车企业正在争相加入中国市 场参与竞争。自主品牌也在不断参与其中，中国已成为世界上汽车品牌最多的国家。由于中国 的政策一定程度上限制了外资汽车公司合资企业的发展，若进一步放开，汽车制造业的竞争将 进一步加剧。各厂商要想从竞争激烈的市场中求得生存，需要加强成本的管理，并提升生产效 率。汽车制造过程中的物流配送问题将对汽车生产效率和成本产生较大的影响，需要对物流进 行合理的规划。 L 公司为某集团施行自主汽车品牌向上策略新成立的汽车公司。物流作为汽车生产过程中 的重要保障部分，拥有良好的物流运作体系将大大降低 L 公司运营成本，因此 L 公司急需进行 物流运作层面的合理规划。总装车间为汽车制造体系中物流活动最多最复杂的区域，是物流规 划中极其重要的部分。 为了完成对 L 公司总装车间的物流规划，本文深入研究了精益生产、精益物流以及物流仓 储规划的有关研究成果，了解提升物流运作过程中效率的有效手段。对 L 公司总装车间的生产 工艺，建筑空间进行全面分析，然后进行全面的物流规划。其中包括：包装规划、仓库布局规 划、操作流程设计、配送线路设计、人力资源及设备规划。力求通过此规划实现物流运作过程 中高效率、低成本的目标。 本文主要以 L 工厂总装车间展开研究，并通过本研究成果的实施实现降低企业物流成本目 标，为汽车行业其他公司的规划或后续优化改善提供借鉴意义。 关键词：精益物流，物流规划，包装规划基于精益思想的 L 公司总装车间物流规划 II ABSTRACT Chinese people's income is increasing with the rapid development of economy, and the requirements for the quality of life have also changed rapidly. The emergence of automobiles has greatly promoted people's living standard and rapid circulation of people and resources. In the early days, only the government, big companies or wealthy families could afford automobiles. In recent years, the sales volume of automobiles in China have explosive growth. China's automobile production and sales have been ranked first in the world for many years, and they are still glowing at a high speed. The automobile manufacturing industry has become an important pillar industry of China's national economy. The global automobile enterprises are competing to join and participate in the rapid development of China's automobile consumer market. Independent brands are also constantly participating in the market, and China has become the country with the largest number of automobile brands in the world. As China's policy to some extent limits the development of joint ventures of foreign automobile companies, if further liberalization, competition in the automobile manufacturing industry will increasing intensify. In order to survive in the fiercely competitive market, automobile company need to strengthen cost management and improve production efficiency. Logistics distribution in the automobile manufacturing process will have a greater impact on the production efficiency and cost of automobiles. So logistics needs to be planned reasonably. L company is a newly established automobile company which carries out the strategy of independent automobile brand improvement by a group. Logistics as an important part of the automobile production process, with a good logistics operation system will greatly reduce the operating costs of L company, so L company urgently needs to carry out reasonable planning of logistics operation level. TCF shop is the most complex area of logistics activities in the automobile manufacturing system, and it is an extremely important part of logistics planning. In order to complete the logistics planning of L company's TCF workshop, this paper deeply studies the related research results of lean production, lean logistics，logistics warehouse planning, and understands the effective means to improve the efficiency of logistics operation. This paper analyzes production process and building space of L company's assembly workshop comprehensively, and then carry out the comprehensive logistics planning. Which is including: packaging planning, warehouse layout planning, operation process design, distribution line design, human resources and equipment planning. Through this plan, we strive to achieve the goal of high efficiency and low cost in the process of logistics operation.南京航空航天大学硕士学位论文 III This paper mainly studies the L factory TCF workshop, and achieves the goal of reducing enterprise logistics cost through the implementation of the research results, which provides reference for other companies in the automotive industry planning or follow-up optimization and improvement. Keywords: Lean logistics, Logistics planning, Packaging planning南京航空航天大学硕士学位论文 V 目 录 第一章 绪论..........................................................................................................................................1 1.1 研究背景与意义..............................................................................................................................1 1.1.1 研究背景.............................................................................................................................1 1.1.2 研究意义.............................................................................................................................2 1.2 国内外研究现状..............................................................................................................................2 1.2.1 精益物流研究现状.............................................................................................................2 1.2.2 车间物流系统理论研究现状.............................................................................................4 1.3 研究方法与技术路线......................................................................................................................5 1.3.1 研究方法.............................................................................................................................5 1.3.2 技术路线.............................................................................................................................6 1.4 研究内容及结构安排......................................................................................................................6 1.5 本章小结..........................................................................................................................................7 第二章 汽车制造业物流规划与精益物流理论..................................................................................8 2.1 物流规划概述..................................................................................................................................8 2.1.1 物流规划的内涵.................................................................................................................8 2.1.2 物流规划的基本原则....................................................................................................... 11 2.1.3 物流规划流程................................................................................................................... 11 2.2 精益物流思想................................................................................................................................12 2.2.1 精益物流的内涵...............................................................................................................12 2.2.2 精益物流方法...................................................................................................................13 2.2.3 汽车总装车间切入精益物流思想的特征.......................................................................14 2.2.4 汽车总装间切入精益物流的方法...................................................................................15 2.3 本章小结........................................................................................................................................16 第三章 L 公司总装车间物流规划需求分析......................................................................................17 3.1L 公司概况.....................................................................................................................................17 3.2L 公司总装车间工艺布局 .............................................................................................................18 3.3L 公司总装车间厂内物流规划分析..............................................................................................20 3.3.1 规划内容...........................................................................................................................20 3.3.2 规划原则...........................................................................................................................20 3.3.3 总体目标...........................................................................................................................21 3.4 本章小结........................................................................................................................................21基于精益思想的 L 公司总装车间物流规划 VI 第四章 L 公司总装车间物流规划设计.............................................................................................22 4.1L 公司总装车间物流运作模式的规划..........................................................................................22 4.1.1 以需求为导向的零件供线模式规划...............................................................................22 4.1.2 精益的存储策略规划.......................................................................................................22 4.2 物流包装规划................................................................................................................................23 4.2.1 标准循环包装...................................................................................................................24 4.2.2 一次性包装.......................................................................................................................25 4.2.3 专用料架...........................................................................................................................26 4.2.4 排序包装及 Kitting 包装..................................................................................................26 4.2.5 线旁包装...........................................................................................................................27 4.2.6 拖车技术规划...................................................................................................................27 4.3 L 公司总装车间物流区域规划.....................................................................................................27 4.3.1 物流区域功能分析...........................................................................................................27 4.3.2 仓储面积计算...................................................................................................................28 4.3.3 物流区域布局...................................................................................................................29 4.4 满足 JIT 要求的物料配送路径规划............................................................................................30 4.4.1 生产及配送规划前提及约束条件...................................................................................30 4.4.2 物料配送需求分析...........................................................................................................31 4.4.3 配送路径规划...................................................................................................................34 4.4.3.1 线路初始规划................................................................................................................34 4.4.3.2 配送线路优化................................................................................................................39 4.5 物流流程规划................................................................................................................................39 4.5.1 零件卸货与收货流程.......................................................................................................39 4.5.2 零件入库流程...................................................................................................................41 4.5.3 零件出库流程...................................................................................................................42 4.5.4 零件配送流程...................................................................................................................47 4.5.5 Kitting/排序流程 ..............................................................................................................51 4.5.6 空包装管理.......................................................................................................................53 4.5.7 逆向物流...........................................................................................................................53 4.6 重视效率的物流人员与设备规划................................................................................................53 4.6.1MTM 简介.........................................................................................................................54 4.6.2 人员需求设备规划...........................................................................................................54南京航空航天大学硕士学位论文 VII 4.6.3 固定投入设备及周转设备规划.......................................................................................56 4.7 本章小结........................................................................................................................................57 第五章 L 公司总装物流规划的实施保障措施.................................................................................58 5.1 合理配置物流人员........................................................................................................................58 5.2 提高物流规划的执行力................................................................................................................58 5.3 重视精益生产与物流的协同效应................................................................................................58 5.4 本章小结........................................................................................................................................59 第六章 结论和展望............................................................................................................................60 6.1 结论................................................................................................................................................60 6.2 展望................................................................................................................................................60