对装配制造企业来说，生产线平衡率的改善是企业持续改善的课题。当前很多装配 型制造企业仍采用传统的旧式一字型长流水线生产模式，其生产线的平衡率很难取得一 个更大的突破。生产线平衡看过去是一个简单的问题，在交期短、品种多的新订单模式 下却是一个系统的问题。作为手机知名品牌的 A 公司，内部制造管理团队已尝试过多次 生产线平衡改善，但总是事倍功半。本文结合 A 公司装配车间的现状，提出基于交期短， 品种多的新订单模式下的生产线平衡系统解决方案，以突破制造能力难以提升的困境。 首先，对 A 公司的外部经营环境、行业特点、订单结构、内部工艺流程等进行分析 研究，然后对比同行标杆企业提出 A 公司在生产线平衡过程中需要解决的问题。最后， 利用节拍的设定、流水线线体布局设定、瓶颈改善等精益工具结合生产线平衡技术对对 典型产品 R807 进行了多次改善，最终减少开线时间，减少在制品库存，减少总标准时 间，大幅度地提升生产效率与制造能力。 本文在精益生产、产线平衡的理论研究结合 A 公司实践应用的基础上，提炼出手机 装配车间生产线平衡改善过程中值得推广的三个措施，以少人化作业为主体的 U 型柔性 生产线模式，以动作单元为对象的自动化设备导入，以减少总标准时间的模组化改善。 该实践过程总结应该值得很多同行所参考借鉴，提升企业的竞争力。 关键词，精益生产；生产线平衡；柔性生产线；标准时间II Abstract For assembly manufacturing enterprises, the improvement of production line balance rate is the subject of continuous improvement. At present, many assembly manufacturing enterprises still adopt the traditional one-character long-line production mode, and its production line balance rate is difficult to achieve a greater breakthrough. Production line balance used to be a simple problem, but it was a systematic problem under the new order mode with short delivery time and many varieties. As a well-known brand of mobile phones, the internal manufacturing management team has tried many times to improve the balance of production lines, but always with half the effort. In this paper, according to the current situation of assembly rollers in A company, a solution of production line balancing system based on new order mode with short delivery time and many varieties is proposed to break through the predicament that manufacturing capacity is difficult to improve. First of all, analyze the A company's external business environment, industry characteristics, order structure, internal processes, and then comparing the peer benchmarking enterprises put forward A company needs to solve the production line balancing problems. Finally, the typical product R807 has been improved many times by using the Lean Tools such as rhythm setting, pipeline layout setting, bottleneck improvement and production line balancing technology. Finally, the opening time of R807 has been reduced, the inventory of in-process products has been reduced, the total standard time has been reduced, and the production efficiency and manufacturing capacity have been greatly improved. Finally, on the basis of the theoretical research of lean production and production line balance combined with the practical application of A company, this paper extracts three measures worth promoting in the process of improving production line balance in mobile phone assembly workshop: U-type flexible production line mode with fewer people as the main body, and automatic equipment introduction with action unit as the object, in order to reduce the modular improvement of the total standard time. The practice summary should deserve a lot of peer reference, enhance the competitiveness of the enterprise. Key Words: Lean Production; Line Balance; Flexible Production Line; Standard TimeIII 目 录 摘要.........................................................................................................................................I Abstract ..................................................................................................................................... II 第一章 绪论..............................................................................................................................1 1.1 研究背景与意义...................................................................................................1 1.2 国内外研究现状综述...........................................................................................1 1.2.1 精益生产国内外研究现状 ...........................................................................1 1.2.2 生产线平衡国内外研究现状 .......................................................................3 1.2.3 国内外研究现状总结 ...................................................................................4 1.3 研究内容、方法和技术路线...............................................................................5 1.3.1 研究内容 .......................................................................................................5 1.3.2 研究方法 .......................................................................................................6 1.3.3 技术路线 .......................................................................................................6 1.4 本章小结...............................................................................................................7 第二章 精益生产与生产线平衡理论概述..............................................................................8 2.1 精益生产理论概述...............................................................................................8 2.2 精益生产常用工具...............................................................................................8 2.2.1 少人化作业 ...................................................................................................9 2.2.2 5W1H 提问技术.............................................................................................10 2.2.3 ECRS 改善原则.............................................................................................10 2.2.4 流程程序分析法 .........................................................................................11 2.2.5 时间测定 .....................................................................................................12 2.2.6 动作分析 .....................................................................................................13 2.3 生产线平衡理论.................................................................................................14 2.3.1 生产线平衡基本术语 .................................................................................14 2.3.2 生产线平衡评价指标 .................................................................................15 2.3.3 生产线平衡改善方法 .................................................................................16 2.3.4 产线平衡改善的步骤 .................................................................................17 2.4 本章小结.............................................................................................................17 第三章 A 公司生产现场研究分析.........................................................................................18 3.1 A 公司企业相关介绍 .............................................................................................18 3.2 A 公司行业环境现状 .............................................................................................19 3.3 装配车间的能力分析.........................................................................................20 3.4 市场的订单结构分析.........................................................................................21 3.5 选取典型装配线产品.........................................................................................22 3.6 R807 产品作业流程 ...............................................................................................23 3.7 R807 产品作业布局 ...............................................................................................23 3.8 R807 产品工时测定 ...............................................................................................24 3.9 生产线平衡现状..........................................................................................