I 摘要 随着经济的全球化，产品的复杂程度越来越高、产品更新换代加速以及客户定 制化要求越来越高，给企业提出了更高的要求。计算机仿真技术的发展和虚拟现实 技术的产生，使数字化工厂技术（DigitalFactory）逐渐成为一个新的研究热点。数 字化工厂技术将传统的基于手工和经验的设计规划转变为基于计算机仿真和优化的 精确可靠的规划设计。本文以DK公司海外DMA工厂铝合金轮毂轮流生产线规划设计 验证及优化为主题进行仿真，通过仿真该工厂生产线的后期运营，发现生产线设计 中的缺陷，并提出优化方向。从而减少了规划的时间，缩短了生产准备周期，优化 了生产线配置，减少了工程更改量，进而降低了开发成本和投资风险。 本文首先对于轮毂混流生产线工艺流程进行了分析，对工厂规划前提进行了说 明。在此基础上进行轮毂混流生产线运营建模与仿真，进而利用仿真实验的结果数 据开展轮毂混线生产线生产效率分析与优化。文章研究内容详述如下： 首先，对轮毂混流生产工艺流程进行分析。通过分析生产需求，调研现有生产 组织模式及现行工艺流程分析。从生产源头计划化入手，分析生产执行系统。分别 对熔炼、压铸、机加、涂装车间的功能及工艺流程进行了详细调研及分析。从而结 合需求分析出现有问题，并将问题简化建模。 其次，基于工厂仿真技术对整体生产流程进行建模。主要研究对象集中在问题 比较突出的压铸和机加车间。对于仿真资料的设计表格与收集数据，进而对设备构 建二维与三维模型，进一步进行仿真逻辑的实现及仿真结果数据化分析。 再次，基于仿真结果的生产效率分析及优化。根据仿真运算结果，对制造资源 效率进行量化分析，并进行线平衡测算。仿真对于各类设备的利用率进行关注，并 深挖瓶颈环节及瓶颈漂移分析；此外，为了使人员配置符合量化分析及以瓶颈环节 挖掘，研究也对数量配置和人员配置进行优化，对工艺时间提出优化建议。 最后，针对目标公司目前急需解决的库存量大的问题，进行了平准化排产方式 的尝试。 关键词： 精益生产；工厂仿真；轮毂生产；生产计划；数字工厂 燕山大学工商管理硕士学位论文 II Abstract Withtheglobalizationofeconomy,theincreasingcomplexityofproducts,the accelerationofproductupgradingandtheformationofcustomizedproductionmodeput forwardhigherrequirementsforenterprises.Withthedevelopmentofcomputersimulation technologyandtheemergenceofvirtualrealitytechnology,DigitalFactorytechnology hasgraduallybecomeanewresearchhotspot.Digitalfactorytechnologytransformsthe traditionaldesignandplanningbasedonmanualandexperienceintotheaccurateand reliableplanninganddesignbasedoncomputersimulationandoptimization.Thispaper takesthedesignverificationandoptimizationofoverseasDMAfactoriesofDKcompany asthetheme,findsoutthedefectsinthedesignandputsforwardtheoptimization directionthroughthesimulationoflateroperation.Thus,itreducesthetimeofplantand processplanning,shortenstheproductionpreparationperiod,optimizestheproduction lineconfiguration,reducestheamountofengineeringchanges,andreducesthe developmentcostandinvestmentrisk. Inthispaper,firstly,theprocessflowofhubmixedflowproductionlineisanalyzed. Onthisbasis,operationalmodelingandsimulationofhubmixedflowproductionlineare carriedout,andthenproductionefficiencyanalysisandoptimizationofhubmixedflow productionlineiscarriedoutbyusingtheresultdataofsimulationexperiment.The researchcontentsaredetailedasfollows: Firstly,themixedflowproductionprocessofwheelisanalyzed.Analyzeproduction requirements,investigateexistingproductionorganizationandprocessanalysis.Startwith productionsourceplanning,analyzeproductionexecutionsystem.Thefunctionand processflowofmelting,diecasting,machiningandcoatingworkshopwereinvestigated andanalyzedindetail.Therefore,problemsariseincombinationwithrequirements analysis,andsimplifythemodelingoftheproblem. Secondly,theoverallproductionprocessismodeledbasedonthefactorysimulation technology.Themainresearchobjectsfocusonthediecastingandmachiningworkshops withprominentproblems.Methodsandcontentsincludetabledesignandcollectionof Abstract III simulationdata,modelingoftwo-dimensionalandthree-dimensionalmodelsofequipment, implementationofsimulationlogic,anddatalizationofsimulationresults. Finally,productionefficiencyanalysisandoptimizationbasedonsimulation results.Accordingtothesimulationresults,themanufacturingresourceefficiencyis quantifiedandthelinebalanceiscalculated.Itmainlycoverstheutilizationrateofall kindsofequipment,deepexcavationofbottlenecklinksandbottleneckdrift analysis;Quantitativeanalysisofpersonnelcomplianceandbottleneckmining.Sothe quantityallocationandpersonnelallocationareoptimized,andtheprocesstimeis optimized. Inaddition,aimingattheproblemoflargeinventorythatthetargetcompanyurgently needstosolveatpresent,theattemptoflevelingproductionschedulingismade. Keywords: leanproduction;plantsimulation;wheelmanufacturing;productionplan;digital factory 目录 I 目录 摘要...........................................................................................................................................I Abstract........................................................................................................................................II 第1章绪论.............................................................................................................................1 1.1选题背景及意义............................................................................................................1 1.1.1选题背景...................................................................................................................1 1.1.2选题意义...................................................................................................................2 1.2国内外研究现状............................................................................................................2 1.2.1国外研究现状..........................................................................................................2 1.2.2国内研究现状..........................................................................................................4 1.2.3国内外研究现状评述..............................................................................................6 1.3研究内容及研究方法....................................................................................................7 1.3.1研究内容....................................................................................................................7 1.3.2研究方法...................................................................................................................8 第2章轮毂混流生产线工艺流程分析及DMA工厂规划依据........................................9 2.1轮毂类工厂生产需求概述及轮毂生产线现状..........................................................9 2.1.1轮毂生产线生产现状..............................................................................................9 2.1.2轮毂类工厂生产需求............................................................................................10 2.2现有的生产组织模式与工艺分析.............................................................................12 2.2.1工厂计划与排产....................................................................................................12 2.2.2熔炼车间功能与工艺流程...................................................................................14 2.2.3压铸车间功能与工艺流程...................................................................................15 2.2.4机加车间功能与工艺流程...................................................................................18 2.2.5涂装车间功能与工艺流程...................................................................................22 2.3DMA工厂设计说明..................................................................................................26 2.4工厂规划中存在的问题及需求分析.........................................................................28 2.4.1存在问题.................................................................................................................28 燕山大学工商管理硕士学位论文 II 2.4.2需求分析.................................................................................................................29 2.5本章小结.......................................................................................................................30 第3章轮毂混流生产线的建模与仿真.................................