焊轨基地生产线瓶颈分析与优化  

Bottleneck Analysis and Optimization for Welding Base Assembly Line

作　　者：郭军锋[1] 

机构地区：[1]郑州铁路局郑州工务机械段,郑州450052

出　　处：《铁道工程学报》2017年第7期42-46,90,共6页Journal of Railway Engineering Society

摘　　要：研究目的:为满足全国路网建设需要,原铁道部在全国布局11个百米钢轨焊轨基地,焊轨基地的焊轨作业流水线的效率是管理人员重点关注的问题。以郑州局小李庄焊轨基地焊轨生产线中"母材进轨线"至"热线"段生产流水线为例,我们发现目前实际运行的生产节拍与原定设计存在较大差距,部分工序瓶颈效应明显。同时,在双线并行的流水线系统中,调度和协调也会影响整个系统的作业效率。基于此,本文旨在通过调研、建模以及仿真试验,对焊轨生产线进行效率评估,并分析整个双线生产线中的瓶颈效应,进而对瓶颈部分提出针对性的优化方案,最后再次用仿真试验分析和验证优化方案的结果。研究结论:(1)通过调研、建模和仿真试验,发现了吊运阶段是整个"外勤-热线"段生产线的显著瓶颈;(2)针对吊运瓶颈,本研究提出了在既有7片横梁上添加一组电动葫芦解决吊运阶段的瓶颈问题;(3)提升吊运阶段效率后,"热线"段将会成为系统的瓶颈,因此提出了将"热线"段利用率最高的焊接工位的焊后检查工序调至利用率最低的粗磨工位,以提高"热线"段的线平衡和效率;(4)提出通过提升辊道的行进速度来提升"热线"段的效率;(5)通过仿真试验发现,优化方案对整个"外勤-热线"段确有优化效果,效率可提升30%~40%;(6)本研究成果可应用于既有焊轨基地针对生产效率的提升改造,也可应用于新建焊轨基地时设计参考。Research purposes： In order to meet the maintenance requirements of national railway network, the former ministry of railways set up 11 one hundred meters long CWR （ Continuous Welded Rail） welding bases national wide. The efficiency of the rail welding assembly line is one of important issues to the manager. In this paper, based on the example of assembly line from rail entrance to ＂hot - line＂ in Xiaolizhuang rail welding base of Zhengzhou Railway Bureau, we find that there is a large gap between the actual takt and the original design. Bottleneck effect is obvious. At the same time, in the parallel line of the assembly system, scheduling and coordination will also affect the efficiency of the entire system. Through the methods of survey, modeling and simulation experiments, we evaluate the efficiency of welding assembly line, anlyze bottleneck effect of the parallel line of the assembly system, and then put forward the optimization scheme. Finally we conduct the simulation experiments to analyze the optimized results. Research conclusions： （ 1 ） Through investigation, modeling and simulation experiments, we find that the hoisting phase is the outstanding bottleneck of the whole ＂ hot- line＂ welding assembly line. （2） To eliminate the bottleneck, this paper propose to add one more set of electric hoist on the existing 7 cross beams. （3） After enhancing the efficiency of the hoisting phase, ＂hot -line＂ phase becomes the bottleneck. To tackle this problem, the paper proposes to adjust the post- welding check from the high occupied welding platform to low occupied crude grinder platform. （4） Propose to enhance the efficiency of ＂ hot - line＂ through accelerating the moving speed of hoisting track. （ 5 ） The simulation experiment shows the outcome is effective, the efficiency rate is increased by 30 -40%. （6） The research results can not only be applied on the production capacity expansion of existing CWR welding base but also on the design of new CWR welding base.

关 键 词：工程材料 流水线优化 试验研究 基地焊接 离散事件系统仿真 

分 类 号：U215.54[交通运输工程—道路与铁道工程]