Professional Documents
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Chuong 7
Chuong 7
H.A. ElMaraghy (ed.), Changeable and Reconfigurable Manufacturing Systems, Springer 2009
128
high
diversity
high
low
low
productivity
low
high
low
quantity
high
Fig. 7.1 Cc khu vc s dng khi nim qui trnh s dng, lp rp v t ng lai
, lp rp hn hp v lp rp t ng. C th thy rng ngy cng nhiu cc mc t ng ha lm tng nng sut; tuy nhin tnh linh hot v iu khin gim thiu s bin i a dng v hnh th. C hai sn phm v nhu cu th trng rt quan trng khi la chn mt m hnh lp rp. Trc ht, kch thc, trng lng v c cu cng nh thay i v s lng cc mt hng ca sn phm xc nh cc iu kin gii hn ca k thut. Hn na, h thng lp rp phi tun th mt s yu cu bao gm: thi gian bn hng d kin, s lng d kin ca chi tit cho mi n v thi gian cng nh nhu cu ca th trng m tt c cc bin th c cung cp theo tng phn nh v ch trong thi gian yu cu. Tng qut c th ni rng h thng lp rp c xy dng ban u vi cc thnh phn m-un. iu ny d dng hn nhiu hn so vi h thng sn xut, bi v cc c cu cn thit kt ni cc b phn thng t hn nhiu so vi nhng yu cu trong gia cng v qu trnh hnh thnh. iu ny p dng i vi chnh xc v cng ca khung my mc v thit b dn hng. Trong cc h thng lp rp cc b phn cn phi c cung cp, di chuyn c xu hng a dng, nhiu v nhy cm hn trong h thng sn xut khc. Trong qu trnh pht trin cc h thng lp rp cng nghip, c su hnh dng c bn c to ra p ng s a dng ca cc cng vic kt qu. Hnh 7.2 phn loi cc khi nim ny vo h thng lp rp cng (ch yu l t ng) v linh hot (ch yu l th cng). Hai nhm ny sau c phn loi thm theo sn lng (sn phm / gi) v s phc tp ca sn phm (th hin trong s nhng linh kin lp rp). S khc bit c bn gia hai nhm vi cc h thng t ng cng nhc, trng tm l thit k k thut, trong khi vi cc h thng hng dn s dng linh hot, b tr cng vic ca nhn vin chim u th. N c th c thy r trong hnh. 7,2 rng cc gii hn ca t l u ra cho mt h thng hng dn s dng l khong 720 sn phm mi gi, tng ng vi mt thi gian chu k ca nm giy. Trong so snh vi mt h thng t ng (vi ngoi l ca ci gi l t ng tc cao)
flexibility
manual assembly
rigid assembly
gii hn l 1800 sn phm / gi v do thi gian mt chu k ca hai giy. Yu t tip theo c xem xt lin quan n cc h thng l tnh linh hot ca h thng.
press assembly fixture P5 P4 P3 P2 P1 turntable 2 for 6 bins (bulk ware) P6 turntable 1 for 18 produ cts
joint position
m m
placement final product
s linh hot cng d dng kim sot bng cch ko di hoc rt ngn lch trnh hot ng hng ngy. Ni tm li iu cn ch y l s cn i mt t l ln ca khng gian lp rp cc thnh phn c th c ti s dng. thit lp cho sn phm khc, ch c sn phm lp rp mi cn c thay i.
base parts
final products
Fig. 7.4 a,b Mt mnh dng lp rp trm thay i thit b cung cp cho cc b phn b
Tt c nhng g cn thit thay i v tr cng vic l mt chuyn ng c th ti thiu , theo khu vc lm vic vn cn trong khu vc quan st ca ngi lao ng. Kh nng thay i ca khi nim ny my trm c lin quan n cc bin th ca sn phm t c bng cch loi b cc thit b phn cung cp ton b t bng ti dn hng bng bi v thay th n vi mt s khc c thit lp . Thi gian chuyn i yu cu t mt trong nhng sn phm mi l cc k ngn . Tuy nhin, s linh hot khi lng khng ln hn so vi lp rp thit lp linh hot.
a
variant determining items (picked to light)
packing shipping
PC + printer
entrance
Cc h thng lp rp c thit k cho vic ny (Hnh 7.5) bao gm hai phn: khu vc vn hnh v dy chuyn lp rp thc t . Cc thnh phn khc nhau ph thuc c lu tr trong khu vc vn hnh, c t chc nh mt siu th , trong khi cc b phn trung lp bin th c cung cp cng dy chuyn lp rp s dng . Dy chuyn sn xut c hon thnh trong cc bc sau: khu vc vn hnh c trang b vi mt my tnh v mt my in . Ngi lao ng di chuyn cc sn phm lp rp hon chnh, kim tra sn phm tr v v t n vo cc dy chuyn ng gi . Ngi tip sau gi th t tip theo trn my tnh , in ln lt mt nhn nhn dng , m sau c t trn cc bng ti ti mt im xc nh trc. H thng " chn vi nh sng" cng c kch hot . N bao gm hin th nh sng trn mi hp ch ra cho ngi cng nhn cc b phn cn c chn v t trn cc bng ti mt phn trng cho cc bin th tip theo . c c khng gian cn thit cho cc b phn , B phn di chuyn c ghp trc sau hoc mt phn kt hp c bng ti vn chuyn nh m t trong hnh . 7.6. di chuyn mt phn c s hoc vt c nh lp rp t trn , c th hin trong hnh . 7.6a trong khi vic ni rng di chuyn c minh ha trong hnh . 7.6b . Nhng tm di chuyn cng gi nhng mn ph thuc bin th trong mt loi u vo v trong trng hp ny c phn vng cho sn phm . Nu sn phm l phc tp hn v c phn bin th c th hn cn phi c gn kt , th ta c th kt hp thm nh trong hnh . 7.6c . Ngi cng nhn ti ni bng ti vn chuyn s thm cc b phn trong cc ti ng trn cc tm di chuyn. Mt phn c ly ra t hp tng ng trong khu vc lm vic, mn hnh hin th nh sng i ra . Khi tt c
Fig. 7.6 ac Part carrier sys- tem for versatile products assembly
n tt , di chuyn c c a tr li dy chuyn lp rp. Sau , ngi cng nhn sp xp li cc tm di chuyn ln bng ti v ghp chng li ph hp vi dng sn phm s c lp rp. Khi nim ny c tnh linh hot cao nh nhau c hai u lin quan n s lng tm cng nh s lng ca cc bin th . Cc thnh phn thc hin cng v cng kh dng. Hn na, n c th d dng ni ghp li , bi v chng c tnh linh hot cao v c ch to theo tiu chun. Trong khi nim v tm di chuyn cc bin th t c bng cch thay i mt phn . T l sn xut c th c thay i bng cch b tr mt, hai hoc ba nhn vin trong vng trn bn trong ca h thng.
Fig. 7.7 Modular system for linear transfer assembly lines (Courtesy Teamtechnik)
Fig. 7.8 Extension stages of linear transfer assembly lines (Courtesy Teamtechnik)
Mt khc , kch thc ca h thng cng c th c gim theo cng mt cch khi s lng ca sn phm gim trong giai on cui vng i ca n . Do vic xy dng tiu chun ca cc m-un , cc thnh phn h thng m sau khng phi u t chi ph lp rp th h tip theo ca sn phm . Tnh hay thay i i vi t l sn xut c m bo trong khi nim ny bng cch thay i t th cng sang cc trm t ng v / hoc thm hoc loi b trm . im bt li nm trong chi ph tng i cao i vi cc m-un qu trnh nu chng khng cn cn thit na . Ngoi ra nu thi gian tn ti ca sn phm ngn hn nhiu hn so vi gii hn k thut ca cc m-un vic ti s dng cc m-un s tr thnh vn .
Chi ph lp rp trn mt n v sn phm 0,30 USD. Thi gian hon vn u t khng qu 5 nm. C mt h thng lp rp t ng v mt lai ang c ln k hoch v so
snh vi nhau. i vi vic lp rp t ng , bng 80% s dng, vn u t ca 1,6 triu USD v lp rp n v vi chi ph 0,29 USD vi 2,5 triu chic / nm c xc nh. Cc k hoch cho cng ngh lp rp lai bao gm vic thc hin hai h thng . Tng vn u t c tnh theo 445 000 USD, mc s dng 90 % , v n v 0,245USD. Hnh 7,9 minh ha cc gii php c tm thy cho mt h thng lp rp lai v ba c th m rng giai on bao gm cc tc d liu u ra . Hnh 7,10 gii thch cc qui trnh cng vic trn mt trong nhng my trm lm vic c th . Cc ni dung cng vic ca giai on m rng u tin c phn chia gia my 'A' trm v my trm 'B' . Theo nguyn tc qui trnh linh hot, b tr trc sau vi 12 g lp rp , c ng b ha trong trm. Phn c s c cha trong mt palette. Trn my trm ' A' , 8-10 phn khc nhau c chn bng tay ty thuc vo cc bin th ca sn phm . Cc phn cn li c chuyn sang my trm 'B ' v tip tc di chuyn . y, ngi lao ng bng tay chn phn cn li
station A
station B
output in 14 hrs
+ +
+ +
1,564 pieces
+ +
+ +
3,124 pieces
station B
buffer 2 station C
+ +
+ +
5,040 pieces
Fig. 7.9 Extension stages of a hybrid assembly system (example clamping tool)
station station A
automated station dynamic supply with turn table
station B station B
buffer automated stations
grip bin
P6
P5
P4
P3 P2 P1
T11
+
P7
automated station
P8
P9
P10
cc b phn v ti cng mt thi gian chy cc qu trnh t ng. Sau khi hon thnh, ngi lao ng chuyn sang bng ti tr li my trm 'A' v c chuyn i 12 thnh phm. Chu trnh lp rp sau c khi ng li. T l u ra ca giai on m rng u tin trong mt ch thay i hai trong tng s 14 gi mi ngy lm vic l 1 564 sn phm. Khong 70% ca tng s ni dung cng vic c thc hin trn my trm 'A' v khong 30% my trm 'B'. Trong giai on m rng th hai (xem hnh 7.10) h thng c m rng thng qua mt trm lm vic thm 'C' (mt bn sao ca my trm 'A'). Kt qu l hai nhn vin khc s dng my trm 'B' l bt buc. Vi hai ca, t l sn lng tng 3 124 sn phm mi ngy. Trong giai on m rng th ba, mt s hot ng t my trm 'A' v 'C' cng vi mt nhn vin b sung c giao cho my trm 'B'. T l u ra ca h thng, vi hai ca tng 5040 sn phm mi ngy. tch ring cc my trm lm vic 'A' v 'B' v / hoc 'B' v 'C' b m ln k hoch. iu ny cho php vic trao i ca cc phn gia cc my trm. Vi nhu cu nng cao nng lc, h thng lp rp lai th hai cng c th c tng t nh vy thc hin trong giai on m rng khc nhau. Cc chi ph vn cng c thc hin trong giai on song song vi vic thc hin cc giai on m rng. V vy, i vi mt h thng trong giai on m rng u tin yu cu 127 000 USD giai on th hai m rng 54 000 USD giai on m rng th ba 41 500 USD. i vi mt h thng th hai, chi ph vn c th c d kin s tng t. Trong hnh. 7,11, xu hng ca cc chi ph lp rp nh l mt chc nng ca sn lng sn xut, cho c h thng hon ton t ng v h thng vi ba trm lai c so snh.
2.0
1.8 1.6 1.4 assembly costs [/piece] assembly automat
1.2 1.0 0.8 0.6 hybrid system 1 0.4 0.2 0.245 0.0 1 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 output [pieces/day]
Fig. 7.11 Comparison of assembly costs for automated vs. hybrid system (example)
Nhng li th c bn ca cc gii php lai l: tnh chi ph lp rp 0,245USD lun thp hn so vi h thng t ng , chi ph vn r rng thp hn, v trong trng hp ( thng xuyn quan st ) , ni t l sn xut khng ln vn u t l thp hn . Tng t nh phn tch cc hng mc lp rp khc ch ra rng v d ny khng l ngoi l . D liu trong by v d c s dng so snh kt qu lp rp t ng v lp rp lai . Cc d liu quy hoch c ch nh trong hnh . 7,12 . S dng cc gi tr tiu chun ha , c chi ph nhn s cng nh cc chi ph c nh v bin c xc nh thng qua chi ph lm vic chun. Ch c thi gian hot ng hng ngy khc nhau.
example item name parts [ ] 12 7 810 12 17 12 25 planned output [ pieces / year ] 2,500,000 2,200,000 2,850,000 500,000 1,500,000 2,300,000 950,000 working schedule [ hrs / day ] 15 15 14 14 22.5 14 15
1 2 3 4 5 6 7
electrical switch electric motor drill chuck (final assembly) water water boiler faucet
250
200
150
100
50
330
300
0 33
1
4 2 aut. 10 hyb. 2 2 aut. aut.
2
4 4 6 6 hyb. hyb. 2 2 aut. aut.
3
8 8 8 8 hyb. hyb.
4
10 2 10 6 2 aut. aut. 6 hyb. hyb. 0.48 0.48 2 2 aut. aut.
5
2 2 12 12 2 aut.
6
5 12 12 hyb. 2 2 aut.
7
4 16 hyb.
product
no. of variants operators/day assembly type assembly type cost per piece []
0.29 hyb. aut. 0.244 0.89 hyb. 0.88 hyb. aut. hyb. 0.244 0.89 0.88
Hnh 7,13 cho thy cc chi ph lp rp tnh trong by v d , chia thnh chi ph c nh v bin . Cc chi ph ca h thng t ng ( ct bn tri ) c so snh vi chi ph ca cc gii php lai ( trong ct bn phi ) . Chi ph n v lp rp v s lng nhn vin trong giai on cng sut cui cng cng c hin th.
Mc thp ca t ng ha trong cc h thng lai tng kh nng ti s dng m-un trong mt h thng mi, sau khi kt thc vng i ca mt sn phm. Kh nng thay i i vi t l u ra ca t ng cng nh lp rp lai c th t c bng cch hoc l tng dn mc t ng ha v / hoc thm hoc loi b cc m-un. S khc bit gia cc ty chn ny nm trong s tin vn u t. ng nhin, cng ngh lp rp lai cng c nhng hn ch ca n. Cn c xem xt mc d khi a ra quyt nh: chc chn ca tin lng bn hng trong mi quan h n i sng sn phm, s lng bin th, kch thc l hng, s lng sn xut hng nm, chin lc bn bn hng. Lp rp t ng hiu qu hn khi t l sn xut sn lng cao vi thi gian chu k t hn ba giy l cn thit v doanh s bn hng nht nh. Khi c quyt nh l khng r rng, l khuyn co rng c hai gii php c th c nh gi v so snh.
7.5 Kt lun
H thng lp rp d dng hn thit k cho kh nng hay thay i cao so vi cc h thng sn xut cho cc b phn c kh. Ni chung, chng c b tr m-un khng ch lin quan n cc qu trnh m cn cc chc nng chuyn giao v b m, cng nh h thng kim sot. Cc bin th sn phm c th c x l bng cch chn g mt phn linh hot vo cc khay v gi . Cc s thay i khi lng thng c a v chm sc bi kh nng thay th cc hot ng bng tay ca cc mun t ng v / hoc nhn i cc trm. Xu hng chung l lm cho nhiu thnh phn ca h thng c th c lp vi hnh dng c th ca cc b phn x l. M hnh kinh doanh trong tng lai nhm mc ch cho vic s dng cc khi nim cho thu cc m-un gim vn u t gn lin vi ti sn c nh.
References
Al-Kashroum O., 1998 Einfluss des Arbeitsablaufs bei der Montage (The Impact of Work Flow in Assemblies). Dissertation TU Chemnitz Kinkel S., (ed)2004, Erfolgsfaktor Standortplanung (Success Factors for Location Planning). Springer Verlag, Berlin/Heidelberg Lotter B. et al., 2006, Primr-Sekundr-Analyse (Primary Secondary Analysis). Expert-Verlag Remmingen 2002 Lotter, B; Wiendahl H.-P. (eds.) Montage in der industriellen Produktion. Ein Handbuch fr die Praxis (Assembly in Industrial Production A Practical Handbook). Springer Verlag Berlin/Heidelberg Lotter E., 2006, Hybride Montagesysteme (Hybrid Assembly Systems). In: Lotter B., Wiendahl H.-P. (eds) Montage in der industriellen Produktion Ein Handbuch fr die Praxis. Springer Verlag, Berlin/Heidelberg, Assembly in Industrial Production A Practical Handbook Rosskopf M., Reinisch H., 2004, Prozessmodulare Gestaltung von Produktionssystemen (Design of Modular Process Production Systems). In: Wiendahl H.-P., Gerst D., Keunecke L. (eds) Variantenbeherrschung in der Montage Konzept und Praxis der flexiblen Produktionsendstufe (Mastering Variants in Assembly Concept and Practices of the Flexible Production Final Segment). Springer Verlag, Berlin/Heidelberg, pp 231260