破解智能制造落地瓶颈:基于精益的生产工艺设计方法及案例研究

    Breaking Through the Implementation Bottleneck of Intelligent Manufacturing: A Lean-Based Production Process Design Method and Case Study

    • 摘要: 本研究旨在破解智能制造在复杂装备制造领域落地难的核心瓶颈,即生产工艺缺乏精益设计与标准化的问题。为此,提出并深入探讨基于精益的生产工艺设计方法,聚焦于产品工艺向生产工艺转化的3个关键过程:工序向要素作业的细化、工序向工位的重组以及生产工艺的深度优化。通过A公司包装工序与B企业光学装备装配线的实例分析,采用作业测时、标准作业组合票及改进型工艺流程图等方法,系统验证了该方法的有效性。研究结果表明,该方法可显著提升生产效率与工艺标准化水平:在未增加自动化设备的情况下,使包装工序必要人工数降低19%、装配线人均效率提升420%,并生成可直接支撑智能制造运行的制造物料清单与精细化工艺流程模型。本文所构建的生产工艺精益设计流程,为智能制造的系统化落地提供了可操作的方法依据,突出了通过工艺前端精益化实现制造系统高效化、数字化与智能化的重要路径。

       

      Abstract: This study aims to address the core bottleneck hindering the implementation of intelligent manufacturing in the field of complex equipment manufacturing—namely, the lack of lean design and standardization in production processes. To this end, a lean-based production process design method is proposed and investigated, focusing on three key transformation processes from product process to production process: the refinement of processes into elemental operations, the reorganization of processes into workstations, and the in-depth optimization of production processes. Through case studies of the packaging operation at Company A and the assembly line for optical equipment at Company B, methods such as work measurement, standard work combination charts, and improved process flow diagrams are applied to systematically validate the effectiveness of the proposed approach. The results demonstrate that this method significantly enhances production efficiency and process standardization: without additional automated equipment, the required labor for the packaging operation is reduced by 19%, the per-capita efficiency of the assembly line is increased by 420%, and a manufacturing bill of materials along with a refined process flow model that directly supports intelligent manufacturing operation are generated. The lean production process design framework established in this study provides an operable methodological basis for the systematic implementation of intelligent manufacturing, highlighting the critical path of achieving high efficiency, digitalization, and intelligence in manufacturing systems through front-end lean process design.

       

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