摘 要
生产物流是现代化生产的重要组成部分，随着生产力水平的不断提高，生产物流系统中的所蕴藏的巨大潜力越来越引起人们的注意。在提高加工制造设备本身能力与企业效益的同时，挖掘物流的潜力，追求提高生产系统的总体效益已成为现代化生产的重要标志。现代生产物流系统是一个复杂的综合性系统，如何提高其效率和效益是至关重要的，系统仿真作为一项用于系统分析和研究的十分有效的技术，在许多领域都已得到广泛应用。配合计算机仿真，使得对生产过程中的物流系统分析、运作管理、宏观与微观管理领域的研究更具说服力和直观性。
中国的很多机械制造企业，由于各方面的原因的困扰，物流基础设施和物流技术落后、专业人才缺乏，加上企业高层重视不够，造成生产流程混乱、生产效率低下。在此情况下，本文以典型的机械制造企业汽车转向器厂为研究对象，运用系统仿真技术的可试验性、可量化、和快速有效性，配合计算机建模仿真，对该厂的生产过程、生产物流、物料搬运、设备以及车间生产运作情况进行建模仿真和分析。其中，根据该厂的生产系统现状，以及计算机仿真的结果，利用工业工程、物流工程的相关理论和方法，对现有生产物流系统做出评价，提出不同的改进和调整方案。引入当量物流量和玛格数对生产物流进行统一量化，在此基础上，对生产系统物料搬运优化，同时验证仿真中的改进设想。另外本文详细介绍了基于Flexsim 仿真软件的汽车转向器厂生产过程、生产物流建模方法，仿真过程，仿真结果分析和系统优化方案的分析。为中小型机械制造企业进行生产流程重组、生产物流系统优化、提高生产系统柔性、提高生产效率提供建议和问题解决途径。
关键词：生产物流 系统仿真 工艺流程 系统优化
—I — I
Abstract
Production Logistics is important constituent of the modernized production. Along with the productivity level’s unceasing improvement, The production logistics s ystem’s huge potential attacks people's attention day after day. During enhancing manufacturing equipment ’s ability and the enterprise benefit, excavating logistics potential capacity, and pursue the total benefit enhancement of production system has become the important symbol of modernized production .The modernized production logistics system is a complex comprehensive system, how to enhance its efficiency and the benefit is very important, Being the extremely effective technology of system analysis and research, system simulation is widely used in many domains. With computer simulation, making the production process’s logistics system analysis、operation management、the research on macroscopic and the micro management area has the persuasive power and direct-viewing.
Puzzled by the reason of various aspects, many machinery manufacturing enterprise in china have weak logistics infrastructure，underdeveloped logistics technologies and shortage of the expert of logistics, More seriously, high layer administrator of the enterprise didn ’t attach importance to this(only attach importance to the operation of logistics in the two circulation fields of supply and marketing), Which make the production process in chaos and the low production efficiency. Under this background .the paper takes a typical machinery manufacturing enterprise-----Automobile steering factory as an object of study. Use the system sim ulation’s experimentable, quantifiable high-speed and effectiveness, computer modeling and simulation, to model, simulate and analysis the factory’s production process, production logistics, material handling, the equipment as well as the workshop ,manufacturing and operation situation. In this process, according to this factory’s production system situations, as well as the computer simulation results, using the related theory or method of Industrial Engineering and Logistics Engineering, Makes the appraisal to the existing production logistics system, and proposes the different improvement and the adjustment plan. Introducing logistic equivalent and Magnitude to make the unified quantification of production logistics, in this foundation, to optimize material transporting, and proof the improvement assumption in simulation process. In addition, this paper detailed introduces the modeling methods of Automobile steering gear factory’s production process and production logistics ，simulation process, simulation results analysis, system optimization plan analysis basing on Flexsim simulation software. Providing the suggestion and resolution of production process reorganization, production logistics system optimization, it enhances the production system’s flexibility and efficiency to the Mid- and small-scale manufacturing enterprise.
Key Words: Production Logistics ；System Simulation ；Technology Process ；System
Optimization
—II — II
目 录
1 绪 论 ………………………………………………………………………………1
1.1 引 言………………………………………………………………………..1
1.2 研究的背景与意义…………………………………………………………..1
1.2.1 机械制造企业发展现状………………………………………………2
1.2.2 机械制造企业生产物流改进需求…………………………………..3
1.3 现代生产物流………………………………………………………………..4
1.3.1 物流与生产制造……………………………………………………..4
1.3.2 生产物流在整个物流体系中的作用………………………………..5
1.3.3 物流工程在机械制造企业应用与发展………………………………6
1.4 系统仿真技术8
1.4.1 系统仿真技术概述8
1.4.2 现代系统仿真的特点9
1.4.3 系统仿真在生产物流系统研究中的应用10
1.5 研究问题的提出11
2 系统仿真的基本原理与方法 ……………………………………………………..13
2.1 系统仿真基础知识………………………………………………………….13
2.1.1 系统仿真相关技术……………………………………………………13
2.1.2 系统、模型与系统仿真…………………………………………….14
2.1.3 离散事件系统仿真方法…………………………………………….16
2.1.4 系统仿真的一般步骤……………………………………………….17
2.2 现代生产物流系统仿真…………………………………………………….20
2.3 仿真结果的分析…………………………………………………………….22 3 转向器厂生产过程与物流系统 …………………………………………………23
3.1 转向器生产运作流程……………………………………………………….23
3.2 转向器厂部门划分………………………………………………………….24
3.3 汽车转向器生产工艺过程………………………………………………….25
3.3.1 转向器零件明细表………………………………………………….26
3.3.2 汽车转向器生产工艺流程与加工时间…………………………….26
3.4 汽车转向器厂生产物流综合分析…………………………………………27
3.4.1 汽车转向器厂的物流特点………………………………………….28
3.4.2 生产物流环节中存在的问题……………………………………….28
3.5 汽车转向器厂生产物流建模………………………………………………29
3.5.1 汽车转向器厂生产物流系统模型建立的基本要求……………….29
3.5.2 仿真分析的过程…………………………………………………….30
3.5.3 转向器厂生产物流系统模型的建立……………………………….31
3.5.4 转向器厂生产物流系统的离散系统仿真………………………….32 4 基于Flexsim 的生产物流系统仿真 …………………………………………….33
4.1 计算机统仿真软件Flexsim ……………………………………………….33
4.1.1 Flexsim简介………………………………………………………..33
4.1.2 Flexsim基本功能与特点…………………………………………..35
4.1.3 基于Flexsim 的建模………………………………………………..36
—III — III
4.2 建立转向器生产概念模型…………………………………………………38
4.2.1 汽车转向器厂生产物流系统描述………………………………….38
4.2.2 系统数据…………………………………………………………….38
4.2.3 概念模型…………………………………………………………….40
4.3 建立Flexsim 仿真模型…………………………………………………….40
4.3.1 模型实体设计……………………………………………………….40
4.3.2 设置模型的属性和相关参数……………………………………….42
4.4 模型运行与结果……………………………………………………………49
4.4.1 模型运行…………………………………………………………….49
4.4.2 模型运行结果……………………………………………………….50
5 仿真结果分析与物流系统优化 ………………………………………………..53
5.1 转向器生产物流系统优化…………………………………………………53
5.1.1 现有系统的优化…………………………………………………….53
5.1.2 增加系统瓶颈处理能力…………………………………………….57
5.2 生产物流搬运优化方案…………………………………………………..58
5.2.1 生产物流强度的量化计算…………………………………………58
5.2.1 物料搬运的优量化…………………………………………………60
6 结 论 ……………………………………………………………………………63
6.1 全文总结……………………………………………………………………63
6.2 研究结果对企业的改进建议……………………………………………..64
毕业论文心得体会 ………………………………………………………………….. 65
致 谢……………………………………………………………………………….. 66 参考文献………………………………………………………………………………. 67
附图A 汽车转向器厂平面图 ……………………………………………………..68 附表B 汽车转向器厂流量距计算表 …………………………………………….69
附表C 玛格数修正因素及参数值……………………………………………….. 71 附图D 汽车转向器生产工艺流程…………………………………………………. 72
—IV — IV
摘 要
生产物流是现代化生产的重要组成部分，随着生产力水平的不断提高，生产物流系统中的所蕴藏的巨大潜力越来越引起人们的注意。在提高加工制造设备本身能力与企业效益的同时，挖掘物流的潜力，追求提高生产系统的总体效益已成为现代化生产的重要标志。现代生产物流系统是一个复杂的综合性系统，如何提高其效率和效益是至关重要的，系统仿真作为一项用于系统分析和研究的十分有效的技术，在许多领域都已得到广泛应用。配合计算机仿真，使得对生产过程中的物流系统分析、运作管理、宏观与微观管理领域的研究更具说服力和直观性。
中国的很多机械制造企业，由于各方面的原因的困扰，物流基础设施和物流技术落后、专业人才缺乏，加上企业高层重视不够，造成生产流程混乱、生产效率低下。在此情况下，本文以典型的机械制造企业汽车转向器厂为研究对象，运用系统仿真技术的可试验性、可量化、和快速有效性，配合计算机建模仿真，对该厂的生产过程、生产物流、物料搬运、设备以及车间生产运作情况进行建模仿真和分析。其中，根据该厂的生产系统现状，以及计算机仿真的结果，利用工业工程、物流工程的相关理论和方法，对现有生产物流系统做出评价，提出不同的改进和调整方案。引入当量物流量和玛格数对生产物流进行统一量化，在此基础上，对生产系统物料搬运优化，同时验证仿真中的改进设想。另外本文详细介绍了基于Flexsim 仿真软件的汽车转向器厂生产过程、生产物流建模方法，仿真过程，仿真结果分析和系统优化方案的分析。为中小型机械制造企业进行生产流程重组、生产物流系统优化、提高生产系统柔性、提高生产效率提供建议和问题解决途径。
关键词：生产物流 系统仿真 工艺流程 系统优化
—I — I
Abstract
Production Logistics is important constituent of the modernized production. Along with the productivity level’s unceasing improvement, The production logistics s ystem’s huge potential attacks people's attention day after day. During enhancing manufacturing equipment ’s ability and the enterprise benefit, excavating logistics potential capacity, and pursue the total benefit enhancement of production system has become the important symbol of modernized production .The modernized production logistics system is a complex comprehensive system, how to enhance its efficiency and the benefit is very important, Being the extremely effective technology of system analysis and research, system simulation is widely used in many domains. With computer simulation, making the production process’s logistics system analysis、operation management、the research on macroscopic and the micro management area has the persuasive power and direct-viewing.
Puzzled by the reason of various aspects, many machinery manufacturing enterprise in china have weak logistics infrastructure，underdeveloped logistics technologies and shortage of the expert of logistics, More seriously, high layer administrator of the enterprise didn ’t attach importance to this(only attach importance to the operation of logistics in the two circulation fields of supply and marketing), Which make the production process in chaos and the low production efficiency. Under this background .the paper takes a typical machinery manufacturing enterprise-----Automobile steering factory as an object of study. Use the system sim ulation’s experimentable, quantifiable high-speed and effectiveness, computer modeling and simulation, to model, simulate and analysis the factory’s production process, production logistics, material handling, the equipment as well as the workshop ,manufacturing and operation situation. In this process, according to this factory’s production system situations, as well as the computer simulation results, using the related theory or method of Industrial Engineering and Logistics Engineering, Makes the appraisal to the existing production logistics system, and proposes the different improvement and the adjustment plan. Introducing logistic equivalent and Magnitude to make the unified quantification of production logistics, in this foundation, to optimize material transporting, and proof the improvement assumption in simulation process. In addition, this paper detailed introduces the modeling methods of Automobile steering gear factory’s production process and production logistics ，simulation process, simulation results analysis, system optimization plan analysis basing on Flexsim simulation software. Providing the suggestion and resolution of production process reorganization, production logistics system optimization, it enhances the production system’s flexibility and efficiency to the Mid- and small-scale manufacturing enterprise.
Key Words: Production Logistics ；System Simulation ；Technology Process ；System
Optimization
—II — II
目 录
1 绪 论 ………………………………………………………………………………1
1.1 引 言………………………………………………………………………..1
1.2 研究的背景与意义…………………………………………………………..1
1.2.1 机械制造企业发展现状………………………………………………2
1.2.2 机械制造企业生产物流改进需求…………………………………..3
1.3 现代生产物流………………………………………………………………..4
1.3.1 物流与生产制造……………………………………………………..4
1.3.2 生产物流在整个物流体系中的作用………………………………..5
1.3.3 物流工程在机械制造企业应用与发展………………………………6
1.4 系统仿真技术8
1.4.1 系统仿真技术概述8
1.4.2 现代系统仿真的特点9
1.4.3 系统仿真在生产物流系统研究中的应用10
1.5 研究问题的提出11
2 系统仿真的基本原理与方法 ……………………………………………………..13
2.1 系统仿真基础知识………………………………………………………….13
2.1.1 系统仿真相关技术……………………………………………………13
2.1.2 系统、模型与系统仿真…………………………………………….14
2.1.3 离散事件系统仿真方法…………………………………………….16
2.1.4 系统仿真的一般步骤……………………………………………….17
2.2 现代生产物流系统仿真…………………………………………………….20
2.3 仿真结果的分析…………………………………………………………….22 3 转向器厂生产过程与物流系统 …………………………………………………23
3.1 转向器生产运作流程……………………………………………………….23
3.2 转向器厂部门划分………………………………………………………….24
3.3 汽车转向器生产工艺过程………………………………………………….25
3.3.1 转向器零件明细表………………………………………………….26
3.3.2 汽车转向器生产工艺流程与加工时间…………………………….26
3.4 汽车转向器厂生产物流综合分析…………………………………………27
3.4.1 汽车转向器厂的物流特点………………………………………….28
3.4.2 生产物流环节中存在的问题……………………………………….28
3.5 汽车转向器厂生产物流建模………………………………………………29
3.5.1 汽车转向器厂生产物流系统模型建立的基本要求……………….29
3.5.2 仿真分析的过程…………………………………………………….30
3.5.3 转向器厂生产物流系统模型的建立……………………………….31
3.5.4 转向器厂生产物流系统的离散系统仿真………………………….32 4 基于Flexsim 的生产物流系统仿真 …………………………………………….33
4.1 计算机统仿真软件Flexsim ……………………………………………….33
4.1.1 Flexsim简介………………………………………………………..33
4.1.2 Flexsim基本功能与特点…………………………………………..35
4.1.3 基于Flexsim 的建模………………………………………………..36
—III — III
4.2 建立转向器生产概念模型…………………………………………………38
4.2.1 汽车转向器厂生产物流系统描述………………………………….38
4.2.2 系统数据…………………………………………………………….38
4.2.3 概念模型…………………………………………………………….40
4.3 建立Flexsim 仿真模型…………………………………………………….40
4.3.1 模型实体设计……………………………………………………….40
4.3.2 设置模型的属性和相关参数……………………………………….42
4.4 模型运行与结果……………………………………………………………49
4.4.1 模型运行…………………………………………………………….49
4.4.2 模型运行结果……………………………………………………….50
5 仿真结果分析与物流系统优化 ………………………………………………..53
5.1 转向器生产物流系统优化…………………………………………………53
5.1.1 现有系统的优化…………………………………………………….53
5.1.2 增加系统瓶颈处理能力…………………………………………….57
5.2 生产物流搬运优化方案…………………………………………………..58
5.2.1 生产物流强度的量化计算…………………………………………58
5.2.1 物料搬运的优量化…………………………………………………60
6 结 论 ……………………………………………………………………………63
6.1 全文总结……………………………………………………………………63
6.2 研究结果对企业的改进建议……………………………………………..64
毕业论文心得体会 ………………………………………………………………….. 65
致 谢……………………………………………………………………………….. 66 参考文献………………………………………………………………………………. 67
附图A 汽车转向器厂平面图 ……………………………………………………..68 附表B 汽车转向器厂流量距计算表 …………………………………………….69
附表C 玛格数修正因素及参数值……………………………………………….. 71 附图D 汽车转向器生产工艺流程…………………………………………………. 72
—IV — IV