From improving welding capacity to improving welding efficiency

In the automotive welding shop, eliminating the bottleneck of the welding line, improving and shortening the standard working time, reducing the welding time and increasing the operator and tooling equipment under certain conditions without major transformation or investment Effective measures to increase welding capacity. These methods not only increase productivity, but also promote productivity and efficiency.

The origin of the problem

Like other consumer durables, cars have their product life cycle. Throughout its life cycle, based on scientific predictions and tracking of market reactions, rationally identifying and adjusting production line capacity is an important part of reducing investment, improving efficiency, and increasing return on investment. In general, the ideal capacity should match the market demand. But in fact, it is difficult to achieve flexible production capacity. In order to maximize the utilization rate of production capacity and reduce investment risks, enterprises tend to make the production capacity of the first phase of investment more conservative. After that, according to market feedback, the second or even third phase of the transformation will be carried out to achieve the capacity production of the market demand.

When an investment reaches the market demand capacity, this kind of investment requires extremely high accuracy in market forecasting, and it is easy to generate the risk of overcapacity and reduced investment utilization. In the growth phase of the product life cycle, the capacity is re-engineered according to market demand to meet market demand. Generally speaking, this method of secondary investment brings about less waste of overcapacity than one investment, and the risk is also small. However, the secondary capacity transformation should try to avoid the suspension or adopt the production plan to not affect the sales. Short-term stoppage of the car. Due to changes in market demand, the first-stage production capacity can no longer meet the market demand before the second capacity transformation. This is also the problem that this paper focuses on. Additional capacity (capacity III) is formed by the approach taken in this paper.

Increase productivity and increase efficiency and efficiency

In the four major processes of automobile manufacturing, it is difficult to say which process is destined to be the bottleneck. Generally speaking, from the perspective of reducing investment, because the investment in the welding shop is relatively high, the welding shop often becomes the bottleneck of the whole vehicle manufacturing process. For the welding shop, each production line will also have its own bottleneck. Eliminating these bottlenecks can increase production speed and increase production capacity within a certain range, thereby driving the efficiency and efficiency of the entire production line and the entire production process.

The first step is to eliminate the bottleneck by measuring the time-by-station time of the entire production line, sorting by time, and defining the station with the longest time and failing to meet the new beat requirements as the bottleneck station. Then, time analysis is performed on the bottleneck station one by one, and each processing operation step of each processing person of the bottleneck station is analyzed. See if there is a problem of mutual cooperation, whether there is more waiting time, whether there are operations that can be transferred or broken down to other non-bottleneck stations, especially for those critical paths.

The elimination of the bottleneck station also needs to be carried out systematically to avoid creating new bottlenecks after the existing bottlenecks are eliminated. Usually, when eliminating a bottleneck station, it is often necessary to analyze several stations before and after it. With the application of virtual manufacturing technology in the production phase of production, without increasing tooling, equipment or personnel, the possibility of increasing production tempo only by process and step balance will become smaller and smaller.

When the bottleneck is eliminated, the bottleneck elimination mentioned here means that there is no obvious bottleneck in the entire production line, or when the total number of bottleneck stations in the entire production line exceeds 30% of the production line, the efforts to further eliminate the bottleneck will not There will be obvious effects. Improving standard operating time will be another way to further increase productivity and efficiency. The standard operating time here refers to the average time required to complete related operations and actions for a specific group of people after receiving standard job training. The standard operating time is the basis for the engineering staff to prepare the process documentation. In the welding shop, it includes pre-test time, glue time, assembly time, positioning and clamping time, welding time, inspection time, transit time and other related auxiliary time.

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