丰田生产方式在液压支架总装线上的应用.pdf

论文题目丰田生产方式在液压支架总装线上的应用 工程领域机械工程 硕 士 生张燕签名 指导教师郭卫签名 胡红斌签名 摘要 本文在对国内外液压支架发展现状与趋势和国内煤矿机械制造企业现行的液压支 架装配生产方式进行调研和分析的基础上， 针对液压支架装配生产组织方式中存在的产 能不足、生产周期长、浪费现象较为突出等问题，将丰田生产方式应用于该企业液压支 架装配生产线的改造，提出改造方案并对关键问题进行了研究。主要研究内容包括 对该公司制造的煤矿用液压支架的结构与装配工艺进行了系统的分析， 进一步明确 了液压支架由零件到组件、部装和总装的生产流程、工艺过程与装配关系；对原有的液 压支架装配生产线的生产组织与管理及生产现状进行了分析， 明确了现行装配生产过程 中存在的问题与不足，以丰田生产方式Toyota Production System，简称 TPS 的理念与 方法为指导，提出了液压支架装配生产线改造的思路；基于以高品质、低成本为“一个 目标” 、 以准时制Jast in time，简称 JIT 和自动化为“两大支柱” 、 以持续改善为“一 大基础”的丰田生产方式基本框架，研究制定了液压支架生产装配区域分区管理方案； 提出了顶梁部装生产线、掩护梁部装生产线改造方案和液压支架总装生产组织管理方 案；确定了实施液压支架生产线改造的具体方法与步骤，对实施过程中所涉及的生产组 织保障、生产依据的制定、沙盘演练方法、现场准备的具体内容等问题进行了研究。 将 本文研究确定的改造方案和实施改造的方法和步骤应用于装配生产线的改造过程， 实践 证明，改造后的液压支架生产线产出方式变化、产量及效率、在制品数量、产品装配质 量等生产管理效果良好，达到了预期目的。 本文的研究方法、生产线改造方案和实施改造的方法与步骤，不仅适用于煤矿液压 支架装配生产方式及生产线的改造， 对将丰田生产方式应用于同类机械设备的装配生产 方式和生产组织管理也具有借鉴意义。 关 键 词液压支架；总装；丰田生产方式；拉式生产模式 研究类型应用研究 万方数据 万方数据 SubjectSubjectSubjectSubject ApplicationApplicationApplicationApplication ofofofof ToyotaToyotaToyotaToyota productionproductionproductionproduction in in in in hydraulichydraulichydraulichydraulic supportsupportsupportsupport assemblyassemblyassemblyassembly linelinelineline SpecialtySpecialtySpecialtySpecialty MechanicalMechanicalMechanicalMechanical EngineeringEngineeringEngineeringEngineering NameNameNameName ZhangZhangZhangZhangYanYanYanYanSignatureSignatureSignatureSignature InstructorInstructorInstructorInstructor GuoGuoGuoGuoWeiWeiWeiWeiSignatureSignatureSignatureSignature HuHuHuHu HongbinHongbinHongbinHongbinSignatureSignatureSignatureSignature AbstractAbstractAbstractAbstract The paper was based on the investigation and analysis of the hydraulic support development status and trend home and abroad and its assembly mode of production existing in the domestic mine mechanical manufacturing enterprises , aiming to solve the existing problems ofshort production capacity, long production cycle and prominent waste phenomenonthat existing the hydraulic supportassembly organizational mode on the author’scompany, then the Toyota production SystemTPS was used in the transation of hydraulic support assembly line, and the re plan was put forward and the key problems were researched. The main research contents of the paper were particularized as below In order to further clarify the production process, technology process and assembly relation of hydraulic support from parts to subgroup, assembly and final assembly process; the structure and assembly process of mine hydraulic support made in this enterprise was systematically analyzed. The organization, management and production status of the old hydraulic supportassemblyproductionline were analyzed, thenthe problems and shortcomings existedin the assembly process were discovered; based on this, the transation train of thought was proposed when the concepts and s of TPS as a guide. The hydraulic support assembly regional partition management scheme were studied and ulated based on the high quality, low cost named “one goal“, the just in time JIT and automation as the “two pillars“, continuous improvement as “one basics“ TPS production framework. The canopy assembly production line, the golf shield assembly production line project and hydraulic support assembly production organization and management scheme were proposed. The specific s and steps of the implementation of transation of hydraulic support production line were determined, and the problem involved in production guarantee, production basis ulation, sand table rcise and site preparation 万方数据 specific content were researched. To use the transation scheme and implementation transation and steps which determined by this study to assembly line process of transation; The results show that, hydraulic support production line production mode transation after the change, yield and efficiency, the quantity and quality of product assembly and other production management effect is good,the expected goal achieved. The research , transation scheme of the production line and the and steps of implementation reconstruction the paper used is not only suitable for coal mine hydraulic support assembly mode and production lines, but also have he reference significance to which have the similar mechanical equipment assembly and production organization and management that take TPS as the guide. KeyKeyKeyKey wordswordswordswords Hydraulic Support; Final Assembly ; Toyota Production System; Pull Production ThesisThesisThesisThesis Applied Researc 万方数据 目 录 I 目录 1 绪论...............................................................................................................................................1 1.1 选题背景及意义................................................................................................................1 1.2 国内外液压支架发展现状与趋势...................................................................................2 1.2.1 国外液压支架发展情况.........................................................................................2 1.2.2 国内液压支架发展情况.........................................................................................3 1.3 国内外液压支架制造技术现状.......................................................................................3 1.3.1 国外液压支架制造技术现状.................................................................................3 1.3.2 国内液压支架制造技术现状.................................................................................4 1.3.3 国产液压支架与国外差距.....................................................................................5 1.4 公司液压支架装配生产存在的问题...............................................................................6 1.5 研究内容与技术路线........................................................................................................7 1.5.1 研究内容..................................................................................................................7 1.5.2 技术路线..................................................................................................................8 2 液压支架的结构与工艺分析......................................................................................................9 2.1 液压支架结构及工作原理............................................................................................... 9 2.1.1 液压支架结构..........................................................................................................9 2.1.2 液压支架工作原理............................................................................................... 10 2.2 液压支架装配工艺分析..................................................................................................11 2.2.1 顶梁组件装配........................................................................................................11 2.2.2 底座组件装配........................................................................................................12 2.2.3 掩护梁组件装配....................................................................................................12 2.2.4 立柱装配................................................................................................................12 2.2.5 千斤顶装配............................................................................................................12 2.2.6 液压支架总装工艺............................................................................................... 13 2.3 本章小结.......................................................................................................................... 13 3 丰田生产方式的理论基础与基本框架...................................................................................14 3.1 丰田生产方式的理论基础.............................................................................................14 3.1.1 丰田生产方式的诞生...........................................................................................14 3.1.2 丰田生产方式的基本理念...................................................................................15 3.2 丰田生产方式的基本框架.............................................................................................16 3.2.1 屋顶的“一个目标”................................................................................................17 万方数据 目录 II 3.2.2 房屋的“两大支柱”................................................................................................18 3.2.3 房屋的“一大基础”................................................................................................21 3.3 实施丰田生产方式的步骤.............................................................................................21 3.3.1 丰田生产方式在国外企业的导入...................................................................... 21 3.3.2 丰田生产方式在国内企业的运用...................................................................... 22 3.3.3 导入丰田生产方式的步骤...................................................................................23 3.3.4 导入丰田生产方式的障碍...................................................................................25 3.4 本章小结.......................................................................................................................... 25 4 液压支架装配生产线改造方案............................................................................................... 26 4.1 液压支架装配生产现状与分析.....................................................................................26 4.1.1 生产现状................................................................................................................26 4.1.2 现状分析................................................................................................................29 4.2 液压支架装配生产线改造思路.....................................................................................33 4.2.1 实施车间分区管理............................................................................................... 33 4.2.2 实时观测现场作业时间.......................................................................................34 4.2.3 实时工位制节拍化生产......................................................................................34 4.2.4 采用标准作业方式............................................................................................... 35 4.2.5 进行生产过程的看板管理...................................................................................35 4.3 液压支架总装车间生产功能区域划分........................................................................ 36 4.4 部件与组件装配方式......................................................................................................37 4.4.1 顶梁组件部装生产线改造...................................................................................37 4.4.2 掩护梁组件装配生产线改造...............................................................................40 4.4.3 立柱生产线改造....................................................................................................43 4.4.4 千斤顶生产线改造............................................................................................... 43 4.6 总成装配生产线的改造................................................................................................. 44 4.6.1 方案一....................................................................................................................44 4.6.2 方案二....................................................................................................................45 4.7 本章小结.......................................................................................................................... 49 5 液压支架装配生产的实施........................................................................................................50 5.1 生产组织保障..................................................................................................................50 5.2 生产依据的制定..............................................................................................................50 5.2.1 制定节拍时间........................................................................................................50 5.2.2 绘制总装价值流程未来图...................................................................................50 5.2.3 工位分割................................................................................................................52 万方数据 目 录 III 5.2.4 物料清单................................................................................................................52 5.2.5 编制标准作业指导书...........................................................................................53 5.3 沙盘演练.......................................................................................................................... 53 5.4 现场准备.......................................................................................................................... 53 5.5 液压支架总成装配线改造方案的实施........................................................................ 55 5.6 本章小结.......................................................................................................................... 56 6 液压支架总成装配丰田生产方式的实施效果...................................................................... 57 6.1 产出方式变化..................................................................................................................57 6.2 产量及效率提高..............................................................................................................58 6.3 在制品数量降低..............................................................................................................58 6.4 物流路径与距离优化......................................................................................................59 6.5 质量提升.......................................................................................................................... 59 6.6 现场响应速度加快..........................................................................................................59 6.7 本章小结.......................................................................................................................... 59 7 结论.............................................................................................................................................60 致谢................................................................................................................................................61 参考文献........................................................................................................................................62 附录................................................................................................................................................64 附表 1......................................................................................................................................64 附表 2......................................................................................................................................65 附表 3......................................................................................................................................66 附表 4......................................................................................................................................68 附表 5................................................