杨志鹏

摘 要：随着全球经济一体化程度的逐步加深，制造业市场竞争愈发激烈。德国为了复兴制造业率先提出工业4.0计划，中国提出中国制造2025计划来提升在制造业领域的国际竞争力。汽车制造环节中总装装配是劳动密集型工艺，劳动量大，装配用时长，场地占用大，对整车制造成本，生产任务完成等均有直接影响，迫切需要推行精益生产来降低成本、提高效益、维持高竞争力。本文以汽车生产线装配工艺为研究对象，针对公司装配工艺的精益性不足，工序分配及装配线布局不合理、线平衡率低等问题展开研究。

关键词：精益生产 装配线平衡 产能

Lean and Line Balance Optimization of Automobile Production Line Assembly Process

Yang Zhipeng

Abstract：With the gradual deepening of global economic integration， the manufacturing market has become increasingly competitive. In order to revive the manufacturing industry， Germany took the lead in proposing the industry 4.0 plan， and China proposed the Made-in-China 2025 plan to enhance its international competitiveness in the manufacturing sector. In the automobile manufacturing process， the final assembly is a labor-intensive process. The labor is large， the assembly time is long， and the space is occupied. It has a direct impact on the vehicle manufacturing cost and the completion of production tasks. There is an urgent need to implement lean production to reduce costs， improve benefits， and maintain high competitiveness. This article takes the assembly process of the automobile production line as the research object， and studies the problems of insufficient leanness of the company's assembly process， such as unreasonable process allocation， assembly line layout， and low line balance rate.

Key words：lean production， assembly line balance， productivity

1 汽车生产线装配工艺存在的问题

某汽车公司市场需求量日渐增加，年销售量在66万以上，年产能在70万以上，每月订单在6万以上。总装车间生产线在5.8万平方米，共有三条生产线。每条线的单件生产工时76s，生产线装配能力与节拍有较大差距。用工艺精益性的标准深入分析装配线的现状后，目前主要存在以下几个问题：

1.1 装配生产线整体工艺配置不精益，存在浪费

某生产线人员配置308人，线速设置76S，单车人工用时HPV6.5h（即一辆车需要用到的人工工时，可在一定程度上衡量生产线整体精益性），生产线产品装配零件数在1200个左右。对整体工艺与某国内主流汽车装配工艺进行具体对比，存在装配工艺设置不精益的问题，最直接的表现就是装配用人多。

1.2 汽车生产线装配布局不合理，局部存在瓶颈

將所有工位的装配时间按顺序排列后，可以用均衡性衡量工位的精益性。……