许金海，朱天波，肖朋，周建力，彭焱婷

摘  要：商用车汽车总装配过程，多多少少都会存在困难作业。减少或消除困难作业，是提升汽车总装配效率的有效途径之一。减少或消除困难作业的程度，体现一个工厂工艺水平的高低;同时消除困难作业可以降低工人劳动强度，提升质量水平。随着我国对环境保护要求力度进一步加大，国六排放标准已经成为强制要求。本文以东风D560国六后处理系统困难作业的分析与解决为例，详细论述了导致该问题的设计原因、部品质量控制原因，装配工艺方法原因等。并针对这些因素制定有效对策，实现困难作业的消除过程。

关键词：问题收集;对比分析;垂直度;辅助工装

中图分类号：U468    文献标识码：A    文章编号：1005-2550（2021）05-0072-04

The Analysis and Solution of the Difficult Operation of the Dongfeng D560 National VI Post-processing System

XU Jin-hai， ZHU Tian-bo， XIAO Peng， ZHOU Jian-li， PENG Yan-ting

（ Dongfeng commercial automobile co.， ltd. vehicles factory， Shiyan 442000， China）

Abstract： In the general assembly process of commercial vehicles， there are more or less difficult operations. Reducing or eliminating difficult operations is one of the effective ways to improve the overall assembly efficiency of automobiles. Reducing or eliminating the degree of difficult operations reflects the level of a factory's technological level; at the same time， eliminating difficult operations can reduce labor intensity and improve quality. As our country's requirements for environmental protection are further increased， the National Sixth Emission Standard has become a mandatory requirement. This paper takes the analysis and solution of the difficult operation of the Dongfeng D560 National VI post-processing system as an example， and discusses in detail the reasons for the design， quality control， and assembly process methods that led to the problem. And to formulate effective countermeasures against these factors to achieve the elimination of difficult operations.

對于商用车总装配，困难作业一直伴随行业存在。对于汽车总装配技术人员，减少或消除困难作业，提升总装配效率是我们技术人员的一项重要而且有意义的工作。

本文以东风商用车KA2N车型的后处理系统为实例，进行困难作业问题收集，困难作业问题分析及对策，展现一个完整的困难作业解决过程。为其他困难作业的解决提供一种分析思路和参考方法。

1    困难作业问题收集

1.1   问题①排气管在下部对接困难

我们从图中不难看出，为了确保从发动机到EGP排气系统热量损失最小化，EGP布置的位置非常靠前。但是这种布置虽然保证了环保性能的要求，但是对于排气管对接相对于国五排气管装配，打破了原有的装配习惯，带来了困难作业。……