Detailed information of assembly line

Assembly line, also known as assembly line, an industrial production method, refers to each production unit to focus on dealing with a certain segment of the work, in order to improve efficiency and yield; according to the assembly line can be divided into the conveyor mode: belt assembly line, plate chain line, times the speed of the chain, the outside of the program line, the mesh belt line, the suspension line and the roller assembly line of the seven types of assembly line. Generally include traction parts, load-bearing components, driving devices, tightening devices, redirection devices and support parts and other components. The assembly line is highly scalable, can be designed according to the demand for conveying capacity, conveying speed, assembly stations, auxiliary components (including quick connectors, fans, lights, sockets, process boards, shelves, 24V power supply, wind batch, etc., and is therefore widely welcomed by the enterprise; the assembly line is an effective combination of people and machines, the most fully reflect the flexibility of the equipment, which will be the conveyor system, the accompanying fixtures and special machines on the line, the combination of testing equipment organic In order to meet the requirements of multi-species product transportation. Conveyor line transmission mode has synchronous transmission / (mandatory), can also be non-synchronous transmission / (flexible), according to the configuration of the choice, can achieve the requirements of the assembly and conveyor. Conveying line is indispensable in the mass production of enterprises.

Basic introduction Chinese name ：Assembly line Foreign name ：Assembly line Alias ：Assembly line, production line Composition ：Traction bearing support parts Driving tightening device From, the advantages of the assembly line, the characteristics of the assembly line, the form of the assembly line, the optimization of the knowledge of the equipment, a variety of assembly line features, transport storage, Q & A, features, operating procedures, computers, From In 1769, the Englishman Josiah Wedgwood opened Etruscan ceramics factory, in the field of the implementation of fine division of labor, he was originally by a person from start to finish the process of pottery production into dozens of specialized processes, respectively, completed by specialists. In this way, the original sense of the "potter" no longer exists, there are only diggers, transport mud workers, dress soil workers, billeting workers and other ceramic craftsmen into a ceramic workshop workers, they must be in accordance with a fixed rhythm of labor, subject to the unified labor management. (Based on the above information, it is clear that Wedgwood's method of work can be fully defined as an "assembly line". Another theory is that Henry Ford invented the assembly line assembly process, which is obviously inaccurate, because Henry Ford was born in 1863, more than ninety years later than Wedgwood's life, almost a century.) Advantages of the assembly line 1. Integration of the production process, can be arranged in the assembly line a variety of workstations to meet the production needs; 2. High scalability, according to the needs of the factory, the design of the assembly line to meet the production needs of the product; 3. Saving the factory's production costs, can be a certain degree of saving the number of production workers, to achieve a certain degree of automation of the production, the initial investment is not large, the rate of return is high. Characteristics of the assembly line 1. High degree of specialization of the workplace. 2. The process is closed, the workplace is arranged according to the process sequence, the object of labor in the process to do one-way movement 3. The processing time of each process with the proportion of the number of workplaces in each process. 4. Each process is in accordance with the uniform rhythm of production. The so-called beat refers to the production time interval between two adjacent products. The form of assembly line According to whether the production object is mobile, can be divided into fixed assembly line and mobile assembly line. According to the number of production varieties, can be divided into a single species production line and multi-species production line. According to the degree of production continuity, can be divided into continuous production line and intermittent production line. According to the realization of the rhythm of the way, can be divided into forced beat production line and free beat production line. According to the degree of mechanization, can be divided into manual, mechanized and automated three kinds of assembly line. Optimization assembly line in industrial production plays an important role, optimization assembly line is directly related to the quality of products and production efficiency, so it has become a topic that enterprises have to pay attention to. 1, optimization of the first station of the assembly line operating time, and how long to put a board, this is to meet the production schedule of the necessary input cycle time. But in reality, the bottleneck station's operating time is necessarily greater than the first station, the first station must not be the bottleneck station, so the first station may not be completely in accordance with the requirements of the cycle time to input, because the bottleneck station has slowed down his speed, so from the management point of view, we must really require the first station operators in accordance with the required speed input. The speed of the conveyor belt in the assembly line can also be deduced from the daily output, the following formula for the speed of the conveyor belt: Conveyor belt pitch time = the whole day's work time / daily output * (1 + defective rate) Conveyor belt speed = marking the distance between / conveyor belt pitch time The so-called marking the distance between, in the assembly line of the distance between the marking of the belt, hope that the operator in accordance with the speed of the marking of the speed of the flow through the completion of the work and placed on the belt line; The so-called marking the distance between, in the line of the marking between, hope that operators in accordance with the speed of the marking through the completion of the The distance between the marks is made on the belt of the assembly line, and the operator is expected to finish the work according to the speed at which the marks flow and place them on the belt line; however, the refining line is not marked, so the length of the board is used as the distance between the marks. Why conveyor belts? In addition to the transportation of goods, there are also semi-mandatory operators in accordance with the plan to complete the operation of the function, but not just speed up to try, but should be calculated in accordance with the above formula to find out. 2. Observe which station on the assembly line is the bottleneck station: (1) the station that is always busy; (2) the station that always pulls the boards back; (3) from the station, the original boards one after another, there is a gap in the middle. The above three points can be seen visually, and then measured with a stopwatch, the operation time is the longest among all stations. Bottleneck station's operating time becomes the actual output of the entire assembly line cycle time, and the daily output formula is as follows: daily output = actual day's work time / inter-cycle time Therefore, as long as the field officers to reduce their operating time, you can significantly improve the output, such as parts to other stations to do some of the use of tools to save the action to improve the operation of the field of the configuration, and so on. But after solving the bottleneck station, there may be a new bottleneck station, so we need to improve the new bottleneck station, so continue to focus on the bottleneck station to improve, the efficiency of the entire assembly line will be improved day by day. 3、Observe the cycle time of the last station of the assembly line to collect the boards, that is, the cycle time of the actual output, the cycle time of this station must be equal to the bottleneck station. From this station can be deduced from the efficiency of this assembly line line, the formula is as follows: Efficiency = input cycle time / actual cycle time = the first station's operating time / the last station's operating time Of course, we can also use the bottleneck station's operating time to calculate, but observation of the last station is always simpler and more practical. In the assembly line is equal to the number of work in progress: ( the last station of the operating time - the first station of the operating time ) * ( the whole day's work time / the last station of the operating time ) 4, the observation of the rate of crop crop rate = in the operation of the time / the whole day's work time The so-called crop is the effective work on the assembly line, the operator sits in the seat does not mean that he has in the work, there is a work in order to make the product, so to observe the operator in the operation of the time to work. Therefore, it is necessary to observe the working time of the operator. But in practice, it is not possible to measure each operator throughout the day, so there is a kind of work sampling techniques to simulate the measurement, in fact, to put it bluntly is to see from time to time to see what the operator is doing. 5, assembly line operators sitting on the seat does not mean that he has to work seriously, so the last is to observe the speed of each operator's work, speed is a very abstract concept, just from the visual is difficult to compare and quantify, so in the heart of the establishment of a standard speed, faster than it is considered good, streamlined, fixed and rhythmic action, often have a better speed of operation, and the opposite is not good, so to observe the It is simpler to observe in this way. The assembly line operation is not fast is good, its action must be added value, so it also depends on whether the action is simple and concise, so the concept of the principle of economy of movement is required, in simple terms, human hand movements can be divided into moving, holding, releasing, front, organization, use, disassembly, as well as a kind of mental mental role, which, strictly speaking, there are only two types of action has added value: organization, use, so In order to meet the production requirements of the conditions, try to exclude or simplify other actions. The principles are as follows: 1, move: so that the material automatically to the desired location, shorten the distance to move, reduce the weight of the items to be moved, move around the path to avoid things that would impede the movement, so that the box is placed diagonally to shorten the distance around the edge. 2, grip: the material in the box as much as possible neatly discharged, do not clutter the pile, it is not convenient to pick up things can be reserved for the first holding space. 3、Forward: The same as the grip, the material in the box can be discharged as neatly as possible, do not messy pile up. 4、Organization: Replace manual work with tools. 5、Usage: Make the machine fully automated. 6、Spiritual role: the use of machinery to replace human judgment, reduce the operator's eye movement. The assembly line installation considerations: the layout of the assembly line should ensure that the shortest route for the transportation of parts, production workers to facilitate the operation of auxiliary services to facilitate the work of the department, the most effective use of the production area, and to consider the interconnection between the installation of the assembly line. In order to meet these requirements, in the assembly line layout should be considered in the form of assembly line, assembly line installation workplace arrangement method and other issues. Assembly line installation workplace arrangement should be consistent with the process route, when the process has more than two workplaces, to consider the same process workplace arrangement method. Generally when there are two or more than two even number of the same kind of workplace, to consider the use of double row arrangement, they will be divided into two cases in the transportation route. However, when a worker to look after more than one piece of equipment, it is necessary to consider making the worker move as short a distance as possible. Knowledge of equipment Knowledge of assembly line equipment provides you with professional assembly line equipment, production line equipment, assembly line equipment related concepts and knowledge, as well as assembly line related equipment, such as conveyors, conveyor belts, and other equipment concepts and methods of operation, to facilitate the correct use and maintenance of your assembly line equipment. Features of chain assembly line: 1. Chain assembly line uses chain as traction and carrier to convey materials, and the chain can adopt ordinary sleeve roller conveyor chain or other kinds of special chains; 2. large conveying capacity, can carry large load; 3. accurate and stable conveying speed, can ensure precise synchronous conveying; 4. easy to realize accumulation conveying, can be used as assembly production line or storage and conveying of materials; 5. can be used in various kinds of conveyor lines, can be used in various kinds of assembly lines, can be used in various kinds of assembly lines, can be used in various kinds of assembly lines, can be used in various kinds of assembly lines, can be used in various kinds of storage and conveying of materials; 6. It can be used as assembly line or as material storage and conveying; 5. it can work in all kinds of bad environments (high temperature, dust), and its performance is reliable; A. it is made of special aluminum profiles, and it is easy to be installed; B. it has beautiful structure, and low noise; C. it is multi-functional, and it has a high degree of automation. Production assembly line The production assembly line is characterized by specific people to complete each process, step by step processing． Each person does a specific job. The advantage is that production is faster because each person only needs to do one thing and is very familiar with what he or she is doing. The disadvantage is that the people working will feel very boring. Various assembly line features Plate chain assembly line Features: the bearing of the product is heavy, and the production line is synchronized to run, you can achieve the product climbing; production beat is not very fast; the chain plate surface as a bearing, you can achieve the smooth delivery of the product. Roller type assembly line Features: carrying a wide range of product types, subject to fewer restrictions; used in conjunction with the blocker, the product can be realized continuous, rhythmic operation and accumulation of the function; the use of lifting and panning device, you can realize the product offline repair or testing without affecting the operation of the entire assembly line. Belt type assembly line features: carrying products lighter, less shape limitations; and production line synchronization, can realize the product climbing steering; with the belt as the carrier and conveying, can realize the smooth conveying of the product, noise is small; can realize the light materials or products longer distance conveying. Differential Conveying Line Features: Differential Conveying Line adopts speed chain traction, the workpiece board can be transmitted freely, the use of blocker positioning to make the workpiece free movement or stop, the workpiece can be automatically jacked up at both ends, and traverse transition. It can also be installed on the line body or beside the line body to rotate (90 degrees, 180 degrees...). The line can also be equipped with rotary (90 degree, 180 degree...), specialized machines, testing equipment, manipulators and other devices on or beside the line. Transportation and storage During transportation, the products of the assembly line should comply with the relevant regulations of the transportation department, and should not be in contact with acid and alkali. Driving device, electrical equipment should avoid scraping, touching, falling and other violent vibration and impact. During the storage period should be taken to prevent rain, moisture-proof measures, storage should be placed in a sheltered warehouse. Packaging line Technical Description: Packaging line with lights with fan packaging production line and packaging line with lights, general with lights with fan packaging production line with a wider range of sets, the operation is simple. Mainly used in electronic factories, small hardware factories, toy factories and other packaging workshop. The two sides are seated, the center is a worktable with conveyor belt. Improve production efficiency, greatly reduce labor, wages Usage and characteristics: the packaging production line is composed of cover-type adsorption corrugator, paper frame, glue machine, double-sided machine, paper cutter, preheating roller, double-layer bridge, glue machine and other components. It is characterized by high degree of automation, convenient operation and maintenance, high production efficiency, good cardboard quality, compact structure and beautiful appearance. The process of packaging production line: 1. automatic packaging scale 2. automatic bag feeding machine 3. bag clamping device 4. folding and sewing machine 5. heat laminating machine 6. conveyor 7. bag pouring machine 8. metal detecting machine 9. weight detecting machine 10. rejecting machine 11. car conveyor 12. inclined conveyor 13. palletizing machine 13+ robot palletizing machine 14. automatic control cabinet Q&A 1: Must the assembly line be always from left to right or from right to Q&A 1: Does the assembly line always run from left to right or from right to left? Generally speaking, the assembly line flows from left to right because most people are used to the right hand. However, due to space constraints in some factories, it is possible that at least one of the two or more lines will flow in the opposite direction. 2: Is a U-shaped assembly line the most suitable? Not necessarily, the layout of the production line must be based on the characteristics of the product and process. 3: The faster the speed of the assembly line, the higher his capacity? The level of production capacity should depend on the operating time of the bottleneck process and the fastest operating time of each station, if forced to increase the speed of the production line will cause many problems. 4: Is an assembly line designed to move products? Not exactly. The ultimate goal is to realize the "continuous value flow" of products. 5: Why is the production lower at the beginning of the shift or during the changeover period? It is a preparation phase and a time when problems occur. Therefore, the management of shift changeover is very critical. 6: Does the speed setting of the flow line have to be constant? How about every day? It should be constant in the same product category, but when different products are produced in the same line, there will be changes in the speed. At the same time, because of the problem of new employees, the line speed will be reduced a little. 7: Is it possible to put only one product in each frame of the Pitch mark? Not necessarily. Smooth production flow should be pursued 8: Is the faster the processing speed of pre-assembly the better? Is it better to have more buffer stock? No. Production should be on demand. However, the processing speed of pre-assembly can be slightly faster than the assembly speed. 9: Is it right for an assembly line to facilitate the detection of backlogs, for a Kanban board to show progress, and for a line manager to urge employees to do things faster? The first two are right, but the third is not necessarily, in the case of normal production beat should not urge the staff, which will cause some unnecessary problems (such as: urging the staff to make the work of the hand changes, the check is ignored) 10: line manager said that some people take a leave of absence, can not be lined up right? If we can't borrow someone, is it okay to let employees work separately? First of all, the assembly line is strictly speaking less a person's cooperation and cooperation will not be able to complete all subsequent operations. If one person is missing from one section, there will be a drop in production, but not much. Also where is the emergency response to this situation? If a manager doesn't consider these common problems, how can he run a factory? 11: Who is more reasonable, employees producing standing or sitting? Depends on the product/conditions/facilities 12: Should the containers on the flow line be specialized or generalized and what is his size! Should be designed for most general purpose, not general purpose specialized treatment. 13: The height and width of the flow line and the height and width of the machine how much more reasonable? In accordance with ergonomic principles, seated table height 65 ~ 75CM, seat 38 ~ 45; standing table 85 ~ 95CM, seat 58 ~ 62, and 20 ~ 30 table plate to put feet. Features What is single piece flow line? Single-piece assembly line is also called unit synchronous flow, single-piece assembly line is the personnel, equipment, logistics for the integrated and effective use of organized, planned, targeted progress of each unit balanced production! In production activities, the production batch to a batch, before and after the process without stopping, each completed a process of self-checking a process, the delivery of a production method is called a stream of production, referred to as single-piece flow. The characteristics of the single-piece assembly line 1, target management: capacity targeting, by the industrial engineering staff to the product of each unit (process) for the target capacity setting; 2, time management: time quantization, by the industrial engineering staff to the product of each unit (process) for the target operating time setting; 3, the finished product out of the fast, rapid response to quality problems, zero batch quality accidents; 4, the front push and pull: it is different from traditional production methods, the traditional production methods, the traditional production methods, the traditional production methods, the traditional production methods, the traditional production methods, the traditional production methods, the traditional production methods, the traditional production methods, the traditional production methods, the traditional production methods. Production is different from the traditional production methods, traditional production methods, the production line is passive, can only wait for the former department of materials, cutting, embroidery, printing to determine the normal operation of production, while the single-piece assembly production it is in the active, the former process must meet the production line, all for the production and planning. Forward push, not just the front push on the flow, it includes orders, material supply, product reprocessing. Pull back, in order to meet customer demand, pull the whole production and supply chain pull. Operating procedures (a) equipment operators must be proficient in all kinds of mechanical structure, performance and operation, maintenance methods, to achieve the use of specialists, specialists are responsible for. (B) the operation of woodworking machinery, should wear good overalls, tighten the cuffs, lesbians must wear a good hat, braid into the hat; not allowed to wear gloves, scarves, etc. for the operation. (C) machinery before starting work must be a test drive, the normal operation of the components before starting work. Note: If one or two ignition can not; it is best to turn on the burner fan empty for a while to the gas gas discharge in the furnace chamber before the second trial. (D) equipment on the shaft, chain, pulley, belt and other operating parts, should be set to protect the shield and protective plate. (E) mechanical operation in the event of abnormalities or other failures, should immediately cut off the power supply, stop the car for maintenance. (F) Most of the equipment is surrounded by flammable products, and fire should be strictly prohibited. (G) Debugging maintenance equipment, must cut off the main power. (viii) Please hurry to bring children to play in the assembly line. Computer The computer assembly line was first used by Intel in the 486 chip. The assembly line works like an assembly line in industrial production. An instruction processing pipeline is formed by 5-6 circuit units with different functions in the CPU, and then an X86 instruction is divided into 5-6 steps before it is executed by these circuit units separately, which enables the completion of an instruction in one CPU clock cycle, thus increasing the CPU's computing speed. Classic Pentium each integer pipeline is divided into four levels of flow, that is, instruction prefetching, decoding, execution, write back the results, floating-point flow is divided into eight levels of flow. Computer pipeline (Pipeline) technology is widely used in microprocessor chip (CPU) in a key technology, computer pipeline technology refers to the CPU within the execution of the various instructions of a description of the way to understand it, you must first understand the instructions and their execution process. 1, computer instructions computer instructions, is to tell the CPU to do what a specific set of binary collection. If we compare the CPU to a processing plant, then an instruction is like an order, which triggers a series of actions in the CPU_processing plant, and finally get the result of the operation and the product respectively. So, how do they actually work? First, there must be a department that receives the order - the CPU's instruction-taking organization; second, there must be a workshop that completes the order - the CPU's instruction-executing organization. In the factory, an order on the product is divided into a number of processes, and instructions are also converted into a number of corresponding micro-operations in the CPU, in order to complete them, the execution of the entire instruction. 2, the execution of instructions in the low-grade CPU, the execution of instructions is serial, simply put, is the execution of an instruction, and then execute the next instruction, as we mentioned above that processing plant at the beginning of the business, only a small workshop and the boss of the lone soldier, then, when he received an order, he will be busy completing the first order, but not the ability to pick up the second order. In this way taking orders → completing orders → taking orders → ...... taking orders → executing orders → taking orders → ...... is a serial process. Later, the owner realizes that it doesn't take much time to accept the order, and he has a helper who can work independently of each other, so that the owner is completing the product of the previous order while accepting the order for the next one. This is manifested in the CPU is to take the instruction mechanism and the execution of the instruction mechanism of the separation, so that from the CPU as a whole, the CPU in the execution of the last instruction at the same time, but also in parallel to take the next instruction. This is a qualitative leap in CPU technology, which makes the CPU change from serial work to parallel work, thus having the prototype of pipeline. CPU in the completion of this step above, the rest is how to improve the parallel processing capacity of the problem, CPU designers from the assembly line of the processing plant to get inspired by the execution of an instruction is broken down into a number of different multiple processes _ micro-instruction, which greatly simplifies the complexity of the instructions, simplifies the logic design, and improve the speed. In a CPU with pipelining technology, just after the first "process" of the previous instruction is executed, the second instruction immediately joins the pipeline and starts to be executed. Obviously, this pipelining technique requires multiple execution units, which are realized in X86 chips. Through the above introduction, we have learned what is the pipeline technology, which is not an innovation, but in the realization of the technology is a major difficulty, is the CPU designers of the computer development of a major contribution. So what's the deal with the P6 chip's super pipeline? 3, P6's Super Pipeline Introduction Super Pipeline (Super Pipeline) in essence is still a pipeline technology, but it has made the following improvements. A. The number of pipelines from Pentium's two to three, there are eleven independent execution unit parallel support. B. In the execution of the implementation of the out-of-order execution (out-of-order processing) technology. That is, when an instruction requires some data and not immediately executed, it will be eliminated from the pipeline and wait for data, the CPU will immediately execute the next instruction, just as in the assembly line found that a product is not quite qualified, and was eliminated, waiting for rework a reason. In this way, it can prevent an instruction from not being executed and affecting the efficiency of the whole pipeline. C. In P6, the instructions are divided into finer stages, thus simplifying the logic design, process, etc., and increasing speed. In a 486 chip, an instruction is generally divided into five standard sections, as is the case with the Pentium. In the P6, due to the adoption of near-RISC technology, an instruction is divided into a record fourteen stages. This dramatically increases the speed of the pipeline.