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论文编号：	9419
作者编号：	2120122711
上传时间：	2017/6/21 22:35:19
中文题目：	精益思想在FD公司新厂规划设计中的应用
英文题目：	The Application of Lean Thinking in New Plant’s Design of FD Company
指导老师：	张金成
中文关键字：	新厂规划；系统布置设计；工艺流程设计；厂址选择
英文关键字：	New Plant Planning；System Layout Planning；Process Design；Site Selection
中文摘要：	近年来一汽大众为了扩大市场占有率，突破南方市场日系车一统天下的局面，试图扩充南方市场份额。在此背景下一汽大众预备筹划建设一汽大众佛山分公司，作为其核心供应商的FD公司的天津总部紧随着客户的脚步，希望持续的为一汽大众进行生产供给的服务。据此FD公司确立了在佛山设立分公司的投资意向。 新厂规划作为影响企业运营发展的重要因素，其对整个工厂的生产能力、运营效率、生产成本、未来发展等都有极大的影响。特别是汽车制造业投资额高，同时建厂初期又很少统一的筹划，这样就造成企业在投产运营之后极易出现库存浪费、作业浪费、加工过多浪费等问题。 本文以车用空调器厂家FD公司新厂建设为背景，引出公司新厂建设的诸多实际问题，按照工艺流程设计、车间系统布局设计、厂址选择的步骤，结合精益生产的设计方法，对FD公司新厂规划问题进行了研究分析。力求减少或避免生产中的七大浪费问题，从而实现精益化的低成本、高效运营的样板工厂设计，提高中国的制造业成本核心竞争力。 首先，论文对研究的背景、意义、及内容与方法进行了介绍，并对相关的理论即精益生产、系统布置设计、层次分析法进行了总结与回顾。 然后，文章对FD公司新厂工艺设计中存在的问题进行了探讨与分析，并设定了以精益生产为原则的工艺流程设计的具体目标。研究精益思想指导下的同期化工艺流程的设计，对的概念与方法进行介绍后确定其设施的方法。最后以同期化设计为指导方针，结合企业实际情况，从产品结构分析、工艺流程规划、设备选型、同期化生产节拍的设计、标准作业中工序的重排、平衡生产线的设的实践应用对工艺流程进行了规划设计。 接下来，文章提出了FD公司布局设计中的问题，随后应用系统布置规划方法（SLP），结合FD公司的管理习惯与实际条件限制等，先后通过原产品及原材料、工艺路线、辅助部门、作业单位的划分等原始资料的输入出发、进行作业单位之间的物流相关分析、作业单位之间的非物流相关分析、作业单位之间的综合相关分析、位置相关图的绘制、面积相关图的绘制等流程，综合考虑布局设计中的实际条件约束进行修正，得到了三个备选方案。最后对三个备选方案进行加权因素评价，得到了最终的厂区布局设计方案。 在此之后文章介绍了FD公司选址问题，对其重要性进行了分析探究，并结合以往的文献研究以及作者的实践经验，对影响汽车零部件企业选址的关键因素进行了识别与总结，确定了FD公司新厂建设的选址原则。探讨了传统主流厂房选址方法即因素分析法等的实施优点及局限性，并在此基础上，提出使用定性及定量相结合的层次分析法进行精益选址的方法。使用层次分析法在新厂址选址的过程中，通过对候选地点关键因素的精益考察确定影响其实施的七大因素。构建选址过程的层次分析模型，即从候选地点选择的七大因素的模型构建、构建成对比较矩阵、计算权向量并作一致性检验、计算组合权向量，进行最终的选址决策和结果分析。 总体而言，本文通过精益化的设计方法，对FD公司新厂的设计问题提出了实际解决方案，并且在工艺设计方面，以工艺同期化设计原则为指导，对各个工艺流程进行了创新的设计与改善，极大的避免了中间库存、物料搬运等浪费；在布局设置的过程中，研究将SLP理论系统、完善的运用到了实际设计过程中，是对以往企业内部的布局规划方式的创新，提高了布局的合理性；使用层次分析法对选址问题进行研究，将定性与定量的方法融合在一起，在公司一贯使用的要素评分法上做出了重要的改革，有效的减少了确定权重时的主观性问题。以上实践的创新点为其他制造业特别是汽车零部件制造业新建厂提供可参考的依据，具有宝贵的理论与实践指导意义。
英文摘要：	In recent years, FAW Volkswagen has tried to expand South market share in order to expand its market share and break through the domination of the Japanese car in South market. In this context for planning the construction of FAW Volkswagen Foshan branch, as the core of supplier FD company headquarters in Tianjin, followed by the customer's footsteps, hope to continue for FAW Volkswagen production supply service. Accordingly, FD company established the investment intention of setting up branch in Foshan. As an important factor affecting the operation and development of the enterprise, the new plant planning has a great impact on the whole factory's production capacity, operation efficiency, production costs and future development. Especially in the automotive industry, the amount of investment is high. At the same time, it is seldom unified in the early stage of plant construction, which results in the problems such as waste of inventory, waste of homework, waste of processing and so on. In this paper, with a new car factory building air conditioner manufacturer FD company as the background, many practical problems lead to new plant construction company, in accordance with the design process, design, workshop site selection procedures of the system layout, combined with the design method of lean production, the new plant planning problem of FD company is analyzed. Strive to reduce or avoid the "seven waste" problems in production, so as to realize lean, low-cost, efficient operation of the model factory design, improve China's manufacturing cost, core competitiveness. First of all, the paper introduces the background, significance, content and methods of the research, and summarizes and reviews the relevant theories, namely, lean production, system layout design and analytic hierarchy process. Then, the article discusses and analyzes the problems existing in the process design of FD company's new plant, and sets the specific goal of the process design based on the lean production principle. The design of concurrent process flow under the guidance of lean thinking is studied. The concept and method are introduced and the facilities are determined. Finally, in the same period of design guidelines, combined with the actual situation of the enterprise, from the product structure analysis, process planning, equipment selection, over the same period of production cycle design, standard operation procedure rearrangement, line balancing is a practical application of the process of planning and design. Next, the article puts forward the FD company layout design problems, then the application of system layout planning method (SLP), combined with FD company's management practices and actual conditions, has passed the original products and raw materials, process and auxiliary departments, units of work division of input data, starting between operation units the correlation analysis between operation units, logistics and non logistics related analysis, the correlation analysis between operation units, location related drawing, area of drawing process, the actual conditions of modified considering the layout design, the three alternatives are. Finally, the weighting factors of the three alternatives are evaluated, and the final layout of the plant is obtained. After this article introduces FD's location problem, on the importance of analysis and research, combined with previous literature research and the author's practical experience, the key influence factors on the location of auto parts enterprises are identified and summarized, to determine the location of the principle of FD company's new factory construction. This paper probes into the advantages and limitations of the traditional mainstream plant location method, that is, factor analysis method, and puts forward a method combining qualitative and quantitative analysis for site selection. By using the analytic hierarchy process (AHP), the seven factors influencing the implementation of the new site selection are determined by lean investigation of the key factors of the candidate site. Construction of the model selection process level, namely, construction of the seven factors selected from the candidate sites for constructing the model of the pairwise comparison matrix to calculate the weight vector, and verify the consistency and calculate the combination weight vector, and the final results of location decision analysis. Overall, this design method through the lean, puts forward some practical solutions to design problems of FD company's new factory, and in the process of design, in order to process over the same period of the principle of design for each process design and improvement of innovation, can avoid the middle inventory, and material handling waste; in the process of layout in the study of the SLP theory system, improve the use of the actual design process, is the innovation of the enterprise internal layout planning, improve the layout of rationality; use AHP to carry on the research on location problem, qualitative and quantitative methods together, the elements of the company the consistent use of the score made an important reform, effectively reduce the subjectivity of determining the weight of the. The innovation point of the above practice can provide reference for other manufacturing industries, especially the auto parts manufacturing industry. It has valuable theoretical and practical significance.
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