【作者】 李涛；

【导师】 刘琳琳； 黎博澧；

【作者基本信息】 西安理工大学 ， 材料与化工（专业学位）， 2025， 硕士

【摘要】 目前儿童教育市场的蓬勃发展,促使纸板书这一印刷包装细分行业的生产呈现出小批量、多批次、高定制化的特点。然而,传统的纸板书产线产能评估,依赖历史生产数据,难以适应订单波动或工艺变更。产线瓶颈识别方法简单粗放,瓶颈优化主要在生产前制定静态的优化方案,难以应对生产过程中设备故障、瓶颈工序转移等动态扰动,导致产线平衡率偏低、频繁停机维护,生产效率难以保证。此外,传统方法下的产线重构依赖对前期规划方案的总结,出现的问题在产线运行后才暴露,导致返工、成本激增。因此,本文针对纸板书产线的产能评估、瓶颈识别及优化及产线重构等问题,提出了一套基于Plant Simulation仿真的纸板书产线优化方法,以Y公司生产实例验证方法的有效性,研究内容包括:(1)纸板书产线模型的构建:利用Siemens Plant Simulation搭建涵盖设备、作业人员、工艺流程和生产逻辑的虚拟产线,实现物理产线全要素的数字化镜像映射,利用相关系数法验证模型与真实产线的相关性。通过采集产线数据,为全局优化提供准确完备的数据支撑。并以实际生产为案例,对工时数据进行评测、清洗。(2)产线瓶颈识别和优化:仿真获得各工位多维作业数据,通过数据分析准确识别产线瓶颈工序。基于ECRS方法进行优化方案的制定,并设计仿真实验验证了方案的有效性。以Y公司产线为案例,研究成果提供了具体的产线改善方案,使产线每班次产能提升32.6%,产线平衡率提升22%。(3)产线人员配置的优化:针对人工密集型工序,建立人员配比优化模型,采用多目标遗传算法以产线平衡率和产能最大为目标,搜索最优作业人员分配方案。算法根据不同工序的需求,调整各工序投入人员的数量,实现作业人员的最优配置。(4)产线重构优化:在纸板书产线重构环节引入遗传算法进行优化,多优化目标包括重构时间、平衡率及物料的损耗,实现产线重构时对设备参数、人员配置数量及工艺流程及生产逻辑的调整。优化方案将产线重构的时间缩短1 5%,调试过程中物料损耗减少39%,使得产线再平衡过程更高效。本文将Plant Simulation仿真技术应用于纸板书产线优化的问题,对纸板书产线的多目标优化提供了系统技术方案。更多还原

【Abstract】 The thriving children’s education market has driven the production of the paperboard book industry towards smaller batches,multiple runs,and high customization.However,traditional methods for assessing the capacity of paperboard book production lines rely heavily on historical data,making it difficult to adapt to order fluctuations or process changes.The methods for identifying bottlenecks are often simplistic and crude,with optimization efforts primarily focused on static plans before production begins.This approach fails to address dynamic issues such as equipment failures and process shifts during production,leading to low line balance rates,frequent maintenance shutdowns,and reduced production efficiency.Moreover,the reconstruction of production lines using traditional methods relies heavily on summaries of earlier planning,which only reveal problems after the line is operational,resulting in rework and increased costs.Therefore,this paper puts forward a set of cardboard book production line optimization methods based on Plant Simulation simulation to solve the problems of capacity assessment,bottleneck identification and optimization,and production line reconstruction.The effectiveness of the method is verified by the production example of Company Y.The research contents include:(1)Construction of the cardboard book production line model:Utilize Siemens Plant Simulation to create a virtual production line that encompasses equipment,personnel,process flow.and production logic.This approach achieves a digital representation of all elements of the physical production line,and the correlation between the model and the actual production line is verified using the correlation coefficient method.By collecting data from the production line,it provides accurate and comprehensive data support for global optimization.Additionally,using actual production as a case study,the work hour data is evaluated and cleaned.(2)Identification and Optimization of Production Line Bottlenecks:Through simulation,multidimensional operation data from each workstation is obtained,and the bottleneck processes are accurately identified through data analysis.Based on the ECRS method,an optimization plan is formulated,and simulation experiments are designed to verify the effectiveness of the plan.Using Company Y’s production line as a case study,the research findings provide specific improvement measures,resulting in a 32.6%increase in production capacity per shift and a 22%improvement in production line balance.(3)Optimization of production line personnel allocation:For labor-intensive processes,an optimization model for personnel allocation is established.Using a multi-objective genetic algorithm,the goal is to maximize production line balance and capacity,searching for the optimal assignment of workers.The algorithm adjusts the number of personnel required for each process based on its specific needs,ensuring the optimal allocation of workforce.(4)Production Line Restructuring and Optimization:Genetic algorithms are introduced to optimize the restructuring of the cardboard book production line.The optimization aims to improve the reconstruction time,balance rate,and material loss.This involves adjusting equipment parameters,personnel allocation,process flow,and production logic during the restructuring.The optimization plan reduces the reconstruction time by 15%and decreases material loss by 39%during the debugging phase,making the re-balancing process more efficient.This paper applies Plant Simulation simulation technology to the problem of paperboard book production line optimization,and provides a systematic technical scheme for multi-objective optimization of paperboard book production line.更多还原