Bogie maintenance assembly line workshop layout optimization method

Abstract

The invention discloses a bogie maintenance assembly line workshop layout optimization method, and relates to the technical field of bogie maintenance processes, and the method comprises the steps: determining an optimizable process and process optimization content based on maintenance equipment; optimizing the overhaul process flow of the bogie; carrying out assembly line balance improvement on the optimized bogie maintenance process; partitioning the improved assembly line according to the content of each process to obtain a plurality of functional areas; performing logistics correlation analysis and non-logistics analysis on each functional area to obtain a logistics correlation graph and a non-logistics correlation graph; carrying out integrated calculation on associated data in the logistics correlation graph and the non-logistics correlation graph to obtain a comprehensive relation; and determining the assembly line workshop layout position according to the comprehensive relation and the actual workshop space. Through the optimization method, the labor cost can be reduced, the maintenance efficiency and the flexibility are improved, and the purposes of green maintenance, scientific maintenance and intelligent maintenance are achieved.

Description

Technical Field

[0001] The present disclosure relates to the technical field of bogie maintenance process, and in particular to a method for optimizing the layout of a bogie maintenance assembly line workshop. Background Art

[0002] At present, the railway freight car bogie maintenance is mainly carried out in the suspended assembly line mode. First, after the bogie is put into line, various parts are disassembled. The disassembled parts are sent to the parts maintenance area by forklift for maintenance. After the various parts are repaired, they are assembled in sequence according to the process flow. The assembly process also uses the suspension line method to assemble various parts. After the assembly is completed, the completion inspection is carried out and the expenditure is finally checked. The existing bogie-related maintenance equipment and tooling are developing rapidly. However, there is no matching bogie maintenance model based on advanced maintenance equipment, including process, layout, operation method, etc., which leads to high maintenance cost, poor working environment, high labor intensity, low safety of post personnel, and weak scheduling ability of maintenance process. Summary of the invention

[0003] The present invention provides a method for optimizing the layout of a bogie maintenance line workshop, which can reduce labor costs, improve maintenance efficiency and flexibility, and achieve the goals of green maintenance, scientific maintenance, and intelligent maintenance.

[0004] In a first aspect, the present disclosure provides a method for optimizing the layout of a bogie maintenance assembly line workshop, comprising the following steps:

[0005] Based on the processes and equipment of the bogie maintenance process, determine the processes that can be optimized and the content of process optimization;

[0006] Optimize the bogie maintenance process flow by using the optimizable processes and process optimization content to obtain the optimized bogie maintenance process flow;

[0007] Improve the line balance of the optimized bogie maintenance process to reduce buffering and waiting waste during the maintenance process;

[0008] The improved assembly line is divided into multiple functional areas according to the content of each process;

[0009] Carry out logistics correlation analysis and non-logistics analysis on each functional area respectively, and obtain a logistics correlation diagram for representing the logistics closeness between each functional area and a non-logistics correlation diagram for representing the non-logistics relationship between each functional area;

[0010] Integrate and calculate the associated data in the logistics-related graph and the non-logistics-related graph to obtain a comprehensive relationship that represents the closeness between various functional areas;

[0011] The layout of the assembly line workshop is determined based on the comprehensive relationship between the various functional areas and the actual space of the workshop.

[0012] In some embodiments, the logistics correlation analysis and the non-logistics analysis are performed on each functional area respectively to obtain a logistics correlation diagram for indicating the logistics closeness between each functional area and a non-logistics correlation diagram for indicating the non-logistics relationship between each functional area, including:

[0013] Obtain the daily material flow frequency and material transfer quantity between each functional area, as well as the non-logistics relationship factors between each functional area;

[0014] The closeness of the logistics relationship between the functional areas is graded by using the daily material flow frequency and material transfer quantity between the functional areas, and the level of logistics relationship between the functional areas is determined;

[0015] The non-logistics relationship factors between the functional areas are used to classify the closeness of the non-logistics relationship between the functional areas, and determine the level of the non-logistics relationship between the functional areas;

[0016] According to the logistics interrelationship level and non-logistics interrelationship level between various functional areas, the logistics related diagram and the non-logistics related diagram are determined.

[0017] In some embodiments, the integration and calculation of the associated data in the logistics-related graph and the non-logistics-related graph to obtain a comprehensive relationship for representing the closeness between the functional areas includes:

[0018] According to the importance of the logistics relationship and non-logistics relationship between various functional areas in the bogie maintenance process, weights are set to determine the proportion of the logistics relationship and non-logistics relationship between various functional areas;

[0019] Establishing a calculation relationship for determining the comprehensive relationship scores between various functional areas;

[0020] Calculate the score of the comprehensive relationship of each functional area using the weight value and the calculation formula, and calculate the sum of the comprehensive relationship scores of each functional area and other functional areas using the comprehensive relationship scores of each functional area;

[0021] The comprehensive relationship between the functional areas is determined based on the sum of the comprehensive relationship scores between each functional area and other functional areas.

[0022] In some embodiments, the step of integrating and calculating the associated data in the logistics-related graph and the non-logistics-related graph to obtain a comprehensive relationship for representing the closeness between the functional areas further includes:

[0023] According to the comprehensive relationship between the closeness of each functional area, the level of comprehensive relationship between each functional area is determined;

[0024] The comprehensive relationship level between each functional area is represented by the number of lines and line types, and the position correlation diagram of each functional area is determined based on the lines.

[0025] In some embodiments, the calculation relationship formula for determining the comprehensive relationship scores between the functional areas is:

[0026] CR xy =mMR xy +nN xy ;

[0027] Where: MR xy Indicates the level of logistics interrelationship; NR xy represents the level of non-logistics relationship; m represents the weight value of logistics relationship; n represents the weight value of non-logistics relationship; x and y represent two functional areas.

[0028] In some embodiments, the method of determining the layout position of the assembly line workshop according to the comprehensive relationship between the closeness of each functional area and the actual space of the workshop includes:

[0029] According to the comprehensive relationship between the closeness of each functional area, determine the preliminary workshop layout plan for each functional area;

[0030] The workshop area factor is added to the preliminary workshop layout plan of each functional area to determine the final workshop layout location of the assembly line.

[0031] In some embodiments, the steps of determining the optimizable steps and the process optimization contents based on the process steps and the maintenance equipment of the bogie maintenance process flow include:

[0032] Based on the logical relationship division of the processes of the bogie maintenance process flow, hard logic relationship processes and soft logic relationship processes are determined; the hard logic relationship is the process relationship in which the operation sequence cannot be adjusted in the process flow; the soft logic relationship is the process relationship in which there is no necessary sequence requirement between the processes in the process flow;

[0033] Classify the contents of each process in the hard logic relationship process and the soft logic relationship process, and determine the operation, handling, inspection, storage and waiting processes;

[0034] Classify the operation, handling, inspection, storage and waiting processes into non-value processes and value processes; the non-value processes are used to determine the processes with low importance in the maintenance process flow, and the value processes are used to determine the processes with high importance in the maintenance process flow;

[0035] According to the hard logic relationship process, soft logic relationship process, non-value process and value process, the optimization goal is to reduce the non-value process and improve the efficiency of the value process;

[0036] Based on the logical relationship of the process, each process is divided into unmanned process and manual operation process, and the optimization goal of dividing the process layout into unmanned operation area and manual operation area is established;

[0037] Based on the maintenance equipment and process optimization goals, determine the optimizable processes and process optimization content.

[0038] In some embodiments, determining the process optimization content of the process that can be optimized based on the maintenance equipment and the process optimization target includes:

[0039] Use automated equipment to replace manual labor to perform non-value-added processes;

[0040] By adjusting the process sequence and increasing batches, the parts required for multiple processes can be concentrated to reduce the number of handling times in the handling process;

[0041] Optimize inspection processes and use machine vision equipment to provide automated early warning for quality inspection processes during the maintenance process.

[0042] In some embodiments, the optimized bogie maintenance process flow is improved in line balance to reduce buffering and waiting waste during the maintenance process, including:

[0043] Establish standard working hours for the optimized bogie maintenance process;

[0044] Obtain production demand and daily operation time of the assembly line;

[0045] Calculate the target cycle time based on the production demand of the assembly line and the daily operation time;

[0046] Taking the target cycle as the maximum time of the workstation, the assembly line is divided into workstations using the optimized bogie maintenance process and the standard working hours of the processes; the sum of the standard working hours of the processes in the workstations is less than the target cycle;

[0047] Use the five elements of man, machine, material, method and loop to optimize the divided workstations, determine the optimized workstations, and determine the balanced and improved assembly line.

[0048] In a second aspect, the present disclosure provides a railway freight car bogie maintenance assembly line, which is arranged using the method described in the above aspect.

[0049] In a third aspect, the present disclosure provides a computer device, including a memory, a processor, and a computer program stored in the memory, wherein the processor executes the computer program to implement the steps of the method described in the above aspects.

[0050] In a fourth aspect, the present disclosure provides a computer-readable storage medium having a computer program stored thereon, which implements the steps of the method described in the above aspects when executed by a processor.

[0051] Compared with the prior art, one or more embodiments of the above scheme may have the following advantages or beneficial effects:

[0052] The present invention provides a method for optimizing the workshop layout of a bogie maintenance assembly line. The method optimizes the process flow based on advanced maintenance equipment and intelligent equipment, reasonably analyzes the content of each process, and optimizes the maintenance process by canceling, merging, rearranging, and simplifying processes. The method can improve the flexibility of the bogie, improve the operating efficiency of each workstation, allocate unmanned areas and manual operation areas, replace manual operations with automated equipment as much as possible, reduce labor intensity, avoid overlapping manual operations and equipment operations, and improve intelligent maintenance efficiency. The assembly line is optimized through optimized maintenance processes, and the position of the assembly line in the workshop is reasonably arranged in combination with logistics relationships, which can avoid space waste, reduce transportation time, and improve the bogie maintenance efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] The present disclosure will be described in more detail below based on embodiments and with reference to the accompanying drawings:

[0054] Figure 1 A schematic diagram of a flow chart of a method for optimizing the layout of a bogie maintenance assembly line workshop provided in an embodiment of the present disclosure;

[0055] Figure 2 For the embodiment of the present disclosure Figure 1 An exemplary flow chart of step S2 in FIG.

[0056] Figure 3 and Figure 4 It is a schematic diagram of the process flow after the bogie maintenance process is optimized in the embodiment of the present disclosure;

[0057] Figure 5 The embodiment of the present disclosure corresponds to Figure 1 An exemplary flow chart of step S3 in FIG.

[0058] Figure 6 The embodiment of the present disclosure corresponds to Figure 1 An exemplary flow chart of step S5 in FIG.

[0059] Figure 7 The embodiment of the present disclosure corresponds to Figure 1 An exemplary flow chart of step S6 in FIG.

[0060] Figure 8 The embodiment of the present disclosure corresponds to Figure 1 An exemplary flow chart of step S7 in FIG.

[0061] Fig. 9 This is a logistics relationship diagram of the bogie workshop of Company A in the second embodiment of the present disclosure;

[0062] Fig.10 This is a non-logistics relationship diagram of the maintenance of Company A in the second embodiment of the present disclosure;

[0063] Fig.11 It is a comprehensive relationship diagram of the example in the second embodiment of the present disclosure;

[0064] Fig.12 A schematic block diagram of a computer device provided in an embodiment of the present disclosure;

[0065] Fig.13 A schematic diagram of a readable storage medium provided in an embodiment of the present disclosure.

[0066] In the drawings, the same reference numerals are used for the same components, and the drawings are not drawn to scale. DETAILED DESCRIPTION

[0067] In order to enable those skilled in the art to better understand the technical solution of the present disclosure, and to fully understand and implement how the present disclosure applies technical means to solve technical problems and achieve the corresponding technical effects, the technical solution in the embodiments of the present disclosure will be clearly and completely described below in conjunction with the drawings in the embodiments of the present disclosure. Obviously, the described embodiments are only embodiments of a part of the present disclosure, not all of the embodiments. The embodiments of the present disclosure and the various features in the embodiments can be combined with each other without conflict, and the technical solutions formed are all within the scope of protection of the present disclosure. Based on the embodiments in the present disclosure, all other embodiments obtained by ordinary technicians in this field without making creative work should fall within the scope of protection of the present disclosure.

[0068] It should be noted that the terms "first", "second", etc. in the specification and claims of the present disclosure and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the data used in this way can be interchangeable where appropriate, so that the embodiments of the present disclosure described herein can be implemented in an order other than those illustrated or described herein. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions, for example, a process, method, system, product, or device that includes a series of steps or units is not necessarily limited to those steps or units that are clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products, or devices.

[0069] It should be noted that the steps shown in the flowcharts of the accompanying drawings can be executed in a computer system such as a set of computer executable instructions, and that, although a logical order is shown in the flowcharts, in some cases, the steps shown or described can be executed in an order different from that shown here.

[0070] At present, the maintenance of railway freight car bogies is mainly carried out in a suspended assembly line mode. First, after the bogie is put into line, various parts are disassembled. The disassembled parts are sent to the parts maintenance area by forklifts for maintenance. After the maintenance of various parts, they are assembled in sequence according to the process flow. The assembly process also adopts the method of hanging lines to assemble various parts. After the assembly is completed, a completion inspection is carried out, and finally the payment is checked.

[0071] The process flow of bogie disassembly is: bogie collection → cutting operation → disassembly of stopper → disassembly of lower side bearing → disassembly of lower center plate → disassembly of basic brake device → disassembly of brake beam → disassembly of cross beam → disassembly of upper tie rod → separation of frame and wheelset → disassembly of load-bearing saddle → disassembly of bolster spring wedge → disassembly of cross rod → disassembly of bolster side frame. All disassembly positions are operated by tools + manual labor, and the handling process of accessories is carried out by hanging wire trolley and forklift.

[0072] The process flow of parts maintenance is: parts collection → surface cleaning → shot blasting and rust removal (some parts) → appearance inspection → dimension measurement → magnetic particle inspection (some parts) → parts repair → painting / dip varnish drying → inspection and payment. All parts maintenance positions are operated by tools + manual labor, and the parts are transported by forklift.

[0073] The bogie assembly process is: assemble bolster side frame → put on line → assemble cross bar → positive position detection → assemble bolster spring wedge → assemble upper pull rod assembly → assemble cross beam → assemble brake beam → assemble basic brake device → assemble load saddle → drop wheel → assemble lower side bearing → assemble lower center plate assembly → assemble stop key → bogie completion inspection → inspection and payment. All assembly positions use tools + manual methods, and the handling process of accessories uses hanging line trolleys and forklifts.

[0074] At present, the field of bogie maintenance has not yet reached the standard of a smart factory. In related industries, such as the automotive industry, the digitalization of discrete factories has been realized. However, as a standardized production and manufacturing industry, the entire production process, intelligent equipment tooling and software, and production process management are relatively standard. However, the bogie maintenance process is relatively complex and the maintenance environment is relatively harsh. Therefore, the realization of intelligent, flexible, and efficient bogie maintenance is the direction and difficulty of the bogie maintenance model.

[0075] The content provided by the embodiments of the present disclosure is to provide a method for optimizing the layout of a bogie maintenance assembly line workshop, which reduces labor costs, improves maintenance efficiency and flexibility, and achieves the goals of green maintenance, scientific maintenance, and intelligent maintenance by optimizing the maintenance process and workshop layout.

[0076] Embodiment 1

[0077] Figure 1 The following is a flow chart of a method for optimizing the layout of a bogie maintenance assembly line workshop provided by an embodiment of the present disclosure. Figure 1As shown, a method for optimizing the layout of a bogie maintenance assembly line workshop comprises: determining optimizable processes and process optimization contents based on the processes and maintenance equipment of the bogie maintenance process flow; optimizing the bogie maintenance process flow using the optimizable processes and process optimization contents to obtain an optimized bogie maintenance process flow; improving the assembly line balance of the optimized bogie maintenance process flow to reduce the cache and waiting waste during the maintenance process; partitioning the improved assembly line according to the contents of each process to obtain a plurality of functional areas; performing logistics correlation analysis and non-logistics analysis on each functional area to obtain a logistics correlation diagram for indicating the logistics closeness between each functional area and a non-logistics correlation diagram for indicating the non-logistics relationship between each functional area; integrating and calculating the associated data in the logistics correlation diagram and the non-logistics correlation diagram to obtain a comprehensive relationship for indicating the closeness between each functional area; determining the assembly line workshop layout position according to the comprehensive relationship between each functional area and the actual space of the workshop. Advanced maintenance equipment is used to optimize the bogie maintenance process, and then the assembly line is balanced and improved. The workshop layout is divided into different areas according to the content of each process. The assembly line arranged in the workshop can reduce labor costs, improve maintenance efficiency and flexibility, and achieve the goals of green maintenance, scientific maintenance, and intelligent maintenance.

[0078] Reference below Figure 1 As shown, the bogie maintenance assembly line workshop layout optimization method provided by the embodiment of the present disclosure is described. The bogie maintenance assembly line workshop layout optimization method includes steps S1 to S7, which are specifically as follows:

[0079] S1. Based on the processes and maintenance equipment of the bogie maintenance process, determine the processes that can be optimized and the process optimization content.

[0080] In some embodiments, step S1, such as Figure 2 As shown, specifically including S11-S16:

[0081] S11. Based on the process steps of the bogie maintenance process flow, logical relationship division is performed to determine the process steps with hard logic relationship and the process steps with soft logic relationship; the hard logic relationship is the process relationship in the process flow where the operation sequence cannot be adjusted; the soft logic relationship is the process relationship in the process flow where there is no necessary sequence requirement between the processes.

[0082] S12. Classify the contents of each process in the hard logic relationship process and the soft logic relationship process, and determine the operation, transportation, inspection, storage and waiting processes.

[0083] In some embodiments, operations during the bogie maintenance process mainly include disassembly of parts, inspection of parts, repair of parts and assembly of parts; handling mainly includes loading and unloading, transshipment and transportation of parts after disassembly; storage mainly includes caching and cost storage during the parts maintenance process; waiting mainly includes waiting due to waiting for materials, unbalanced working hours and preparation before operation.

[0084] S13. Classify the operation, handling, inspection, storage and waiting processes into non-value processes and value processes; the non-value processes are used to determine the processes with low importance in the maintenance process flow, and the value processes are used to determine the processes with high importance in the maintenance process flow.

[0085] In lean production, operation and inspection processes are more important in the maintenance process, so they are value processes; handling, storage and waiting are auxiliary processes in the maintenance process, with lower importance, so they are non-value processes. During the optimization process, the content of non-value processes should be reduced as much as possible, and operation and inspection processes should be strengthened.

[0086] S14. Based on the hard logic relationship process, soft logic relationship process, non-value process and value process, establish the optimization goal of reducing non-value process and improving the efficiency of value process;

[0087] S15. Based on the logical relationship of the processes, each process is divided into unmanned processes and manual operation processes, and an optimization goal is established to divide the process layout into unmanned operation areas and manual operation areas.

[0088] In some embodiments, an optimization goal is established to divide the process layout into unmanned operation areas and manual operation areas. Specifically, the processes in which robots or intelligent tooling replace manual labor are sorted out, and the sequence is fine-tuned on the basis of the first three points. The unmanned operation areas and manual operation areas are arranged separately as much as possible to realize the unmanned operation areas and manual operation areas of the process layout. This can avoid cross-operation between humans and machines, ensure the safety of personnel operations, and ensure the coordinated operation of equipment in the unmanned operation area.

[0089] S16. Based on the maintenance equipment and process optimization goals, determine the optimizable processes and process optimization content.

[0090] In some embodiments, based on the maintenance equipment and process optimization goals, the process optimization content of the optimizeable process is determined, including: using automated equipment instead of manual labor to perform non-value processes; concentrating the accessories required for multiple processes by adjusting the process sequence and increasing batches to reduce the number of times the process is transported; optimizing inspection processes, and using machine vision equipment to automatically warn of quality inspection processes in the maintenance process.

[0091] Among them, according to the determined process optimization goals, automated maintenance equipment can be used to omit and simplify the operation process, and the number of handling, storage and waiting times can be reduced by reorganizing the process. There are several common methods to reduce non-value processes: first, use robots and other unmanned chemical equipment to replace people to perform non-value processes; second, adjust the process sequence to concentrate a variety of accessories to reduce the number of handling; third, increase the batch to reduce the number of handling; fourth, improve the labor time balance rate to reduce storage, storage time and waiting time. At the same time, focus on tracking unmanned operation processes, the quality of robot operations is higher than that of manual operations, reduce unnecessary quality inspection processes, analyze the root causes of quality inspection processes, redesign the process content of quality mutual control at the root cause level, and use machine vision technology to automatically warn the key points of the maintenance process.

[0092] S2. Optimize the bogie maintenance process flow by using the optimizable processes and process optimization contents to obtain the optimized bogie maintenance process flow.

[0093] In some embodiments, the optimized process flow chart is as follows Figure 3 and Figure 4 As shown, by reasonably determining the process sequence and concentrating the operational work, it is possible to rationally allocate resources for each position and improve maintenance efficiency.

[0094] S3. Improve the line balance of the optimized bogie maintenance process to reduce buffering and waiting waste during the maintenance process.

[0095] In some embodiments, step S3, including S31-S35, such as Figure 5 As shown, the details are as follows:

[0096] S31. Establish standard working hours for the optimized bogie maintenance process.

[0097] In some embodiments, standard working hours are the most basic and important work of scientific production management, and are the benchmark for measuring production planning, production processes and production control of production enterprises. Standard working hours are observed under normal operating conditions, above-average operator proficiency, and in accordance with the operating procedures in the operating instructions, using video recording to observe, eliminating abnormal situations after observing several groups, recording the basic operating time of each process, and determining the standard formula of the process through the calculation method and formula of standard working hours (observation time*rating coefficient*(1+leniency)).

[0098] S32. Obtain the production demand and daily operation time of the assembly line.

[0099] S33. Calculate the target cycle time based on the production demand of the assembly line and the daily operation time.

[0100] In this embodiment, the target beat is calculated based on the production demand of the assembly line and the daily operation time, and the target beat is determined based on the maintenance demand.

[0101] S34. Taking the target cycle as the maximum time of the workstation, the assembly line is divided into workstations using the optimized bogie maintenance process flow and the standard working hours of the processes; the sum of the standard working hours of the processes in the workstations is less than the target cycle.

[0102] In some embodiments, in step S34, specifically: take the target cycle as the maximum time of the workstation, and put each process into the workstation in sequence based on the principle that the sum of process time ≤ the maximum time of the workstation; divide the workstation according to the optimized process flow and process standard working time, and ensure that the sum of the process standard working time in each workstation is less than the target cycle, and the workstation is the workstation.

[0103] S35. Use the five elements of man, machine, material, method and loop to optimize the divided workstations, determine the optimized workstations, and determine the assembly line after balance improvement.

[0104] In some embodiments, step S35 specifically analyzes whether the workstation allocation is optimal based on the five factors of man, machine, material, method and environment. After the workstation is determined, all material requirements and expenditures, standard number of employees, related equipment and tooling, work content and standard working hours involved in the workstation are clarified. At this time, the design and optimization of the workstation are basically completed.

[0105] S4. Divide the improved assembly line into zones according to the contents of each process to obtain multiple functional zones.

[0106] In some embodiments, when zoning the assembly line, it is divided into functional areas such as bogie disassembly area, bogie assembly area, various parts maintenance area, new parts storage warehouse, etc. according to the theme of accessories. Since the logistics supply and demand logic between the various areas is based on the bogie maintenance process, the direction, type and quantity of parts flow in some areas are fixed, and finally the transportation volume between the various areas is sorted out. The calculations involved are: daily transportation volume of parts = total number of parts required + total number of parts supplied, total number of parts = daily maintenance quantity * number of parts per vehicle.

[0107] S5. Perform logistics correlation analysis and non-logistics analysis on each functional area respectively, and obtain a logistics correlation diagram for representing the logistics closeness between each functional area and a non-logistics correlation diagram for representing the non-logistics relationship between each functional area.

[0108] In some embodiments, step S5, including S51-S54, such as Figure 6 As shown, specifically including:

[0109] S51. Obtain the daily material flow frequency and material transfer quantity between each functional area, as well as the non-logistics relationship factors between each functional area.

[0110] In some embodiments, all materials in the bogie maintenance process are usually carried by AGV transporters and conveyor lines. Therefore, the size and weight of the materials do not need to be considered for the time being. They are all distributed in the form of vehicle portions, so that the daily material flow frequency and material transfer quantity are used as the basis for evaluating the closeness of logistics relationships; for the bogie maintenance workshop, non-logistics relationship factors include logical correlation, management convenience, safety and aesthetics, process synchronization, shared equipment and facilities, vibration and pollution, etc.

[0111] S52. Use the daily material flow frequency and material transfer quantity between the functional areas to grade the closeness of the logistics relationship between the functional areas and determine the level of logistics relationship between the functional areas.

[0112] In some embodiments, the amount of material transfer represents the closeness between the functional areas, which is divided into five levels: absolutely important, very important, important, general and unimportant, represented by letters A, E, I, O, and U respectively. Each level is defined according to the proportion of the material transfer volume to the total transfer volume. The specific level table is shown in the following table:

[0113] Table 1 Logistics relevance level table

[0114] evaluate Closeness scope A Absolutely important 80％-100％ E Very important 50％-79％ I important 30％-49％ O generally 7％-29％ U unimportant 0％-6％

[0115] S53. The non-logistics relationship factors between the functional areas are used to classify the closeness of the non-logistics relationship between the functional areas, and the level of the non-logistics relationship between the functional areas is determined.

[0116] In some embodiments, the non-logistics relationship influencing factors are listed as follows:

[0117] Table 2 Non-logistics relationship influencing factors

[0118] serial number factor serial number factor 1 Process logic 4 Management convenience 2 Process synchronization 5 Shared facilities 3 Safe and beautiful 6 Vibration and pollution

[0119] Among them, the classification levels are as in step S52, and 5 levels are also used for classification, and non-logistics relevance is divided into A, E, I, O, U, and X, corresponding to absolutely important, very important, important, general, unimportant, and irrelevant.

[0120] S54. Determine a logistics-related graph and a non-logistics-related graph according to the logistics interrelationship levels and non-logistics interrelationship levels between the functional areas.

[0121] S6. Integrate and calculate the associated data in the logistics-related graph and the non-logistics-related graph to obtain a comprehensive relationship that is used to represent the closeness between the various functional areas.

[0122] In some embodiments, step S6, such as Figure 7 As shown, including:

[0123] S61, setting weights according to the importance of the logistics relationship and the non-logistics relationship between the functional areas in the bogie maintenance process, and determining the weight values ​​of the logistics relationship and the non-logistics relationship between the functional areas;

[0124] S62. Establish a calculation formula for determining the comprehensive relationship scores between the various functional areas.

[0125] In some embodiments, the calculation relationship in step S62 is:

[0126] CR xy =mMR xy +NR xy ;

[0127] Where: MR xy Indicates the level of logistics interrelationship; NR xy represents the level of non-logistics relationship; m represents the weight value of logistics relationship; n represents the weight value of non-logistics relationship; x and y represent two functional areas.

[0128] Normally, the ratio of logistics relationship to non-logistics relationship is m:n between 1:3 and 3:1. The railway freight car bogie maintenance workshop is strictly a discrete factory, so the logistics-related ratio is greater than the non-logistics-related ratio. The value set in this embodiment is 3:1. In order to quantify the closeness of the comprehensive relationship between each functional area, two functional areas are marked with x and y.

[0129] S63, using the weight values ​​and the calculation formula to calculate the comprehensive relationship scores of each functional area, and using the comprehensive relationship scores of each functional area to calculate the sum of the comprehensive relationship scores of each functional area and other functional areas.

[0130] S64. Determine the comprehensive relationship of the closeness between the functional areas based on the sum of the comprehensive relationship scores between each functional area and other functional areas.

[0131] In a further embodiment, step S6 further includes:

[0132] According to the comprehensive relationship between the closeness of each functional area, the level of comprehensive relationship between each functional area is determined;

[0133] The comprehensive relationship level between each functional area is represented by the number of lines and line types, and the position correlation diagram of each functional area is determined based on the lines.

[0134] Among them, the comprehensive relationship level is divided into six levels, and the levels and line representations are shown in the following table:

[0135] Table 3 Comprehensive relationship level table

[0136]

[0137] S7. Determine the layout of the assembly line workshop based on the comprehensive relationship between the various functional areas and the actual space of the workshop.

[0138] In some embodiments, step S7, such as Figure 8 As shown, specifically including:

[0139] S71. Determine the preliminary workshop layout plan for each functional area based on the comprehensive relationship between the closeness of each functional area;

[0140] S72. Add the workshop area factor to the preliminary workshop layout plan of each functional area to determine the final workshop layout position of the assembly line.

[0141] By analyzing the comprehensive relationship to rationally plan the workshop layout, the work efficiency during bogie maintenance can be improved and the transportation time can be reduced. Therefore, the workshop can be rationally arranged based on the workshop area to avoid space waste and long maintenance processes.

[0142] An embodiment of the present disclosure provides a method for optimizing the layout of a bogie maintenance assembly line workshop. By optimizing the process flow based on advanced maintenance equipment and intelligent equipment, reasonably analyzing the content of each process, and optimizing the maintenance process by canceling, merging, rearranging, and simplifying processes, the flexibility of the bogie can be improved, the operating efficiency of each workstation can be improved, and unmanned areas and manual operation areas can be allocated. Manual operations can be replaced by automated equipment as much as possible to reduce labor intensity, avoid overlapping of manual operations and equipment operations, and improve intelligent maintenance efficiency. The assembly line is optimized through optimized maintenance processes, and the position of the assembly line in the workshop is reasonably arranged in combination with logistics relationships, which can avoid space waste, reduce transportation time, and improve the bogie maintenance efficiency.

[0143] Embodiment 2

[0144] On the basis of the above embodiment, the optimization of workshop layout is explained by taking the daily maintenance volume of Company A as an example. The number of bogies that Company A overhauls every day is 32, and the probability of parts being scrapped after maintenance is calculated as 10%. The parts in the decomposition area only have outgoing items, and the parts in the maintenance area have outgoing items and incoming items. The outgoing items flow into the assembly area, and the incoming items come from the new product warehouse. For the new product warehouse, a large number of outgoing items are mainly concentrated in the assembly area, and most of them are small items. The daily transportation volume of parts in each area after inventory summary is as follows:

[0145]

[0146] Among them, area numbers 1-14 represent various functional areas, including: bogie disassembly area, accessories shot blasting area, brake beam maintenance area, cross rod maintenance area, paint spraying and drying, bolster side frame maintenance area 1, bolster side frame maintenance area 2, bolster spring maintenance area, load-bearing saddle maintenance area, cross beam maintenance area, basic brake maintenance area, small accessories maintenance area, bogie assembly area, and new product storage warehouse.

[0147] By calculating the logistics correlation of the above material transfer quantities, the logistics correlation analysis table and logistics relationship diagram are determined. The logistics relationship diagram is as follows: Fig. 9 As shown, the logistics correlation analysis table is as follows:

[0148] area 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 0 7.3 3.6 1.8 0 5.5 0 33 7.3 1.8 16 24 0 0 2 0 0 50 50 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 100 0 0 0 0 0 0 0 0 0 4 0 0 0 0 100 0 0 0 0 0 0 0 0 0 5 0 0 0 0 0 0 0 0 0 0 0 0 100 0 6 0 0 0 0 0 0 100 0 0 0 0 0 0 0 7 0 0 0 0 0 0 0 0 0 0 0 0 100 0 8 0 0 0 0 0 0 0 0 0 0 0 0 100 0 9 0 0 0 0 0 0 0 0 0 0 0 0 100 0 10 0 0 0 0 0 0 0 0 0 0 0 0 100 0 11 0 0 0 0 0 0 0 0 0 0 0 0 100 0 12 0 0 0 0 0 0 0 0 0 0 0 0 100 0 13 0 0 0 0 0 0 0 0 0 0 0 0 0 0 14 0 0 1.7 0 0 0 2.14 2 0 1 0 1.3 91.9 0

[0149] Further analysis of the non-logistics relationship diagram in A Company's maintenance is shown in the figure below: Fig.10 As shown;

[0150] By performing comprehensive analysis and calculation in the manner of Example 1, the comprehensive analysis table obtained is as follows:

[0151] Table 4-6 Comprehensive correlation analysis table

[0152]

[0153] The comprehensive relationship level between each functional area is represented by the number of lines and line types, and the position correlation diagram of each functional area is determined based on the lines.

[0154] Among them, the comprehensive relationship level is divided into six levels, and the levels and line representations are shown in the following table:

[0155] Table 3 Comprehensive relationship level table

[0156]

[0157] By combining the logistics relationship diagram with the non-logistics relationship diagram, the comprehensive relationship diagram is obtained as follows: Fig.11 As shown:

[0158] Through the close relationship of various levels in the functional area position correlation diagram, the close relationship of each functional area is expressed by the number and type of lines. From this, the level of the comprehensive relationship between the functional areas can be seen, so that the position of each functional area in the workshop can be reasonably arranged in combination with the assembly line. The specific position of each assembly line functional area in the workshop can be further determined according to the size of the workshop space. This can improve the work efficiency of the bogie during maintenance and reduce the transportation time. Therefore, combined with the workshop area, a reasonable layout of the workshop can be achieved to avoid space waste and long maintenance process.

[0159] Embodiment 3

[0160] On the basis of the above-mentioned embodiments, this embodiment provides a railway freight car bogie maintenance assembly line, which is arranged according to the method described in the above-mentioned embodiments.

[0161] Embodiment 4

[0162] Based on the above embodiments, this embodiment provides a computer device, such as Fig.12 As shown, it includes a memory 21, a processor 22 and a computer program stored in the memory 21, and the processor 22 executes the computer program to implement the steps of the method described in the above embodiment.

[0163] In some implementations of this embodiment, a computer readable storage medium is provided, such as Fig.13 As shown, a computer program 31 is stored thereon, and when the computer program is executed by a processor, the steps of the method described in the above embodiment are implemented.

[0164] In some implementations of this embodiment, a computer program product is provided, including a computer program / instructions, and when the computer program is executed by a processor, the steps of the method described in the above embodiment are implemented.

[0165] The processor may include, but is not limited to, one or more processors or microprocessors, etc. Each processor may be an application specific integrated circuit (ASIC), a digital signal processor (DSP), a digital signal processing device (DSPD), a programmable logic device (PLD), a field programmable gate array (FPGA), a controller, a microcontroller, a microprocessor or other electronic components to execute the methods in the above embodiments.

[0166] The computer-readable storage medium may be implemented by any type of volatile or non-volatile storage device or a combination thereof, and the computer-readable storage medium may include but is not limited to, for example, random access memory (RAM), read-only memory (ROM), flash memory, EPROM memory, EEPROM memory, registers, computer storage media (e.g., hard disk, floppy disk, solid-state drive, removable disk, CD-ROM, DVD-ROM, Blu-ray disc, etc.).

[0167] The computer-readable storage medium may also store at least one computer executable program / instruction, which may be, for example, a computer-readable instruction. The computer-readable storage medium includes, but is not limited to, for example, a volatile memory and / or a non-volatile memory. The volatile memory may include, for example, a random access memory (RAM) and / or a cache memory (cache), etc. The computer-readable storage medium may include, for example, a read-only memory (ROM), a hard disk, a flash memory, etc. For example, a non-transitory computer-readable storage medium may be connected to a computing device such as a computer, and then, when the computing device runs the computer-readable instructions stored on the computer-readable storage medium, the various methods described above may be performed.

[0168] In addition, the computer device may also include (but not limited to) a data bus, an input / output (I / O) bus, a display, and input / output devices (eg, keyboard, mouse, speaker, etc.), etc.

[0169] The processor may communicate with external devices via an I / O bus via a wired or wireless network.

[0170] In one embodiment, the at least one computer executable instruction may also be compiled into or constitute a software product / computer program product, wherein one or more computer executable instructions are executed by a processor to perform the various functions and / or method steps in the embodiments described in the present technology.

[0171] In the embodiments provided in the present disclosure, it should be understood that the disclosed devices and methods can also be implemented in other ways. The device embodiments described above are merely schematic. For example, the flowcharts and block diagrams in the accompanying drawings show the possible architecture, functions and operations of the devices, methods and computer program products according to multiple embodiments of the present disclosure. In this regard, each box in the flowchart or block diagram can represent a module, a program segment or a part of a code, and the above-mentioned module, program segment or a part of the code contains one or more executable instructions for implementing the specified logical function. It should also be noted that in some alternative implementations, the functions marked in the box can also occur in a different order from the order marked in the accompanying drawings. For example, two consecutive boxes can actually be executed substantially in parallel, and they can sometimes be executed in the opposite order, depending on the functions involved. It should also be noted that each box in the block diagram and / or flowchart, and the combination of boxes in the block diagram and / or flowchart can be implemented with a dedicated hardware-based system that performs a specified function or action, or can be implemented with a combination of dedicated hardware and computer instructions.

[0172] It should be noted that in the present disclosure, the terms "include", "comprises" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, an element limited by the sentence "includes a ..." does not exclude the existence of other identical elements in the process, method, article or device including the element.

[0173] Although the embodiments disclosed in the present disclosure are as above, the above contents are only embodiments adopted for facilitating the understanding of the present disclosure and are not intended to limit the present disclosure. Any technician in the technical field to which the present disclosure belongs can make any modifications and changes in the form and details of the implementation without departing from the spirit and scope disclosed in the present disclosure, but the scope of patent protection of the present disclosure shall still be subject to the scope defined in the attached claims.

Claims

1. A method for optimizing the layout of a bogie maintenance production line workshop, characterized in that: The following steps are involved: Based on the processes and equipment of the bogie maintenance process, determine the processes that can be optimized and the content of process optimization; Optimize the bogie maintenance process flow by using the optimizable processes and process optimization content to obtain the optimized bogie maintenance process flow; Improve the line balance of the optimized bogie maintenance process to reduce buffering and waiting waste during the maintenance process; The improved assembly line is divided into multiple functional areas according to the content of each process; Carry out logistics correlation analysis and non-logistics analysis on each functional area respectively, and obtain a logistics correlation diagram for representing the logistics closeness between each functional area and a non-logistics correlation diagram for representing the non-logistics relationship between each functional area; Integrate and calculate the associated data in the logistics-related graph and the non-logistics-related graph to obtain a comprehensive relationship that represents the closeness between various functional areas; The layout of the assembly line workshop is determined based on the comprehensive relationship between the various functional areas and the actual space of the workshop.

2. A method for optimizing the layout of a bogie maintenance assembly line workshop according to claim 1, characterized in that: The logistics correlation analysis and non-logistics analysis are performed on each functional area respectively to obtain a logistics correlation diagram for indicating the logistics closeness between each functional area and a non-logistics correlation diagram for indicating the non-logistics relationship between each functional area, including: Obtain the daily material flow frequency and material transfer quantity between each functional area, as well as the non-logistics relationship factors between each functional area; The closeness of the logistics relationship between the functional areas is graded by using the daily material flow frequency and material transfer quantity between the functional areas, and the level of logistics relationship between the functional areas is determined; The non-logistics relationship factors between the functional areas are used to classify the closeness of the non-logistics relationship between the functional areas, and determine the level of the non-logistics relationship between the functional areas; According to the logistics interrelationship level and non-logistics interrelationship level between various functional areas, the logistics related diagram and the non-logistics related diagram are determined.

3. The method for optimizing the layout of a bogie maintenance assembly line workshop according to claim 1, characterized in that: The integrated calculation of the associated data in the logistics-related graph and the non-logistics-related graph to obtain a comprehensive relationship for indicating the closeness between the functional areas includes: According to the importance of the logistics relationship and non-logistics relationship between various functional areas in the bogie maintenance process, weights are set to determine the proportion of the logistics relationship and non-logistics relationship between various functional areas; Establishing a calculation relationship for determining the comprehensive relationship scores between various functional areas; Calculate the score of the comprehensive relationship of each functional area using the weight value and the calculation formula, and calculate the sum of the comprehensive relationship scores of each functional area and other functional areas using the comprehensive relationship scores of each functional area; The comprehensive relationship between the functional areas is determined based on the sum of the comprehensive relationship scores between each functional area and other functional areas.

4. A method for optimizing the layout of a bogie maintenance assembly line workshop according to claim 3, characterized in that: The method of integrating and calculating the associated data in the logistics-related graph and the non-logistics-related graph to obtain a comprehensive relationship for representing the closeness between the functional areas also includes: According to the comprehensive relationship between the closeness of each functional area, the level of comprehensive relationship between each functional area is determined; The comprehensive relationship level between each functional area is represented by the number of lines and line types, and the position correlation diagram of each functional area is determined based on the lines.

5. The method for optimizing the layout of a bogie maintenance assembly line workshop according to claim 3, characterized in that: The calculation relationship formula established to determine the comprehensive relationship scores between the functional areas is: CR xy =mMR xy -nKR xy ; Where: MR xy Indicates the level of logistics interrelationship; NR xy represents the level of non-logistics relationship; m represents the weight value of logistics relationship; n represents the weight value of non-logistics relationship; x and y represent two functional areas.

6. The method for optimizing the layout of a bogie maintenance assembly line workshop according to claim 1, characterized in that: The layout of the assembly line workshop is determined based on the comprehensive relationship between the closeness of each functional area and the actual space of the workshop, including: According to the comprehensive relationship between the closeness of each functional area, determine the preliminary workshop layout plan for each functional area; The workshop area factor is added to the preliminary workshop layout plan of each functional area to determine the final workshop layout location of the assembly line.

7. The method for optimizing the layout of a bogie maintenance assembly line workshop according to claim 1, characterized in that: The process and maintenance equipment based on the bogie maintenance process flow determine the optimizable process and process optimization content, including: Based on the logical relationship division of the processes of the bogie maintenance process flow, hard logic relationship processes and soft logic relationship processes are determined; the hard logic relationship is the process relationship in which the operation sequence cannot be adjusted in the process flow; the soft logic relationship is the process relationship in which there is no necessary sequence requirement between the processes in the process flow; Classify the contents of each process in the hard logic relationship process and the soft logic relationship process, and determine the operation, handling, inspection, storage and waiting processes; Classify the operation, handling, inspection, storage and waiting processes into non-value processes and value processes; the non-value processes are used to determine the processes with low importance in the maintenance process flow, and the value processes are used to determine the processes with high importance in the maintenance process flow; According to the hard logic relationship process, soft logic relationship process, non-value process and value process, the optimization goal is to reduce the non-value process and improve the efficiency of the value process; Based on the logical relationship of the process, each process is divided into unmanned process and manual operation process, and the optimization goal of dividing the process layout into unmanned operation area and manual operation area is established; Based on the maintenance equipment and process optimization goals, determine the optimizable processes and process optimization content.

8. A method for optimizing the layout of a bogie maintenance assembly line workshop according to claim 7, characterized in that: The process optimization content of the process that can be optimized is determined based on the maintenance equipment and process optimization objectives, including: Use automated equipment to replace manual labor to perform non-value-added processes; By adjusting the process sequence and increasing batches, the parts required for multiple processes can be concentrated to reduce the number of handling times in the handling process; Optimize inspection processes and use machine vision equipment to provide automated early warning for quality inspection processes during the maintenance process.

9. The method for optimizing the layout of a bogie maintenance assembly line workshop according to claim 1, characterized in that: The optimized bogie maintenance process flow is improved by balancing the assembly line to reduce the buffering and waiting waste during the maintenance process, including: Establish standard working hours for the optimized bogie maintenance process; Obtain production demand and daily operation time of the assembly line; Calculate the target cycle time based on the production demand of the assembly line and the daily operation time; The target cycle is used as the maximum time of the workstation, and the assembly line is divided into workstations using the optimized bogie maintenance process and the standard working hours of the processes; the sum of the standard working hours of the processes in the workstations is less than the target cycle; Use the five elements of man, machine, material, method and loop to optimize the divided workstations, determine the optimized workstations, and determine the balanced and improved assembly line.

10. A railway freight car bogie maintenance line, characterized in that: The assembly line is arranged using the method described in any one of claims 1-9.

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