Layout planning method for upgrading and reconstruction of fan general assembly workshop

Abstract

The invention belongs to the technical field of industrial workshop layout planning, and particularly discloses a fan general assembly workshop upgrading and reconstruction layout planning method which is characterized by comprising the following steps: S1, current situation investigation and analysis; s2, demand and target setting; s3, designing a layout scheme; s4, evaluating and optimizing the scheme; s5, making an implementation plan; s6, training and communication; s7, implementing and supervising; s8, checking and accepting and summarizing: checking and accepting the upgraded and reconstructed workshop, verifying whether a set target is reached or not, collecting operation data for continuous improvement, and summarizing upgrading and reconstruction experience; according to the whole process from current situation analysis to acceptance summarization, the production efficiency can be effectively improved, the logistics cost is reduced, and future intelligent upgrading is supported; the method is suitable for layout optimization of various manufacturing workshops, and has high practicability and popularization value.

Description

Technical Field

[0001] The present invention relates to the technical field of industrial workshop layout planning, and in particular to a layout planning method for upgrading and transforming a fan assembly workshop. Background Art

[0002] The wind turbine assembly workshop is the core link in the wind turbine production process. It is responsible for the systematic assembly, commissioning, and testing of various components (blades, hubs, gearboxes, generators, tower sections, etc.), ultimately forming a complete wind turbine. With the rapid development of the new energy industry, wind turbines, as key equipment for wind power generation, their production efficiency and product quality are crucial to the efficiency and safe operation of wind power generation.

[0003] With the rapid development of the wind turbine manufacturing industry, production efficiency, cost control, and process optimization in wind turbine assembly workshops have become key areas of focus for companies. However, traditional workshop layouts often suffer from issues such as irrational equipment configuration, lengthy logistics routes, and production bottlenecks, which limit improvements in production efficiency. Summary of the Invention

[0004] The purpose of the present invention is to provide a layout planning method for upgrading and transforming a wind turbine assembly workshop, so as to solve the problems of unreasonable equipment configuration, lengthy logistics routes, production bottlenecks and the limitation of production efficiency improvement in traditional workshop layout.

[0005] To achieve the above-mentioned purpose, the present invention provides the following technical solution: a layout planning method for upgrading and renovating a wind turbine assembly workshop, comprising the following steps:

[0006] S1. Current situation investigation and analysis: Conduct a detailed investigation of the current wind turbine assembly workshop layout, equipment configuration, production process, and logistics routes. Collect workshop floor plans, equipment lists, production process flow charts, material flow data, and personnel configuration data to analyze the advantages and disadvantages of the existing layout.

[0007] S2. Demand and goal setting: Set upgrade and transformation goals based on the company's development strategy and market demand. The upgrade and transformation goals include improving production efficiency, reducing logistics costs, and alleviating production bottlenecks. They also determine the production capacity requirements, equipment configuration, and staffing after the upgrade and transformation.

[0008] S3. Layout scheme design: Based on the results of the current situation survey, the system layout design (SLP) method is adopted to combine logistics relationships, non-logistics relationships and space requirements to design a new layout scheme and draw a layout diagram.

[0009] S4. Scheme evaluation and optimization: Use discrete event simulation software or cardboard simulation to simulate and evaluate layout schemes, optimize material handling paths, equipment utilization, production cycle time, and space utilization.

[0010] S5. Develop an implementation plan. Develop a detailed upgrade and renovation implementation plan, including timetable, personnel division of labor, material preparation, risk assessment and response measures.

[0011] S6. Training and Communication: Provide training to personnel involved in the upgrade and renovation, covering the operating procedures, safety regulations and emergency response processes of the new layout, and strengthen communication between departments to ensure collaboration.

[0012] S7. Implementation and supervision: Gradually advance the upgrade and renovation work according to the implementation plan, regularly check progress, quality control and problem solving to ensure that the upgrade and renovation are carried out as planned.

[0013] S8. Acceptance and summary: Acceptance of the upgraded workshop to verify whether the set goals have been achieved, collection of operating data for continuous improvement, and summary of the upgrade and transformation experience.

[0014] Preferably, the current situation investigation and analysis steps include data collection, process analysis, problem diagnosis and data modeling.

[0015] Data collection: collect information on the model, quantity, and location of existing equipment in the workshop, and record material flow paths, storage areas, and handling tools.

[0016] Process analysis, drawing the existing production process flow chart, identifying key processes, bottleneck stations and links with low logistics efficiency.

[0017] Problem diagnosis: Use the 5W1H analysis method (What-Why-Where-When-Who-How) to evaluate the rationality of the existing layout and identify the key factors affecting production efficiency.

[0018] Data modeling: Use CAD or 3D modeling software to build a digital twin model of the workshop to facilitate subsequent simulation optimization.

[0019] Preferably, the demand and goal setting includes determining the target production capacity after the workshop upgrade, evaluating whether it is necessary to add, eliminate or rearrange equipment based on production process requirements, setting targets for shortening material handling distances and reducing work-in-process inventory, considering the operator's work comfort and safety, and optimizing the workstation layout.

[0020] Preferably, the system layout design includes logistics relationship analysis, non-logistics relationship analysis, and space planning.

[0021] Logistics relationship analysis: calculate the material flow intensity between each process and optimize equipment layout to reduce transportation distance.

[0022] Non-logistics relationship analysis: Consider the impact of personnel collaboration and environmental factors (such as noise, temperature and humidity) on the layout.

[0023] Space planning: rationally allocate workshop space based on equipment size, safety distance, and future expansion needs.

[0024] Generate at least 2-3 feasible layout plans based on the system layout design for subsequent evaluation and selection.

[0025] Preferably, the solution evaluation and optimization includes simulation modeling, cardboard simulation verification, key indicator optimization and cost-benefit analysis.

[0026] Simulation modeling uses discrete event simulation software such as FlexSim and Plant Simulation to simulate production processes and evaluate equipment utilization, production cycle time, and logistics efficiency.

[0027] Cardboard simulation verification: simulate the new layout on a physical model or sandbox to verify the rationality of equipment placement and logistics paths.

[0028] Optimize key indicators and adjust layout plans based on simulation results to shorten production cycles, reduce material handling time, and improve space utilization.

[0029] Cost-benefit analysis: evaluate the renovation costs and expected benefits of different layout options and select the optimal option.

[0030] Preferably, the implementation plan formulation includes dividing the upgrade and renovation into equipment relocation, new equipment installation, and system debugging stages, and formulating a detailed timetable; clarifying personnel responsibilities and arranging the collaboration method between equipment suppliers, construction teams, and internal personnel; identifying possible equipment failures, construction delays, and other problems, and formulating countermeasures; and calculating the upgrade and renovation costs to ensure that the renovation is completed within the budget.

[0031] Preferably, the training and communication include special training on equipment operation, logistics management, and safety regulations under the new layout; organizing production, logistics, equipment maintenance and other departments to jointly participate in program discussions to ensure that the needs of each department are met; and conducting small-scale trial runs before formal implementation to identify and resolve potential problems.

[0032] Preferably, the implementation and supervision include using a Gantt chart or project management software to track the progress of the transformation to ensure that it proceeds as planned; conducting quality inspections on key links such as equipment installation and system debugging; and establishing a rapid response mechanism to promptly resolve problems encountered during implementation.

[0033] Preferably, the acceptance and summary include comparing key indicators of production efficiency and logistics costs before and after the upgrade to verify the transformation effect; summarizing problems encountered during the implementation process and solutions to form experience documents.

[0034] Compared with the prior art, the present invention has the following beneficial effects:

[0035] This method, which covers the entire process from current situation analysis to acceptance summary, can effectively improve production efficiency, reduce logistics costs, and support future intelligent upgrades. This method is applicable to layout optimization of workshops in various manufacturing industries and has high practicality and promotion value. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 It is a schematic diagram of the process of the present invention. DETAILED DESCRIPTION

[0037] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0038] See also Figure 1 The present invention provides a technical solution, a layout planning method for upgrading and renovating a wind turbine assembly workshop, comprising the following steps:

[0039] Step 1. Current Situation Research and Analysis: Conduct a detailed investigation of the current wind turbine assembly workshop layout, equipment configuration, production process, and logistics routes. Collect workshop floor plans, equipment lists, production process flow charts, material flow data, and personnel configuration data to analyze the advantages and disadvantages of the existing layout.

[0040] Furthermore, the current situation investigation and analysis includes data collection, process analysis, problem diagnosis and data modeling.

[0041] Data collection: collect information on the model, quantity, and location of existing equipment in the workshop, and record material flow paths, storage areas, and handling tools.

[0042] Process analysis, drawing the existing production process flow chart, identifying key processes, bottleneck stations and links with low logistics efficiency.

[0043] Problem diagnosis: Use the 5W1H analysis method (What-Why-Where-When-Who-How) to evaluate the rationality of the existing layout and identify the key factors affecting production efficiency.

[0044] Data modeling: Use CAD or 3D modeling software to build a digital twin model of the workshop to facilitate subsequent simulation optimization.

[0045] Step 2: Demand and goal setting: Set upgrade and transformation goals based on the company's development strategy and market demand. The upgrade and transformation goals include improving production efficiency, reducing logistics costs, and reducing production bottlenecks. They also determine the production capacity requirements, equipment configuration, and staffing after the upgrade and transformation.

[0046] Furthermore, the demand and goal setting includes determining the target production capacity after the workshop upgrade, evaluating whether it is necessary to add, eliminate or rearrange equipment based on production process requirements, setting targets for shortening material handling distances and reducing work-in-process inventory, considering the work comfort and safety of operators, and optimizing workstation layout.

[0047] Step 3: Layout plan design: Based on the results of the current situation survey, the system layout design (SLP) method is adopted to combine logistics relationships, non-logistics relationships and space requirements to design a new layout plan and draw a layout diagram.

[0048] Furthermore, the system layout design includes logistics relationship analysis, non-logistics relationship analysis, and space planning.

[0049] Logistics relationship analysis: calculate the material flow intensity between each process and optimize equipment layout to reduce transportation distance.

[0050] Non-logistics relationship analysis: Consider the impact of personnel collaboration and environmental factors (such as noise, temperature and humidity) on the layout.

[0051] Space planning: Rationally allocate workshop space based on equipment size, safety spacing, and future expansion needs.

[0052] Generate at least 2-3 feasible layout plans based on the system layout design for subsequent evaluation and selection.

[0053] Step 4: Plan evaluation and optimization: Use discrete event simulation software or cardboard simulation to simulate and evaluate the layout plan to optimize material handling paths, equipment utilization, production cycle time and space utilization.

[0054] Furthermore, the solution evaluation and optimization includes simulation modeling, cardboard simulation verification, key indicator optimization and cost-benefit analysis.

[0055] Simulation modeling uses discrete event simulation software such as FlexSim and Plant Simulation to simulate production processes and evaluate equipment utilization, production cycle time, and logistics efficiency.

[0056] Cardboard simulation verification: simulate the new layout on a physical model or sandbox to verify the rationality of equipment placement and logistics paths.

[0057] Optimize key indicators and adjust layout plans based on simulation results to shorten production cycles, reduce material handling time, and improve space utilization.

[0058] Cost-benefit analysis: evaluate the renovation costs and expected benefits of different layout options and select the optimal option.

[0059] Step 5: Develop an implementation plan. Develop a detailed upgrade and renovation implementation plan, including timetable, personnel division of labor, material preparation, risk assessment and response measures.

[0060] Furthermore, the implementation plan includes dividing the upgrade and renovation into equipment relocation, new equipment installation, and system debugging stages, and formulating a detailed timetable; clarifying personnel responsibilities and arranging the collaboration method between equipment suppliers, construction teams, and internal personnel; identifying possible equipment failures, construction delays, and other problems, and formulating countermeasures; calculating the upgrade and renovation costs to ensure that the renovation is completed within the budget.

[0061] Step 6: Training and Communication: Provide training to personnel involved in the upgrade and renovation, covering the operating procedures, safety regulations and emergency response processes of the new layout, and strengthen communication between departments to ensure collaboration.

[0062] Furthermore, the training and communication include special training on equipment operation, logistics management, and safety regulations under the new layout; organizing production, logistics, equipment maintenance and other departments to jointly participate in plan discussions to ensure that the needs of each department are met; and conducting small-scale trial runs before formal implementation to identify and resolve potential problems.

[0063] Step 7: Implementation and Supervision: Gradually advance the upgrade and renovation work according to the implementation plan, regularly check progress, quality control and problem solving to ensure that the upgrade and renovation are carried out as planned.

[0064] Furthermore, the implementation and supervision include using Gantt charts or project management software to track the progress of the transformation to ensure that it proceeds as planned; conducting quality inspections on key links such as equipment installation and system debugging; and establishing a rapid response mechanism to promptly resolve problems encountered during implementation.

[0065] Step 8: Acceptance and Summary: Acceptance of the upgraded workshop to verify whether the set goals have been achieved, collect operating data for continuous improvement, and summarize the upgrade and transformation experience.

[0066] Furthermore, the acceptance and summary include comparing key indicators of production efficiency and logistics costs before and after the upgrade to verify the transformation effect; summarizing problems encountered and solutions during the implementation process to form an experience document.

[0067] In summary, this invention provides a systematic layout planning method for upgrading and renovating wind turbine assembly workshops, achieving scientific optimization through eight key steps. This method first establishes a digital twin model through a detailed current situation survey. Then, based on the company's strategic needs, quantitative goals are set. Multiple optimization solutions are generated using the System Layout Design (SLP) method, which are then validated and evaluated through a combination of digital and physical simulations. During the implementation phase, a project management approach is employed to ensure the quality of the renovation, and the results are ultimately verified through data comparison. This method specifically emphasizes logistics optimization, flexible production, ergonomics, and digital integration, addressing the challenges of low logistics efficiency, insufficient production flexibility, and poor space utilization inherent in traditional workshop layouts. By incorporating advanced technologies such as discrete event simulation and digital twins, layout planning shifts from experience-driven to data-driven, providing a systematic solution for the intelligent upgrade of wind turbine assembly workshops. This method is quantifiable, verifiable, and scalable, effectively improving production efficiency by over 20%, reducing logistics costs by 15%-30%, and providing a framework for subsequent intelligent manufacturing upgrades.

[0068] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus.

[0069] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A layout planning method for upgrading and renovating a wind turbine assembly workshop, characterized in that , including the following steps: S1. Current situation investigation and analysis: Conduct a detailed investigation of the current wind turbine assembly workshop layout, equipment configuration, production process, and logistics routes. Collect workshop floor plans, equipment lists, production process flow charts, material flow data, and personnel allocation data to analyze the advantages and disadvantages of the existing layout. S2. Demand and goal setting: Based on the company's development strategy and market demand, set upgrade and transformation goals. These goals include improving production efficiency, reducing logistics costs, and alleviating production bottlenecks. The production capacity requirements, equipment configuration, and staffing requirements after the upgrade and transformation are also determined. S3. Layout design: Based on the results of the current situation survey, a system layout design method is used to combine logistics relationships, non-logistics relationships and space requirements to design a new layout plan and draw a layout diagram; S4. Scheme evaluation and optimization: Use discrete event simulation software or cardboard simulation to simulate and evaluate layout schemes, optimize material handling paths, equipment utilization, production cycle time, and space utilization; S5. Implementation plan formulation: Develop a detailed implementation plan for the upgrade and renovation, including timetable, personnel division, material preparation, risk assessment, and response measures; S6. Training and Communication: Provide training to personnel involved in the upgrade and renovation, covering the new layout's operating procedures, safety regulations, and emergency response processes, and strengthen inter-departmental communication to ensure collaboration; S7. Implementation and supervision: Progressively advance the upgrade and renovation work according to the implementation plan, regularly check progress, quality control, and problem solving to ensure that the upgrade and renovation are carried out as planned; S8. Acceptance and summary: Acceptance of the upgraded workshop to verify whether the set goals have been achieved, collection of operating data for continuous improvement, and summary of the upgrade and transformation experience.

2. A layout planning method for upgrading and renovating a wind turbine assembly workshop according to claim 1, characterized in that: The current situation investigation and analysis steps include data collection, process analysis, problem diagnosis and data modeling; Data collection: collect information on the model, quantity, and location of existing equipment in the workshop, and record material flow paths, storage areas, and handling tools. Process analysis, drawing the existing production process flow chart, identifying key processes, bottleneck stations and links with low logistics efficiency. Problem diagnosis: Use the 5W1H analysis method to evaluate the rationality of the existing layout and identify the key factors affecting production efficiency. Data modeling: Use CAD or 3D modeling software to build a digital twin model of the workshop to facilitate subsequent simulation optimization.

3. The layout planning method for upgrading and renovating a wind turbine assembly workshop according to claim 1, characterized in that: The demand and goal setting includes determining the target production capacity after the workshop upgrade, evaluating whether it is necessary to add, eliminate or rearrange equipment based on production process requirements, setting targets for shortening material handling distances and reducing work-in-process inventory, considering the work comfort and safety of operators, and optimizing workstation layout.

4. The layout planning method for upgrading and renovating a wind turbine assembly workshop according to claim 1, characterized in that: The system layout design includes logistics relationship analysis, non-logistics relationship analysis, and space planning; Logistics relationship analysis: calculate the material flow intensity between each process and optimize equipment layout to reduce transportation distance; Non-logistics relationship analysis: consider the impact of personnel collaboration and environmental factors on layout; Space planning: Rationally allocate workshop space based on equipment size, safety spacing, and future expansion needs.

5. The layout planning method for upgrading and renovating a wind turbine assembly workshop according to claim 1 is characterized by: The solution evaluation and optimization includes simulation modeling, cardboard simulation verification, key indicator optimization and cost-benefit analysis; Simulation modeling, using discrete event simulation software such as FlexSim and Plant Simulation to simulate production processes and evaluate equipment utilization, production cycle time, and logistics efficiency; Cardboard simulation verification: simulate the new layout on a physical model or sandbox to verify the rationality of equipment placement and logistics paths; Optimize key indicators and adjust layout plans based on simulation results to shorten production cycles, reduce material handling time, and improve space utilization; Cost-benefit analysis: evaluate the renovation costs and expected benefits of different layout options and select the optimal option.

6. The layout planning method for upgrading and renovating a wind turbine assembly workshop according to claim 1, characterized in that: The implementation plan includes dividing the upgrade and renovation into the stages of equipment relocation, new equipment installation, and system commissioning, and establishing a detailed timetable; clarifying personnel responsibilities and arranging collaboration methods for equipment suppliers, construction teams, and internal personnel; identifying possible equipment failures, construction delays, and other problems, and formulating countermeasures; and calculating the upgrade and renovation costs to ensure that the renovation is completed within the budget.

7. The layout planning method for upgrading and renovating a wind turbine assembly workshop according to claim 1, characterized in that: The training and communication include specialized training on equipment operation, logistics management, and safety regulations under the new layout; Organize production, logistics, equipment maintenance and other departments to participate in plan discussions to ensure that the needs of each department are met; conduct small-scale trial runs before formal implementation to identify and resolve potential problems.

8. The layout planning method for upgrading and renovating a wind turbine assembly workshop according to claim 1, characterized in that: The implementation and supervision mentioned above include using Gantt charts or project management software to track the progress of the transformation to ensure that it is carried out as planned; conducting quality inspections on key links such as equipment installation and system debugging; and establishing a rapid response mechanism to promptly resolve problems encountered during the implementation process.

9. The layout planning method for upgrading and renovating a wind turbine assembly workshop according to claim 1, characterized in that: The acceptance and summary includes comparing key indicators of production efficiency and logistics costs before and after the upgrade to verify the transformation effect; Summarize the problems and solutions encountered during the implementation process to form an experience document.

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