Production line balancing method, system, equipment and medium

Abstract

The invention provides a production line balancing system, method, equipment and medium, and relates to the technical field of intelligent manufacturing, a process data reading module is used for obtaining process list data of an automobile product to be subjected to balance analysis and factory production line data, and a single-line production line balancing module is used for carrying out balance analysis on the automobile product based on basic description information of each process; determining the key level of each process; and based on the basic resource information of the plurality of stations, according to the station allocation mode corresponding to the key level of each process, allocating the station for each process from the plurality of stations, so as to realize automatic production line balance analysis and improve the efficiency of the production line.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing technology, and more specifically, to a production line balancing method, system, equipment, and medium. Background Technology

[0002] In existing technologies, production line balancing analysis technology mainly relies on manually constructing a standard time library, allocating standard actions to each process, and manually dividing workstations and manually configuring workers in the Bill of Process (BOP). Since subjective judgment by humans can easily lead to the allocation scheme deviating from the optimal solution, it is difficult to guarantee the consistency and reliability of the analysis results. Furthermore, the process of manually allocating process, workstation, and worker information is extremely cumbersome, especially in complex production lines, where repeated adjustments and verifications are required, resulting in significant consumption of manpower and time costs. Summary of the Invention

[0003] In view of this, the purpose of the present invention is to provide a production line balancing method, system, equipment and medium to achieve automated production line balancing analysis and improve production line efficiency.

[0004] In a first aspect, this application provides a production line balancing system, comprising: The process data reading module is used to acquire the process list data and factory production line data of the automotive products to be balanced and analyzed. The process list data includes multiple processes and basic description information of multiple processes; the factory production line data includes multiple workstations and basic resource information of multiple workstations. The single-line production line balancing module is used to determine the criticality level of each process based on the basic description information of each process; and to allocate workstations to each process from multiple workstations based on the basic resource information of multiple workstations, according to the workstation allocation method corresponding to the criticality level of each process.

[0005] Optionally, the process data reading module is used to read the process list data of the automotive product to be balanced from the PLM system, extract the factory production line identifier, cycle time, and allowance factor of the automotive product, as well as the process duration of each process from the process list data; obtain the total number of workstations in the factory production line corresponding to the automotive product based on the factory production line identifier; determine the baseline operation time of each workstation based on the total number of workstations and the process duration of each process; determine the baseline number of workers for each workstation based on the baseline operation time, cycle time, and allowance factor; and determine the basic resource information of each workstation based on the baseline operation time and the baseline number of workers.

[0006] Optionally, the single-line production line balancing module is used to extract the workstation association information, process sequence identifier, process duration, and number of preceding processes for each process from the process list data; based on the workstation association information of each process, processes with specified workstations are classified as first critical level; based on the process sequence identifier, process duration, and number of preceding processes for each process, critical path processes are selected from processes other than those of the first critical level and classified as second critical level; processes other than those of the first and second critical levels are classified as third critical level; wherein, the workstation allocation priority of the first critical level is higher than that of the second critical level, and the workstation allocation priority of the second critical level is higher than that of the third critical level.

[0007] Optionally, the single-line production line balancing module is used to assign each process to the workstation corresponding to its workstation association information for each process of the first critical level; for each process of the second critical level, based on the process sequence identifier, process duration, and number of preceding processes, the criticality of each process is determined, and each process is selected as the current process in descending order of criticality. Based on the workstation association information of the current process, each workstation associated with the current process is determined as a candidate workstation, and a workstation that meets the set conditions is selected as the target workstation, and the current process is assigned to the target workstation; For each process in the third critical level, a random selection method without replacement is used to select each process as the current process. Based on the workstation association information of the current process, each workstation associated with the current process is determined as a candidate workstation. From the candidate workstations, a workstation that meets the set conditions is selected as the target workstation, and the current process is assigned to the target workstation. The set conditions include: after the current process is assigned to a candidate workstation, the total number of workers required for the candidate workstation is less than the baseline number of workers for the candidate workstation, the total operation time including losses for the candidate workstation is less than the cycle time, and the total operation time of all critical path processes of the candidate workstation is less than the cycle time.

[0008] Optionally, the single-line production line balancing module is used to determine the total worker demand for the next target station based on the difference between the base number of workers at the target station and the total worker demand at the target station if the total worker demand at the current target station is less than the base number of workers at the target station.

[0009] Optionally, the single-line production line balancing module is used to determine the current line balancing rate of the automotive product to be analyzed based on the standard operating time and maximum total working time required for all processes of the automotive product to be analyzed; if the current line balancing rate is determined to be less than the preset value of the line balancing rate, then based on the worker load rate, the workstation corresponding to the highest worker load rate is determined as the adjustment workstation, and any process in the adjustment workstation is assigned to the workstation adjacent to the adjustment workstation, and then the workstation adjacent to the adjustment workstation is determined to meet the set conditions.

[0010] Optionally, the production line balancing system provided in this application further includes: The mixed-line production line balancing module is used to allocate the processes corresponding to each automotive product model to each workstation through the single-line production line balancing module. Each workstation has a total number of workers corresponding to each automotive product model, and the total number of workers with the largest number is selected as the target total number of workers for each workstation. The mixed-line balancing rate is determined based on the actual total working hours required for each automotive product model and the total working hours of each workstation. When the mixed-line balancing rate is less than the mixed-line balancing rate threshold, the worker load rate for each worker at each workstation is determined based on the number of workers corresponding to each automotive product model at each workstation and the production proportion of each automotive product model. If the worker load rate for each worker at each workstation fluctuates greatly, the movable processes in the preceding or following processes of each workstation are allocated to workers with low worker load rates.

[0011] Secondly, this application provides a production line balancing method, applied to a production line balancing system, comprising: Obtain the process list data and factory production line data of the automotive products to be balanced; the process list data includes multiple processes and basic descriptions of multiple processes; the factory production line data includes multiple workstations and basic resource information of multiple workstations. Based on the basic description information of each process, determine the criticality level of each process; Based on the basic resource information of multiple workstations, workstations are allocated to each process from multiple workstations according to the workstation allocation method corresponding to the critical level of each process.

[0012] Thirdly, this application also provides a computer device, including a memory and a processor, wherein the memory stores a computer program that can run on the processor, characterized in that the processor executes the computer program to implement the above-mentioned production line balancing method.

[0013] Fourthly, this application also provides a computer-readable storage medium storing machine-executable instructions that, when called and executed by a processor, implement the above-described production line balancing method.

[0014] This invention provides a production line balancing system, method, equipment, and medium. The system acquires process list data and factory production line data for the automotive product to be balanced through a process data reading module. A single-line production line balancing module determines the criticality level of each process based on its basic description information. Based on the basic resource information of multiple workstations, workstations are allocated to each process from among multiple workstations according to the workstation allocation method corresponding to the criticality level of each process, thereby achieving automated production line balancing analysis and improving production line efficiency.

[0015] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 A schematic diagram of a production line balancing system provided in an embodiment of the present invention is shown; Figure 2 This diagram illustrates the structure of the product-process-factory-resource data provided in an embodiment of the present invention. Figure 3 This diagram illustrates the structure of the process list data provided in an embodiment of the present invention. Figure 4 A schematic diagram of the process and fixed equipment provided in an embodiment of the present invention is shown; Figure 5 This diagram illustrates the structure of BOP data provided in an embodiment of the present invention. Figure 6 A schematic diagram of the overall constraint information provided in an embodiment of the present invention is shown; Figure 7 A schematic diagram of the process sequence relationship model provided in an embodiment of the present invention is shown; Figure 8 A schematic diagram of the line balance analysis results provided in an embodiment of the present invention is shown; Figure 9 A bar chart showing the single-line equilibrium analysis results provided in an embodiment of the present invention is shown. Figure 10 A schematic diagram of the work instruction provided in an embodiment of the present invention is shown; Figure 11 A bar chart showing the results of line mixing equilibrium analysis provided in an embodiment of the present invention is shown. Figure 12 A schematic flowchart of a production line balancing method provided by an embodiment of the present invention is shown; Figure 13 A schematic diagram of the structure of an electronic device provided by an embodiment of the present invention is shown. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0019] To facilitate a better understanding of this application by those skilled in the art, the technical terms used in this application will be briefly introduced below.

[0020] Single-line production line balancing involves optimizing the allocation of work processes on a production line that produces only one type of vehicle model, so that the operation time of each process is as close as possible to the production line cycle time.

[0021] Mixed-line production line balancing optimizes the production line process when multiple different vehicle models are produced simultaneously on the same production line.

[0022] Takt Time (TT) is the maximum time interval allowed for a production line to produce one product or complete one production unit.

[0023] The allowance factor (also known as the "allowance rate") is a proportional coefficient set on the basis of pure operating time (ideal operating time without any delays) to compensate for non-value-added time (such as fatigue, minor equipment failures, material handling delays, etc.) that cannot be completely eliminated in the production process.

[0024] A Bill of Process (BOP) is a detailed list of all processes or steps in the production process, centered on the product. The BOP includes, but is not limited to, vehicle model code, vehicle model name, production line code, production line name, BOP name, BOP identifier (BOPuid), process identifier, process code, process name, process description, working hours, workstation, and preceding processes.

[0025] Product Lifecycle Management (PLM) is a management system applied to the entire lifecycle of a product, from concept design to retirement.

[0026] After introducing the technical terms used in this application, the technical solution provided in this application will be described in detail below.

[0027] This application provides a production line balancing system, see below. Figure 1 As shown, the production line balancing system provided in this application embodiment includes a process data reading module 110, a single-line production line balancing module 120, and a mixed-line production line balancing module 130.

[0028] The process data reading module 110 is used to acquire the process list data and factory production line data of the automotive products to be balanced and analyzed; wherein, the process list data includes multiple processes and basic description information of multiple processes; the factory production line data includes multiple workstations and basic resource information of multiple workstations.

[0029] In this embodiment of the application, by associating the process list with automotive products and factory production lines in the PLM system, complete 3PR data (product-process-factory-resource data) is formed, such as... Figure 2 As shown, process list related attributes are set in the 3PR data to complete the structural association between material input and process resources (such as tools and fixtures).

[0030] To facilitate automatic process allocation during line balancing analysis, such as Figure 3 As shown, the process list data for automotive products is designed as flat data, meaning that the process list data includes basic description information for multiple processes. The basic description information for each process includes process number, process name, process description, working hours, work station number, preceding processes and / or the preceding and following relationships between processes.

[0031] To ensure a precise match between process design and on-site equipment resources, such as Figure 4 As shown, the factory production line data provided in this application embodiment includes production lines and workstations. Each workstation is equipped with fixed equipment. If a certain process requires the use of specific fixed equipment to complete, the workstation number information corresponding to the process is marked in the process attribute of the process data to clarify that the process must be performed at the designated workstation.

[0032] In practical implementation, after obtaining the process list of the automotive product to be balanced and analyzed, the process data reading module 110 reads information such as vehicle model code, vehicle model name, production line code, production line name, BOP name, BOPuid, process uid, process code, process name, process description, working hours, workstation, and preceding processes from the process list. Structurally, it stores this information in a production line-vehicle model-BOP structure. Because the process may undergo optimization and changes, the process data reading module 110 adds a time suffix to the BOP name when obtaining it. This time is the current system operation time, to distinguish BOP data obtained at different times. Figure 5 As shown.

[0033] The single-line production line balancing module 120 is used to determine the critical level of each process based on the basic description information of each process; and to allocate workstations for each process from multiple workstations based on the basic resource information of multiple workstations and according to the workstation allocation method corresponding to the critical level of each process.

[0034] In the production line balancing system provided in this application embodiment, the process data reading module 110 acquires the process list data and factory production line data of the automotive product to be balanced and analyzed. The single-line production line balancing module 120 takes the basic description information of each process as input, and according to the critical level of each process, adopts the corresponding workstation allocation method or rule corresponding to the critical level to allocate a suitable workstation from multiple available workstations to each process, so as to achieve the balancing optimization of the production line, so that the processes on the production line can be better allocated to the corresponding workstations, thereby improving the efficiency of the entire production process.

[0035] In this embodiment, the process data reading module 110 is used to read the process list data of the automotive product to be balanced from the PLM system, extract the factory production line identifier, cycle time, and allowance factor of the automotive product, as well as the process duration of each process from the process list data; obtain the total number of workstations in the factory production line corresponding to the automotive product based on the factory production line identifier; determine the baseline operation time of each workstation based on the total number of workstations and the process duration of each process; determine the baseline number of workers for each workstation based on the baseline operation time, cycle time, and allowance factor; and determine the basic resource information of each workstation based on the baseline operation time and the baseline number of workers.

[0036] In practical implementation, the process data reading module 110 reads the process list data of the automotive product to be balanced from the PLM system, and extracts the corresponding overall constraint information of the automotive product from the process list data. This overall constraint information includes factory production line identification, cycle time and / or allowance factor, and the process time of each operation, such as... Figure 6 As shown.

[0037] In the embodiments of this application, the baseline number of workers for each workstation is determined in ways including but not limited to the following: Based on the time taken for each process, determine the total working time for all processes in the BOP; Based on the total working hours of all processes in the BOP and the total number of workstations in the factory production line, determine the baseline operation time for each workstation. The baseline number of workers for each workstation is determined based on the baseline operation time, relaxation factor, and cycle time for each workstation.

[0038] The mathematical expression for the total working time of all processes in BOP is:

[0039] In the formula, The total man-hours for all processes in BOP. The time allotted for each process step; The mathematical expression for the baseline operation time of each workstation:

[0040] In the formula, The baseline operation time for each workstation, where N is the total number of workstations in the factory production line; The mathematical expression for the baseline number of workers per workstation is:

[0041] In the formula, The baseline number of workers for each workstation. This is the leniency factor. This refers to the beat time.

[0042] The baseline number of workers for each workstation is an integer. For example, if the baseline number of workers for a workstation is calculated to be 2.8, then the baseline number of workers for that workstation is 3.

[0043] In this embodiment, the single-line production line balancing module 120 is used to extract the workstation association information, process sequence identifier, process duration, and number of preceding processes for each process from the process list data; based on the workstation association information of each process, processes with designated workstations are classified into a first critical level; based on the process sequence identifier, process duration, and number of preceding processes for each process, critical path processes are selected from processes other than those in the first critical level and classified into a second critical level; processes other than those in the first and second critical levels are classified into a third critical level; wherein, the workstation allocation priority of the first critical level is greater than that of the second critical level, and the workstation allocation priority of the second critical level is greater than that of the third critical level.

[0044] In the embodiments of this application, the key levels of each process include, but are not limited to, the following: The single-line production line balancing module 120 extracts the station association information of each process (i.e., the complete process at a specific station) from the process list data, and establishes a first critical level mapping relationship according to the station code and process set. For example, if processes A and B must be at station 1, then processes A and B constitute a process set and establish a mapping relationship with station 1. At the same time, it is necessary to record the process time and the number of preceding processes for processes A and / or B. Based on the pre- and post-process relationships (i.e., the second critical level) in the process list data, a pre- and post-process relationship model is constructed to support logical verification of subsequent process allocations, such as... Figure 7 As shown; All processes other than those at the first and second critical levels are classified as third critical levels.

[0045] In this embodiment, the single-line production line balancing module 120 is used to assign each process of the first critical level to the workstation corresponding to its workstation association information; for each process of the second critical level, based on the process sequence identifier, process duration, and number of preceding processes, the criticality of each process is determined, and each process is selected as the current process in descending order of criticality. Based on the workstation association information of the current process, each workstation associated with the current process is determined as a candidate workstation, and a workstation that meets the set conditions is selected as the target workstation from the candidate workstations, and the current process is assigned to the target workstation. For each process in the third critical level, a random selection method without replacement is used to select each process as the current process. Based on the workstation association information of the current process, each workstation associated with the current process is determined as a candidate workstation. From the candidate workstations, a workstation that meets the set conditions is selected as the target workstation, and the current process is assigned to the target workstation. The set conditions include: after the current process is assigned to a candidate workstation, the total number of workers required for the candidate workstation is less than the baseline number of workers for the candidate workstation, the total operation time including losses for the candidate workstation is less than the cycle time, and the total operation time of all critical path processes of the candidate workstation is less than the cycle time.

[0046] In this embodiment of the application, the single-line production line balancing module 120 is used to determine the total worker demand of the next target station based on the base number of workers at the target station and the difference between the total worker demand of the target station and the base number of workers at the target station if the total worker demand of the current target station is less than the base number of workers at the target station.

[0047] In this embodiment of the application, workstations are allocated to each process from multiple workstations according to the workstation allocation method corresponding to the criticality level of each process. The specific process is as follows: First, based on the mapping relationship of the first critical level, the processes of the first critical level are assigned to the corresponding workstations; Secondly, the processes at the second critical level are allocated based on their sequence identifier, duration, and number of preceding processes. The criticality of each process is determined, and processes are selected as current processes in descending order of criticality. Based on the workstation association information of the current process, each workstation associated with the current process is identified as a candidate workstation. From the candidate workstations, the workstation that meets the set conditions is selected as the target workstation, and the current process is assigned to the target workstation. Finally, the processes at the third critical level are assigned using a random, non-replacement selection method. Each process is selected as the current process. Based on the workstation association information of the current process, each workstation associated with the current process is identified as a candidate workstation. From these candidate workstations, a workstation that meets the set conditions is selected as the target workstation, and the current process is assigned to the target workstation. The set conditions are: the total number of workers required for the candidate workstations is less than the baseline number of workers for the candidate workstations (i.e., ...). The total loss-inclusive operation time of the candidate workstations is less than the cycle time (i.e.) In the formula, Work hours have been allocated to the current workers. If the total process time of all critical path processes of the candidate workstation is less than the cycle time, and the set conditions cannot be met, then the next workstation will be assigned. If the number of workers allocated is less than the baseline number of workers due to the pre-process constraints of the previous workstation, the next workstation will prioritize allocating workers based on the baseline number of workers plus the number of workers short of the previous workstation. For example, if the calculated value of μ is 3 people, and the number of workers allocated to workstation 001 is 2 people, which does not meet the baseline number of workers and the number of workers short is 1 person, then workstation 002 will allocate processes based on the baseline number of 4 workers (i.e., the baseline number of workers is 3 people plus the number of workers short of 1 person).

[0048] In this embodiment, the single-line production line balancing module 120 is used to determine the current line balancing rate of the automotive product to be analyzed based on the standard operating time and maximum total working time required for all processes of the automotive product to be analyzed. If the current line balancing rate is determined to be less than the preset value of the line balancing rate, the workstation corresponding to the highest workstation load rate is determined as the adjustment workstation based on the worker load rate. After any process in the adjustment workstation is assigned to the workstation adjacent to the adjustment workstation, it is determined that the workstation adjacent to the adjustment workstation meets the set conditions.

[0049] In a specific implementation, after all processes are assigned to their corresponding workstations, the current line balance rate is first calculated using the following formula:

[0050] In the formula, Line balance rate For the largest total worker process time, The total number of workers; Then, determine whether the current line balance rate is less than the preset line balance rate value (e.g., 85%). If it is less, adjust the production line corresponding to the current line balance rate. If it is greater, determine the line balance analysis result corresponding to the last adjusted production line. The adjustment process is as follows: from the processes assigned to the worker with the highest worker load rate, assign any process corresponding to the worker with the highest worker load rate to the worker corresponding to the adjacent workstation, and the adjacent workstation meets the set conditions (i.e., the total worker demand is less than the baseline number of workers for the candidate workstation, the total loss-inclusive operation time of the candidate workstation is less than the cycle time, and the total operation time of all critical path processes of the candidate workstation is less than the cycle time). The adjacent workstation is the workstation adjacent to the workstation corresponding to the worker with the highest worker load rate. The mathematical expression for worker load rate is:

[0051] In the formula, For worker load rate, The total work hours for a certain worker; Adjustment will stop when the line balance rate is greater than or equal to the preset line balance rate value or when the number of adjustments is reached. If the line balance rate is less than the preset line balance rate value or the number of adjustments has not been reached, then based on the last adjusted production line, the work process list of the 10 workers with the highest current worker load rate in that production line is determined. The line balance analysis results include indicators such as line balance rate, worker-assigned working hours, worker load rate, total load rate, and / or total number of workstations. The total load rate of a single-line production line whose line balance rate is greater than or equal to the preset line balance rate value is calculated using the following formula. :

[0052] The single-line balance rate reflects the uniformity of the process distribution across all workstations; the load rate reflects the saturation level of the production line.

[0053] In this embodiment, the single-line production line balancing module 120 saves the line balancing analysis results into a BOP named with the line balancing BOP name and the sequence number; wherein, the BOP stores the results after the line balancing analysis, including overall parameters such as line balancing rate and total load rate, as well as the workers and process contents allocated to each workstation, such as... Figure 8 As shown.

[0054] In this embodiment, the production line balancing system further includes: a mixed-line production line balancing module 130 for allocating the processes corresponding to each automobile product model to each workstation through the single-line production line balancing module 120; each workstation has a total number of workers corresponding to each automobile product model, and the total number of workers with the largest number is selected as the target total number of workers for each workstation; the mixed-line balancing rate is determined based on the actual total working hours required for each automobile product model and the total working hours of each workstation; when the mixed-line balancing rate is less than the mixed-line balancing rate threshold, the worker load rate corresponding to each worker in each workstation is determined based on the number of workers corresponding to each automobile product model in each workstation and the production proportion of each automobile product model; if the worker load rate corresponding to each worker in each workstation fluctuates greatly, the movable processes in the preceding or following processes in each workstation are allocated to workers with low worker load rates.

[0055] To meet the requirements of flexible production, a mixed-line production line balancing analysis is conducted. In practice, firstly, under the same constraints such as cycle time and allowance factor, the single-line production line balancing module 120 analyzes different car models to obtain the single-line production line balancing results corresponding to different car models. Secondly, based on the mixed-line production ratio (e.g., model A accounts for 60% of production and model B accounts for 40%), and using the single-line production line balancing results for different car models as a basis, the processes corresponding to each car model are determined according to the single-line production line balancing results. Based on the worker demand for each car model at each workstation, processes with low worker demand at workstations are reassigned according to the requirement of more workers. For example, workstation TA004 originally had 2 workers for model A and 3 workers for model B. However, if the worker demand for model B at workstation TA004 is greater than that for model A, then all processes at workstation TA004 that were previously assigned to model A need to be reassigned according to the required number of 3 workers for model B. The number of workers corresponding to each workstation is determined by the number of workers with higher demand for each car model, ensuring that workers can meet the operation requirements of multiple car models during mixed-line production. Then, the mixing balance rate of the mixing production line is calculated using the following formula:

[0056] In the formula, For the line balance rate, Total process time for each vehicle model Production ratio for each vehicle model; If the line mixing balance rate is less than the preset value, the line mixing production line will be adjusted. If the line mixing balance rate is greater than or equal to the preset value, the line mixing balance analysis result will be determined based on the last adjusted line mixing production line. The line mixing balance analysis result includes the calculation of the line mixing balance rate, the number of workers, the worker's single-machine working hours, the worker's line mixing working hours, and / or the total number of workers. The adjustment of mixed-line production lines specifically involves: calculating the weighted load rate of each worker; when there are significant differences in worker load rates, selecting transferable processes from upstream or downstream processes to assign workers with lower load rates; where the worker's weighted load rate... The mathematical expression is:

[0057] The total load rate of a mixing production line with a mixing balance rate greater than or equal to a preset value is calculated using the following formula:

[0058] The line balance rate reflects the uniformity of the process distribution across all workstations; the load rate reflects the saturation level of the production line.

[0059] In this embodiment, the production line balancing system further includes a report generation module 140 and a data interaction module 150; wherein, the report generation module 140 is used to generate a difference report based on the line balancing analysis data obtained by the single-line production line balancing module 120 and / or the mixed-line production line balancing module 130; the data interaction module 150 is used to synchronize the line balancing analysis results, work instructions, and difference reports to the manufacturing operations management system through an interface to support workshop resource management.

[0060] In practical implementation, the report generation module 140 generates a report based on the single-line balancing analysis results output by the single-line production line balancing module 120, such as... Figure 9 The bar chart shown has the X-axis representing workstation number and worker number, and the Y-axis representing working hours. Based on the line balancing analysis results, work instructions are automatically generated according to workstation, worker, and information such as material input, process description, and diagrams in the PLM-BOP. Figure 10As shown; when changes in market demand or proactive adjustments in enterprise production necessitate changes in cycle time, such as increasing production volume and adjusting hourly output, a line balancing analysis can be performed again based on the already read BOP to obtain the line balancing analysis results under the new cycle time. If product or process changes lead to BOP adjustments (such as adding, deleting, or modifying process content), the BOP information in the PLM needs to be reread, and a new line balancing analysis needs to be performed. A difference report can be output based on the results of the two line balancing analyses. The difference report includes constraints (such as single-model versus mixed-line production and cycle time adjustments), basic data and process structure (such as process additions / reductions and changes in fixed workstation processes), resource allocation (such as workstation process replacement costs, number of workers, and division of labor adjustments), load and efficiency indicators (such as changes in quantitative data like line balancing rate and workstation load rate fluctuations), and visual comparisons (such as workstation and worker load differences presented in bar charts). This helps the workshop view changes in process resources and assists in quickly identifying resource adjustment needs. Based on the line mixing balance analysis results output by the line mixing production line balancing module 130, the following is generated: Figure 11 The bar chart shown; and the automatic generation of work instructions based on the mixed-line balancing analysis results, according to the workstation, worker, and information such as material input, process description, and diagrams in PLM-BOP; when the cycle time needs to be changed due to changes in market demand or proactive adjustments in enterprise production, or when BOP needs to be adjusted due to product or process changes (such as adding, deleting, or modifying process content), the BOP information in PLM needs to be reread and the line balancing analysis needs to be performed again; a difference report can be output based on the results of the two line balancing analyses.

[0061] The data interaction module 150 transmits the line balancing analysis results and work instructions to the MOM system through an interface, supporting the production workshop in adjusting process resources and preparing for production.

[0062] The production line balancing system provided in this application embodiment achieves full-process digitization and automation from BOP data reading, constraint definition, automatic process allocation to work instruction generation through deep integration of PLM system and line balancing analysis module, significantly improving engineering design efficiency and consistency of analysis results. By constructing an intelligent allocation model with multi-dimensional constraints including workstation equipment constraints, process pre- and post-process relationships, leniency coefficients, and worker load, and through priority ranking strategies (such as prioritizing critical path processes) and dynamic fine-tuning mechanisms (cross-workstation process transfer, worker number balancing), the system effectively improves line balancing analysis efficiency, reduces compliance rate, and effectively reduces capacity waste and waiting time caused by uneven process allocation. For multi-model mixed-line production needs, a weighted time calculation model based on production ratio and a cross-model process dynamic redistribution strategy are established to support efficient co-line production of different models on the same production line. When the production ratio or model combination changes, the system can automatically update the weighted data and re-optimize process allocation, reducing response time from several days for traditional manual adjustments to hours, significantly improving the production line's ability to quickly respond to personalized market demands. Through PLM… The system's two-way data interaction with the manufacturing operations management system enables real-time synchronization and accurate distribution of line balancing analysis results, work instructions, and variance reports. This ensures complete consistency between the process information obtained in the workshop and the design end, avoids information distortion caused by manual transmission, standardizes production operation processes, reduces process execution deviation rates, and guarantees product quality stability and production management continuity. Based on an independent database storing historical line balancing analysis results and variance comparison data, it supports horizontal comparison and traceability of different versions of BOP and multiple rounds of optimization schemes. Visual variance reports intuitively present resource adjustment needs (such as changes in workstation equipment and worker configuration), providing data support for continuous process improvement and capacity planning, forming a closed-loop management system of "analysis-optimization-verification-iteration".

[0063] This application provides a production line balancing method, such as... Figure 12 As shown, the production line balancing method provided in this application is applied to a production line balancing system, and the method includes: Step 210: Obtain the process list data and factory production line data of the automotive products to be balanced; wherein, the process list data includes multiple processes and basic description information of multiple processes; the factory production line data includes multiple workstations and basic resource information of multiple workstations; Step 220: Based on the basic description information of each process, determine the criticality level of each process; Step 230: Based on the basic resource information of multiple workstations, allocate workstations to each process from multiple workstations according to the workstation allocation method corresponding to the key level of each process.

[0064] It should be noted that the principle of the production line balancing method provided in this application embodiment to solve the technical problem is similar to that of the production line balancing system provided in this application embodiment. Therefore, the implementation of the production line balancing method provided in this application embodiment can refer to the implementation of the production line balancing system provided in this application embodiment, and the repeated parts will not be described again.

[0065] After introducing the production line balancing method and apparatus provided in the embodiments of this application, the electronic equipment provided in the embodiments of this application will be briefly introduced next.

[0066] See Figure 13 As shown, the electronic device 500 provided in this application embodiment includes at least a processor 501, a memory 502, and a computer program stored in the memory 502 and executable on the processor 501. When the processor 501 executes the computer program, it implements the production line balancing method provided in this application embodiment.

[0067] The electronic device 500 provided in this application embodiment may further include a bus 503 connecting different components (including processor 501 and memory 502). The bus 503 represents one or more types of bus structures, including memory bus, peripheral bus, local area bus, etc.

[0068] Memory 502 may include a readable storage medium in the form of volatile memory, such as random access memory (RAM) 5021 and / or cache memory 5022, and may further include read-only memory (ROM) 5023. Memory 502 may also include a program tool 5025 having a set (at least one) of program modules 5024, including but not limited to an operating subsystem, one or more application programs, other program modules, and program data, each or some combination of these examples may include an implementation of a network environment.

[0069] Processor 501 can be a single processing element or a collective term for multiple processing elements. For example, processor 501 can be a central processing unit (CPU) or one or more integrated circuits configured to implement the production line balancing method provided in the embodiments of this application. Specifically, processor 501 can be a general-purpose processor, including but not limited to CPUs, application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc.

[0070] Electronic device 500 can communicate with one or more external devices 504 (e.g., keyboard, remote control, etc.), and also with one or more devices that enable a user to interact with electronic device 500 (e.g., mobile phone, computer, etc.), and / or with devices that enable electronic device 500 to communicate with one or more other electronic devices 500 (e.g., router, modem, etc.). This communication can be performed through input / output (I / O) interface 505. Furthermore, electronic device 500 can also communicate with one or more networks (e.g., local area network (LAN), wide area network (WAN), and / or public networks, such as the Internet) through network adapter 506. Figure 13 As shown, network adapter 506 communicates with other modules of electronic device 500 via bus 503. It should be understood that, although... Figure 13 As not shown, other hardware and / or software modules may be used in conjunction with the electronic device 500, including but not limited to microcode, device drivers, redundant processors, external disk drive arrays, Redundant Arrays of Independent Disks (RAID) subsystems, tape drives, and data backup storage subsystems.

[0071] It should be noted that, Figure 13 The electronic device 500 shown is merely an example and should not impose any limitations on the functionality and scope of use of the embodiments of this application.

[0072] The computer-readable storage medium provided in the embodiments of this application is described below. The computer-readable storage medium provided in the embodiments of this application stores computer instructions, which, when executed by a processor, implement the production line balancing method provided in the embodiments of this application. Specifically, the computer instructions can be built into or installed in the processor, so that the processor can implement the production line balancing method provided in the embodiments of this application by executing the built-in or installed computer instructions.

[0073] In addition, the production line balancing method provided in this application embodiment can also be implemented as a computer program product, which includes program code. The program code implements the production line balancing method provided in this application embodiment when it is run on a processor.

[0074] The computer program product provided in this application embodiment may employ one or more computer-readable storage media, which may be, but is not limited to, an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination thereof. Specifically, more specific examples (a non-exhaustive list) of computer-readable storage media include electrical connections with one or more wires, portable disks, hard disks, RAM, ROM, erasable programmable read-only memory (EPROM), optical fibers, portable compact disc read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any suitable combination thereof.

[0075] The computer program product provided in this application embodiment can be a CD-ROM and include program code, and can also run on electronic devices such as computers. However, the computer program product provided in this application embodiment is not limited thereto. In this application embodiment, the computer-readable storage medium can be any tangible medium that contains or stores program code, which can be used by or in conjunction with an instruction execution system, device, or apparatus.

[0076] It should be noted that although several units or sub-units of the device have been mentioned in the detailed description above, this division is merely exemplary and not mandatory. In fact, according to embodiments of this application, the features and functions of two or more units described above can be embodied in one unit. Conversely, the features and functions of one unit described above can be further divided and embodied by multiple units.

[0077] Furthermore, although the operations of the method of this application are described in a specific order in the accompanying drawings, this does not require or imply that these operations must be performed in that specific order, or that all the operations shown must be performed to achieve the desired result. Additionally or alternatively, certain steps may be omitted, multiple steps may be combined into one step, and / or one step may be broken down into multiple steps.

[0078] Although preferred embodiments of this application have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of this application.

[0079] Obviously, those skilled in the art can make various modifications and variations to the embodiments of this application without departing from the spirit and scope of the embodiments of this application. Therefore, if these modifications and variations to the embodiments of this application fall within the scope of the claims of this application and their equivalents, this application also intends to include these modifications and variations.

Claims

1. A production line balancing system, characterized in that, include: The process data reading module is used to acquire the process list data and factory production line data of the automotive product to be balanced and analyzed; wherein, the process list data includes multiple processes and basic description information of the multiple processes; the factory production line data includes multiple workstations and basic resource information of the multiple workstations; The single-line production line balancing module is used to determine the criticality level of each process based on the basic description information of each process; and to allocate workstations from the multiple workstations to each process according to the workstation allocation method corresponding to the criticality level of each process based on the basic resource information of multiple workstations.

2. The production line balancing system according to claim 1, characterized in that, The process data reading module is used to read the process list data of the automotive product to be balanced and analyzed from the PLM system, and extract the factory production line identifier, cycle time and allowance coefficient of the automotive product and the process time of each process from the process list data. Based on the factory production line identifier, obtain the total number of workstations in the factory production line corresponding to the automobile product; based on the total number of workstations and the process time of each process, determine the baseline operation time of each workstation; based on the baseline operation time, the cycle time, and the allowance coefficient, determine the baseline number of workers for each workstation. The baseline operation time and baseline number of workers for each workstation are respectively determined as the basic resource information for each workstation.

3. The production line balancing system according to claim 2, characterized in that, The single-line production line balancing module is used to extract the workstation association information, process sequence identifier, process duration, and number of preceding processes for each process from the process list data; based on the workstation association information of each process, processes with designated workstations are classified into a first critical level; based on the process sequence identifier, process duration, and number of preceding processes of each process, critical path processes are selected from processes other than those in the first critical level and classified into a second critical level; processes other than those in the first and second critical levels are classified into a third critical level; wherein, the workstation allocation priority of the first critical level is greater than that of the second critical level, and the workstation allocation priority of the second critical level is greater than that of the third critical level.

4. The production line balancing system according to claim 3, characterized in that, The single-line production line balancing module is used to allocate each process of the first critical level to the workstation corresponding to its workstation association information; for each process of the second critical level, based on the process sequence identifier, process duration, and number of preceding processes, determine the criticality of each process, select each process as the current process in descending order of criticality, determine each workstation associated with the current process as a candidate workstation based on the workstation association information of the current process, select a workstation that meets the set conditions from the candidate workstations as the target workstation, and allocate the current process to the target workstation; for the third critical level... For each critical-level process, a random, non-replacement selection method is used to select each process as the current process. Based on the workstation association information of the current process, each workstation associated with the current process is determined as a candidate workstation. From the candidate workstations, a workstation that meets the set conditions is selected as the target workstation, and the current process is assigned to the target workstation. The set conditions include: after assigning the current process to the candidate workstation, the total worker requirement of the candidate workstation is less than the baseline worker number of the candidate workstation, the total operation time including losses of the candidate workstation is less than the cycle time, and the total operation time of all critical path processes of the candidate workstation is less than the cycle time.

5. The production line balancing system according to claim 4, characterized in that, The single-line production line balancing module is used to determine the total worker demand for the next target workstation if the total worker demand for the current target workstation is less than the baseline worker quantity for the target workstation, based on the baseline worker quantity for the target workstation and the difference between the total worker demand for the target workstation and the baseline worker quantity for the target workstation.

6. The production line balancing system according to any one of claims 3 to 5, characterized in that, The single-line production line balancing module is used to determine the current line balancing rate of the automotive product to be analyzed based on the standard operating time and maximum total working time required for all processes of the automotive product to be analyzed. If the current line balancing rate is less than the preset line balancing rate, the workstation corresponding to the highest workstation load rate is determined as the adjustment workstation based on the worker load rate. After any of the processes in the adjustment workstation is assigned to the workstation adjacent to the adjustment workstation, it is determined that the workstation adjacent to the adjustment workstation meets the set conditions.

7. The production line balancing system according to claim 1, characterized in that, Also includes: The mixed-line production line balancing module is used to allocate the processes corresponding to each automobile product model to each workstation through the single-line production line balancing module. Each workstation corresponds to a total number of workers for each automobile product model, and the total number of workers with the largest number is selected as the target total number of workers for each workstation. A mixed-line balancing rate is determined based on the actual total working hours required for each automobile product model and the total working hours for each workstation. When the mixed-line balancing rate is less than a threshold, the worker load rate for each worker at each workstation is determined based on the number of workers corresponding to each automobile product model at each workstation and the production proportion of each automobile product model. If the worker load rate for each worker at each workstation fluctuates significantly, movable processes in the preceding or following processes of each workstation are allocated to workers with low worker load rates.

8. A production line balancing method, characterized in that, Applied to the production line balancing system as described in any one of claims 1 to 7, the method comprises: Obtain the process list data and factory production line data of the automotive product to be balanced; wherein, the process list data includes multiple processes and basic description information of the multiple processes; the factory production line data includes multiple workstations and basic resource information of the multiple workstations; Based on the basic description information of each process, the criticality level of each process is determined; Based on the basic resource information of the multiple workstations, workstations are allocated to each process from the multiple workstations according to the workstation allocation method corresponding to the critical level of each process.

9. A computer device, comprising a memory and a processor, wherein the memory stores a computer program executable on the processor, characterized in that, When the processor executes the computer program, it implements the production line balancing method of claim 8.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores machine-executable instructions that, when invoked and executed by a processor, implement the production line balancing method of claim 8.

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