Locomotive maintenance layout optimization method

Abstract

The invention discloses a locomotive maintenance layout optimization method, which comprises the following steps of: after determining a main line node beat, reversely deducing and calculating the quantity of products in process of parts by utilizing part demand time of each node, and determining the storage area of the parts; secondly, the components with the same route are split and packaged by means of process route analysis of the components, and a modular functional layout is formed; and finally, carrying out logistics route optimization by using a path analysis method, adjusting the layout of the functional modules, and finally forming the overall locomotive maintenance layout. The problems of inflexible layout, long logistics path, low site utilization rate and the like in the prior art are solved.

Description

Technical Field

[0001] This invention relates to the field of locomotive maintenance technology, and in particular to a locomotive maintenance layout optimization method based on process flow analysis, modular layout and logistics path optimization. Background Technology

[0002] Existing locomotive maintenance layouts typically employ a rather extensive approach. The first type involves using the existing site layout and integrating the locomotive maintenance sections into it. This is common when the site's functions have already been defined, fixed assets have been invested in, or significant adjustments or investments in equipment and facilities have been made. This phenomenon is prevalent in the maintenance industry. The second type of layout involves optimizing and dividing components according to the process route before maintenance operations commence. However, if the expected goals during the construction period are too small or too large, the site structure may not match the actual needs, leading to wasted space or bottlenecks in processes or workstations.

[0003] The shortcomings of existing technologies are as follows: The first layout has the following main problems: a. Since the layout of key facilities such as the paint warehouse is fixed, the maintenance of locomotives or large components involving these facilities inevitably faces the problems of difficult adjustments or long logistics routes; b. Long logistics routes lead to an increase in logistics tools and personnel, resulting in increased costs. The main problems of the second layout are: a. Equipment or facilities purchased during the production line construction period are not very practical due to the difference between construction expectations and reality. If adjustments are needed, asset management issues will arise, leading to difficult adjustments and high costs; b. Layout optimization is difficult when adjusting the production line. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a method for optimizing the layout of locomotive maintenance, thereby solving the problems of inflexible layout, long logistics paths, and low site utilization in the prior art.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is: a method for optimizing the layout of locomotive maintenance, comprising the following steps: (1) Process flow analysis steps: analyze the process flow of the entire locomotive maintenance process, clarify the entry time, completion time, input components and output components of each workstation, so as to determine the working rhythm and material relationship of each workstation; (2) Production line model construction steps: Based on the process flow, components with the same or similar process routes are classified, functional modules are constructed, and a "1+1+N" production line model is formed with a locomotive maintenance main line, a bogie line and at least one functional module as the core. (3) Site area calculation steps: For each component in the production line model, calculate the site area required during the maintenance process based on its maintenance cycle and the quantity of work-in-process, combined with the size and specifications of the component and process equipment. (4) Modular layout design steps: Based on the 1+1+N production line model data and the calculated site area, the maintenance areas of components with the same process route are combined into functional modules, and modular spatial layout is carried out. (5) Logistics route optimization steps: Using the minimum path analysis method, the layout of the functional modules is adjusted according to the busyness and distance of the logistics to optimize the overall logistics route.

[0006] As an improvement, in step (2), there are N functional modules formed by classifying the component process routes, where N≥3, including at least the locomotive accessory maintenance module, the cabinet maintenance module, and the bogie accessory maintenance module.

[0007] As an improvement, the air supply system, cable trays, cables, air cylinders, horn wheel spray, electrical components, and mechanical components are grouped into a locomotive accessory maintenance module; each panel cabinet is grouped into a panel cabinet maintenance module; the frame and drive are combined into a bogie sub-line module; and rods, springs, hook and buffer devices, and frame accessories are combined into a bogie accessory maintenance module.

[0008] As an improvement, in step (3), the site area is calculated as follows: (3.1) For any component A, let its maintenance period be T+n and its assembly period be T+m, then the theoretical quantity of work-in-process for this component is (mn). (3.2) Based on the number K of the trolley configuration of the component, calculate its actual work-in-process quantity as K × (mn); (3.3) Based on the actual quantity of work-in-process, component size and process equipment size, and taking into account the operational redundancy space and passage area, the required storage and operation area of ​​the component is finally determined.

[0009] As an improvement, in step (4), the process routes of different components are analyzed, and components with completely identical or highly overlapping process routes are split and packaged; the packaged component set is used as a unit to form a closed functional area with specific functions and a relatively concentrated layout.

[0010] As an improvement, in step (5), the minimum path analysis method is implemented in one or more of the following ways: The proximity principle: Set up the component repair area near the key node with the closest logistical relationship to it; Intensity adjustment: The relative positions between modules are dynamically adjusted according to the busyness and length of the logistics routes between modules; Turnover setup: When logistics routes are too long due to space limitations, logistics turnover sites are set up at critical path nodes to shorten the effective transportation distance.

[0011] As an improvement, the output of the process flow analysis step is a process relationship table, which includes at least the fields of workstation number, workstation name, work start time, work finish time, output component, and input component.

[0012] The beneficial effects of this invention compared to the prior art are: 1. Improve site utilization by accurately calculating the quantity of work-in-process and the site area; 2. Adopt a modular layout to enhance the flexibility and adaptability of the production line; 3. By applying the minimum path analysis method, logistics routes can be significantly shortened, and operating costs can be reduced; 4. Applicable to various site conditions and maintenance needs, with good versatility and practicality. Attached Figure Description

[0013] Figure 1 This is a process flow diagram. Detailed Implementation

[0014] The present invention will now be further described with reference to the accompanying drawings.

[0015] A method for optimizing locomotive maintenance layout. The technical solution of this invention is mainly divided into three parts: process flow analysis, business analysis, and layout design and optimization.

[0016] Part 1: Process Flow Analysis First, the process flow of locomotive maintenance is streamlined, identifying the workstations involved, their start and end times, output components (the main tasks completed at each workstation), and deliverables. This achieves two objectives: firstly, it clarifies the cycle time of each workstation; secondly, it defines the input and output standards for each workstation. The table below illustrates this (where T refers to the start date):

[0017] Part Two: Business Overview Transpose the contents of the table above and organize the operation time and related relationships in the form of a flowchart to form a process flow diagram, such as... Figure 1 As shown.

[0018] The locomotive accessory maintenance module categorizes components such as the air supply system, cable trays, cables, air cylinders, horn wheel sprayers, electrical components, and mechanical components; the cabinets are categorized into cabinet maintenance modules; the frame and drive system are combined into bogie sub-line modules; and rods, springs, hook and buffer devices, and frame accessories are combined into bogie accessory maintenance modules. This establishes a 1+1+3 production line model with the locomotive maintenance main line as the core and the bogie sub-line and three modules forming the core.

[0019] Part Three: Layout Design and Optimization

[0020] 1. Calculation of site area required for maintenance work Based on the production line model data, assuming that the time for component A to enter the maintenance period is T+n, and the actual time for it to enter the assembly stage is T+m, then the work-in-process (WIP) of component A is (T+m) - (T+n) = mn. Assuming that the number of trolleys for component A is 2, then the total WIP quantity is 2(mn). Based on the WIP quantity, and combined with the dimensions of component A and the dimensions of the process equipment, after considering redundancy and space aisles in the calculation formula, the required area for component A during the maintenance cycle can be determined.

[0021] 2. Modular design of site layout Based on the 1+1+N production line model data, the quantity and types of products requiring maintenance are summarized according to the output and input requirements of the production line. Then, the maintenance area for each component is calculated based on the required area for maintenance operations. This area is then further subdivided and combined according to the component's process route, ultimately forming functional modules (a collection of products with the same process route). For example, assuming the maintenance route for component A is: disassembly → cleaning → maintenance → painting → assembly → testing, and the maintenance route for component B is: disassembly → cleaning → maintenance → assembly → testing, then the disassembly, cleaning, maintenance, assembly, and testing of components A and B can be considered as functional modules. Setting up these functional modules according to lean workflow principles results in closed-loop modules, forming a modular design for the site layout.

[0022] 3. Application of minimum path analysis in layout The minimum path analysis method is a way to set up logistics routes using the shortest distance. It is generally implemented using three methods: First, the proximity principle, placing component maintenance areas near critical nodes, such as disassembly or assembly areas; second, adjusting the distance between modules based on the busyness and length of the logistics route; and third, setting up logistics transfer areas when site constraints cause logistics routes to be too long.

Claims

1. A locomotive service layout optimization method, characterized by, The method comprises the following steps: (1) process flow carding step: carding the whole process of locomotive maintenance process flow, clear each station into the repair time, repair time, input components and output components, to determine the operation cycle and material relationship of each station; (2) production line model construction step: based on the process flow, classify the components with the same or similar process route, construct the function module, and form a "1+1+N" production line model with a locomotive maintenance main line, a bogie subline and at least one function module as the core; (3) site area calculation step: for each component in the production line model, according to its maintenance cycle and work-in-process quantity, combined with the size specification of components and process equipment, the required site area during maintenance is calculated; (4) modular layout design step: according to the 1+1+N production line model data and the calculated site area, the component maintenance areas with the same process route are combined into function modules, and modular space layout is carried out; (5) logistics path optimization step: using the minimum path analysis method, according to the busy degree and distance of logistics, the layout position of the function module is adjusted to optimize the overall logistics route.

2. The method of claim 1, wherein: In step (2), N function modules are formed by classifying components according to process route, wherein N≥3, at least including locomotive accessory maintenance module, screen cabinet maintenance module and bogie accessory maintenance module.

3. The method of claim 2, wherein: The wind source system, wire slot, cable, air cylinder, horn wheel spray, electrical components and mechanical components are classified as locomotive accessory maintenance module; each screen cabinet is classified as screen cabinet maintenance module; the frame and drive are combined as bogie subline module; the rod, spring, hook buffer device and frame accessory are combined as bogie accessory maintenance module.

4. The method of claim 1, wherein: In step (3), the site area is calculated as follows: (3.1) for any component A, let its entering maintenance period be T+n and its entering assembly period be T+m, then the theoretical quantity of work-in-process of the component is (m-n); (3.2) according to the trolley configuration quantity K of the component, the actual quantity of work-in-process is K × (m-n); (3.3) according to the actual quantity of work-in-process, component size and process equipment size, and considering the operation redundancy space and channel area, the required storage and operation site area of the component is finally confirmed.

5. The method of claim 1, wherein: In step (4), the process route of different components is analyzed, and components with completely same or highly coincident process route are split and packaged; the packaged component set is used as a unit to form a closed function area with specific function and relatively concentrated layout.

6. The method of claim 1, wherein: In step (5), the minimum path analysis method is implemented in one or more of the following ways: proximity principle: the component maintenance area is arranged near the key node with the closest logistics relationship; intensity adjustment: dynamically adjust the relative position between modules according to the busy degree and line length of the logistics route between modules; turnover setting: when the logistics route is too long due to site limitation, a logistics turnover site is set at the key path node to shorten the effective transportation distance.

7. A locomotive servicing layout optimization method according to any one of claims 1 to 5, characterized in that: The output of the process flow carding step is a process relationship table including at least the fields of station serial number, station name, entry repair time, repair completion time, output component and input component.

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