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Montaj hattı dengeleme ve otomotiv endüstrisi uygulamasıu

Başlık çevirisi mevcut değil.

  1. Tez No: 56038
  2. Yazar: TURGAY ENGİN
  3. Danışmanlar: DOÇ.DR. BÜLENT DURMUŞOĞLU
  4. Tez Türü: Yüksek Lisans
  5. Konular: Endüstri ve Endüstri Mühendisliği, Industrial and Industrial Engineering
  6. Anahtar Kelimeler: Belirtilmemiş.
  7. Yıl: 1996
  8. Dil: Türkçe
  9. Üniversite: İstanbul Teknik Üniversitesi
  10. Enstitü: Fen Bilimleri Enstitüsü
  11. Ana Bilim Dalı: Belirtilmemiş.
  12. Bilim Dalı: Belirtilmemiş.
  13. Sayfa Sayısı: 81

Özet

ÖZET Montaj Hattı Dengeleme (MHD) ve programlama günümüzün seri üretime yönelik toplumunun karşılaştığı önemli ve çözülmesi gerekli bir problemi olup Endüstri Mühendislerinin büyük olasılıkla çözmek zorunda kalabilecekleri bir üretim Programlama problemidir. Montaj hatlarının tasarımının en.önemli sebeplerinden biri kaynakların maksimum seviyede kullanılmasını sağlamaktır. Montaj hattı dengeleme çözüm yöntemleri genel olarak iki başlık altında incelenmektedirler; bunlar sezgisel yöntemler ve kesin çözüm yöntemleridir. Sezgisel yöntemler genellikle optimuma yakın sonuçlar verirler. Ancak algoritma şeklinde uygulanabilmeleri ve bilgisayar programlarının yazılmasının kolay olması nedenleriyle kesin çözüm yöntemlerine göre daha çok tercih edilirler. Montaj hattı dengeleme modeli kurulurken bazı varsayımların yapılması gereklidir. iş elemanı süreleri sabit veya değişken zamanlı olabilirler. iş istasyonlarına tahsis edilen işlemlerin süreleri toplamı ile her istasyonda eşit bekleme süresini içeren çevrim süresi arasındaki fark boş süre olup, tüm istasyonların boş süreleri toplamı ile teorik minimum istasyon sayısı öncelik ilişkileri kısıtları altında optimize edilmeye çalışılan iki ayrı amaç fonksiyonudurlar. Bu çalışmada MHD konusu kavramlar düzeyinde ele alınmış, çözüm yöntemleri incelenmiş ve bunların değerlendirmeleri yapılmıştır. MHD probleminin varsayımlarından ve yöntemin aşamalarından yararlanılarak gerçek bir probleme uygulanması gösterilmiş ya sonuçlarının analizi yapılmıştır. Değişken iş elemanı zamanlı montaj hatları ile karışık model montaj hatları ve maliyet minimizasyon modelleri de incelenmiştir. vii

Özet (Çeviri)

SUMMARY (ASSEMBLY LINE BALANCING AND AUTOMOTIVE INDUSTRY APPLICATION) Assembly line balancing (ALB) and scheduling is an important and challenging problem facing Industrial Engineers in today's mass production society. Henry Ford first used assembly line technique in 1914 in order to assemble automobile parts in production line and obtained the advantage of mass production first in history. General design of an assembly line incorporates a suitable ordering of the work elements and, predetermined moving speed of the line and balancing the load of the work stations. One of the first priority reasons for balancing assembly lines is the usage of the resources in most economical levels. In simpliest form, assembly lines are known with the movement of the work piece from one station to the neKt where parts assembled on the unfinished product in priorly decided order. Every work piece stays in work stations for a constant cycle time period. The work elements are generally divided to the smallest pieces as much as economically and technologically possible. The precedence relations among the work elements are basic character of the assembly which are forced by the real life conditions of the assembly line. The main factors effecting the precedence relations among the work elements are generally originated from the conditions of the technological specifications, production and assembly methods, necessity of locating some enpensive equipment in some predetermined work stations, layout of the plant, producing some parts outside the assembly line because of the safety considerations, requirements that some works be done by talented persons, necessity to carry intermediary stocks. Therefore it is rather important that the precedence relations of the work elements be determined correctly in order to design assembly lines more realisticly. - vis.% -The aim of assembly line balancing is to minimize the idle time or in other words decrease the balance delay to minimum levels and minimize work station number, spread the balance delays among other work stations. In case the assembly lines were balanced perfectly, work done in every work station will be equal and product flow will be so smooth that no delay will occur. The difference between the sum of the work element times assigned to work station and cycle time is the station idle time. The sum of these station idle times and theorical minimum work stations number are two different objective functions which are needed to be minimised together to reach optimum. It is not easy to reach these minimum points at the same time since most of the time they hinder each other depending on the assembly line design conditions.[ 16 ]. The following information is needed in order to design an assembly line balancing system: i ) Production volume in a predetermined period. ii ) Work elements' list and their precedence relations. iii ) Work element times. Production volume is provided by the Sales or Marketing Departments. Since the time spared for production and the amount of production is predetermined, the cycle time is found by dividing this time by the production amount. Theorical minimum station number is found by dividing total work element times by the cycle time. This cycle time is called natural cycle time since it is obtained from real production figures. The cycle time may be changed accordingly in the model to reach the best solution. Balance delay function is generally a determining factor in producing the best solutions to the assembly line balancing problems. But it is difficult to reach the best solution by minimizing the work station number and cycle time at the same time. - ix -The solutions reached together by these criterions must be compared together with the costs of overtime or a second assembly line. Because if the cycle time minimizing the idle time is much longer than the natural cycle time, then overtime or a second assembly line would be needed in order to meet the required demand. On the other side, in case the cycle time minimizing the idle time is smaller than the natural cycle time, the assembly line should be closed for a time. In this case assembly line should work full capacity at the begining in order to make safety stock. The workers in the assembly line could be employed in other departments part time. Another alternative to conveyor type assembly lines could be the Automatic Guided Vehicles (AGV). AGV is a freely moving assembly platform which carries the product being assembled from one work station to another. Thus elasticity of the line could be achieved and space constraints could be loosened In this study assembly line balancing is taken up in concepts level. The solution procedures are investigated and evaluated. A real problem model in automative industry is solved by moving from the assembly line balancing as methods. assumptions and Deterministic and variable work element time models and mixed model assembly lines and cost minimization model are examined. In the literature, there are two approaches to the solution of the problem; heuristic methods and exact methods. Heuristic methods give suboptimal solutions but it is easy to arrive at solutions especially with the help of computers. Whereas exact methods provide optimal solutions while they render computational difficulties in moderate and large problems.There are some assumptions to make in order to make real life conditions to fit. into computationally feasible mathematical models. In this thesis deterministic and variable work element times are assumed. The volume of the assembly line balancing problem increase geometrically by increasing the number of the work elements. Thus the heuristic methods are more suitable for computer applications. There have been many publications about the assembly line balancing problems since 1950' s and heuristic methods seem to be by large the most prefered methods by authors. Kilbridge-Wester method, positioanl weight, method by Helgeson and Birnie [13], precedence relations matcis method (Hoffman Method) by Hoffman [15] and computer method of sequencing operations for assembly lines (C0MS0AL) by Arcus [17] are the best known and well accepted heuristic methods in the literature, Some authers like Mansoor [14] and Moodie [11] have presented some adjustments to some of the heuristic methods to facilitate reaching best solution in less computer time. Some other authors like Baybars [10] have reorgonised the methods in better grouping terminology. They divide methods generally into two sections, first being SALBP ( Simple Assembly Line Balancing Problems) which include deterministic work element times. The second section of methods include Complex Models (CALBP) like variable work element times and mixed model assembly lines. Exact methods like integer programming and dynamic programming models generally produce exact optimum solutions to the problem, but they become unmanagable after 40 or 50 work element assembly line balancing models. Whereas the heuristic methods could be suitable for large problems up to 1000 work elements even though the research have shown that most accurate results are obtained with the medium sized problems up to 100 work elements. However one of the Heuristic methods, COMSOAL is usable up to 1000 work element problems succesfully. Therefore this method is prefered for the application problem in this study which have 200 work elements in the automotive assembly band. - xi -In this study deterministic work element times are assumed. The model with variable work element times and mixed model assemly lines and also cost minimisation model of assembly lines are examined. Automotive industry application of the assembly lines at Mercedes-Bens Türk A.Ş at Hosdere istanbul for bus production is studied. The results of the solutions to the problem brought better productivity figures compared the present situation. it is required that asseıtıby lines be balanced with any changes in production demand. But in the asssembly plants this balancing calculations are not usually applied. XI i

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