Airplane model assembling method for lean production

Abstract

The invention discloses an airplane model assembling method for lean production and relates to an
airplane model assembling method. The existing lean production method has the problem that the
airplane model assembling efficiency is low, the production device layout is chaotic and disorder, the
material movement is waste and the part is loss for transporting operation. The airplane model
assembling method for lean production comprises the steps as follows: three-dimensional simulation
modeling for the selected airplane model part entity and storing the three-dimensional simulation map in
the form of source file and picture; confirming six groups of sub-assembly processes; using Solidworks for
assembling three-dimensional entity of each sub-assembly body, rendering to obtain the three-
dimensional simulation map of each sub-assembly body, forming the assembly sketch map process chart
of the sub-assembly body; confirming airplane model general assembly path; confirming average
assembly time for each sub-assembly process, finding the sub-assembly body process with more labor-
hour as the bottleneck operation, finding the balancing method for realizing process balancing production;
assembling the sub-assembly body; recording the delivery time after assembling the first and last airplane
models; assembling for 3-5 times repeatedly. The airplane model assembling method for lean production
is used for assembling airplane model.
CN104268356A
CN Application
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Chinese
Inventor
吕民
李荣志
张念
王强
蒋建春
 
高鼎豪
Original Assignee
 
哈尔滨工业大学
Priority date 
2014-10-17

Family: CN (1)
DateApp/Pub NumberStatus
2014-10-17CN 201410553719
2015-01-07CN104268356AApplication
2017-04-26CN104268356BGrant

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Patent citations (4)
 
Non-patent citations (5)
 
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Description

translated from Chinese

The method for assembling model aircraft lean production

FIELD

[0001] The present invention relates to a process for assembling an aircraft model for lean manufacturing.

Background technique

[0002] the formation of global economic integration to the Chinese manufacturingindustry has brought
more opportunities for development, but at this stage still belongs to the extensive
Chinese manufacturing industry, in order to meet the challenges of advanced manufacturing industry in
developed countries, many Chinese enterprises began to study Toyota the company, in the enterprise
implementation of lean production, trying to improve production management level backward. Many
companies blindly follow the example of foreign experience in the implementation, hard to
import lean production enterprises, senior management can not be a deep understanding of the essence
of lean production, leading companies can not set a good sense of lean improvement, lean production
eventually became a slogan and movement.

[0003] Existing aircraft model assembly embodiment generally folded paper airplane production
background, lean manufacturing training of personnel in the production of this background production,
specific methods: batch by folding a single piece of folded paper plane and the paper plane, and further
comparison the total time to complete the same number of aircraft models, the conclusion that the
advantages of single-piece production, the kind of lean production training method is simple and rough,
less integration of lean production knowledge, theoretical knowledge into a far-fetched unconvincing
cause actual model aircraft assembly low assembly efficiency, production equipment layout chaos,
disorder, material handling and waste problems moving process, in addition, there is a problem due to
handling a collision, resulting in the loss of parts between each process, a direct result of lean production
methods in the model airplane the assembly process with little success, their training effect is greatly
reduced.

SUMMARY

[0004] The present invention is to solve the existing lean production methods result in low efficiency of
assembly of the aircraft model, production equipment layout chaos, disorder, waste material movement,
handling resulting in missing parts of the problem, and proposes a comprehensive and efficient the
aircraft model assembled a systematic approach.

[0005] A method of assembling aircraft model for lean manufacturing, aircraft assembly method is

implemented by the following steps:

[0006] Step a: part of the selected entity model of the aircraft using three-dimensional simulation software
Solidworks simulation modeling and encoding each aircraft model part entities, and to the source files and
pictures Solidworks the two storage formats of the three-dimensional model aircraft parts simulation map;

[0007] Step 2: Step a part airplane model obtained Solidworks source files different functions, different
operations can be difficult to separate and assembled integrally into six groups principle sub-assembly
step: step of assembling the propeller, the frame assembly process, head assembling process, the seat
assembly process, assembling process and a base shell assembly process, and stored in the source file
format Solidworks six groups of sub-assembly step; wherein the six sets of the number of parts in the step
of sub-assembly does not include screws and nuts where the difference is within 10;

[0008] Step Three: on the six sub-assembly step Solidworks source file Step two is determined, and the
use of Solidworks simulation software for each channel sub-assembly step 3D solid assembly, and each
sub-assembly process is completed are rendered after assembly, to give three-dimensional simulation of
FIG per pass sub-assembly step of storing three-dimensional simulation view of the six groups of sub-
assembly step in image format; then made to fit a schematic process chart sub-assembly based on a
stored after each of said channel subassemblies step of assembling the image;

[0009] Step Four: the propeller mounting step six sets of sub-assembly process in Step II was the
representative point A, point B to the rack on behalf of the assembly process, the assembling process
handpiece to the representative point c, to the seat mounting step point D represents shells point E
represents the assembly process, the base assembly process is performed to the representative point F,
from the start point a, passes through the point B, C, D, E and ending path model aircraft final assembly
point F; wherein, points A, B, C on the line segment AC, points D, E, F on the line segment DF, points C,
D segments formed ⑶, DF and the segment AC and the line segment parallel to and perpendicular to
both the CD and the line segment;

[0010] Step Five: after the step of mounting four general path determination, assembly man-hours for
each channel sub-assembly step count six times to determine the average number of assembling steps
for each channel of the sub-assembly step, to find the largest sub-assembly work step bottleneck step is
determined, and find a balance implemented method of balancing the production process step;

[0011] Step Six: The final total mounting path plane 1¾ type of the assembled schematic process card
subassembly three determination step, step five balance production, the use of image processing
software Photoshop, simulation software Solidworks making the overall assembly process model aircraft
the animation video, three-dimensional simulation of the total assembly process Solidworks FIG source
and the two storage formats airplane model image, and making final assembly of aircraft model animation
video, between the aircraft model and the final assembly process card schematic adjacent sub-assembly
step a schematic view of the card assembly process;

[0012] Step 7: The materials and tools according to the content of each sub-assembly step required in the
process of making the assembly process card list of materials and tools, materials and process card bill of
tools comprising: a schematic view of the assembly of the sub-assembly, the instructions, aircraft parts
model code, name and number;

[0013] Step Eight: The number of sub-assembly is determined in step two of the six groups set operators,
each operator having seven members, the warehouse and a part of it is common among the set of sub-
assembly step the operator, the operator in accordance with assembly animation video subassembly step
three produced, and with reference to the steps made of materials and tools list process card seven
selected aircraft model parts entity assembly process sub-assembly from the box, get six group
subassembly;

[0014] Step 9: operator according Animations video final assembly process of model aircraft Step six
production, sub-assemblies utilizing step VIII was carried out the entire aircraft model assembly, and
record delivery time after the first aircraft model assembled and the last one plus the aircraft model
assembled delivery times;

[0015] Step 10: The operator six groups each assigned sub-assembly step of the assembly operation is
repeated eight steps 3-5 to Step 9 wheels.

[0016] Advantageous effects of the present invention are:

After [0017] The present invention is a method of cross-Lean and assembly process into the model
aircraft, the aircraft model was selected to determine their final assembled configuration; reanalysis model
structure, find the best path to the assembly, and for total assembly path provides a line balancing
method, and complete the production of three-dimensional simulation of a video animation of the model,
based on this, the front design and assembly processes used in the card when assembled. Each operator
must complete sub-assembly prior to assembly by watching the process of assembling a sub-assembly
animation video, animation video model aircraft final assembly process, these assembly animation videos
for student plays before each process operation, each step will help the operator assemble the model,
then the sub-assembly schematic view of the card assembly process, a schematic view of the overall
assembly process card, a schematic view of the content between the sub-assembly mounting step
process card bill of tools and materials and process card functions described adjacent assembly prompt
action. Schematic process card clear and accurate records of the assembly method, each operator is
easy to understand, as the task of assembling model aircraft operator which carries out the assembly, the
assembly process to ensure the smooth completion. By completion time of 24 aircraft model assembled ^
meter run, the fourth round of efficiency for lean production model aircraft assembled increase 5 〇% at
least, has a fundamentally improve the speed of the assembly operator, while improving other operations
personnel the benefits of productivity, operator and sub-assemblies for each group involved in the
enthusiasm is also improved. Making the entire assembly process for the assembly process card operator
and presentation means a "visualization Kanban", combined with the visual management, allowing the
operator to better understood method for producing a lean visual management.

[0018] Step balance through the production process and the path determination final assembly, the U-
shaped path so that the total assembly aircraft model has the effect of reducing the obtained first track to
the last step of sub-assembly a distance between the sub-assembly step, the respective clearer
information transmission between the sub-assembly, and the number of products can also be effectively
controlled, the assembling operation of the production equipment used in an orderly arrangement,
between the sub-assembly and the step of moving the material handling fast and convenient route,
replacement parts store when handling orderly, saving time and effort, no missing phenomenon.

BRIEF DESCRIPTION

[0019] FIG. 1 is a flowchart of a method of assembling an aircraft model of the present invention;

[0020] FIG 2 Total path model aircraft assembly according to the present invention, a schematic diagram;

[0021] FIG 3 is a screenshot of a three-dimensional simulation modeling interfaces based on the size of
the aircraft model Solidworks measurement part;

[0022] FIG. 4 is a rack assembly assembling process diagrams illustrating a process step in the card;

[0023] FIG. 5 is a trend chart of assembling steps average per pass sub-assembly step;

[0024] FIG. 6 is a step of each sub-assembly work trend chart after equilibration.

detailed description

DETAILED DESCRIPTION [0025] a:

The method of assembling aircraft model [0026] for the embodiment according to the present
embodiment lean production, lean production (Lean Production), referred to as "lean", is derived from a
TPS management philosophy. Including many well-known manufacturers and research professor at
Massachusetts Institute of Technology on a global scale of the Toyota production system, application and
development, promote the theory produce lean production and production management system, the
system is still in development among evolving. From Kaizen change the past, focus on the production site
for inventory control, production planning management, process improvement (BPR), cost management,
staff quality to develop, collaborative supply chain optimization, product lifecycle management (product
concept design, product development, production line design , table design, method of operation and
design improvements), quality management, equipment and human resources management, market
development and sales management, and many other aspects of business management involved. As
shown in Figure 1, the aircraft assembly method is implemented by the following steps:

[0027] Step a: part of the selected entity model of the aircraft using three-dimensional simulation software
Solidworks simulation modeling and encoding each aircraft model part entities, and to the source files and
pictures Solidworks the two storage formats of the three-dimensional model aircraft parts simulation map;

[0028] Step 2: Step a part airplane model obtained Solidworks source files different functions, different
operations can be difficult to separate and assembled integrally into six groups principle sub-assembly
step: step of assembling the propeller, the frame assembly process, head assembling process, the seat
assembly process, assembling process and a base shell assembly process, and stored in the source file
format Solidworks six groups of sub-assembly step; wherein the six sets of the number of parts in the step
of sub-assembly does not include screws and nuts where the difference is within 10;

[0029] Step Three: on the six sub-assembly step Solidworks source file Step two is determined, and the
use of Solidworks simulation software for each channel sub-assembly step 3D solid assembly, and each
sub-assembly process is completed are rendered after assembly, to give three-dimensional simulation of
FIG per pass sub-assembly step to store image format above six groups of sub-assembly step of a three-
dimensional simulation diagram; remanufacturing the stored after each of said channel subassemblies
step of assembling the image to fit a schematic process chart sub-assembly, such as Figure 4 shows the
sub-assembly step is a schematic process card rack assembly process;

[0030] Step Four: the propeller mounting step six sets of sub-assembly process in Step II was the
representative point A, point B to the rack on behalf of the assembly process, the handpiece assembly
step C represents a point, to the seat mounting step point D represents shells point E represents the
assembly process, the base assembly process is performed to the representative point F, from the start
point a, passes through the point B, C, D, E and ending path model aircraft final assembly point F;
wherein, points A, B, C on the line segment AC, points D, E, F on the line segment DF, points C, D are
formed line CD, and the segment AC and the segment DF are parallel to and perpendicular to the line
segment ⑶;

[0031] Step Five: after the step of mounting four general path determination, assembly man-hours for
each channel sub-assembly step count six times, it is determined that the average number of assembling
steps for each channel sub-assembly step, as shown in Figure 5, looking work out the maximum sub-
assembly is determined to be the bottleneck process steps, and find a balance implemented method of
balancing the production process step;

[0032] Step Six: The final total mounting path model aircraft after assembly schematic process card
subassembly Step three is determined in step five balance production, the use of image processing
software Photoshop, simulation software Solidworks making the overall assembly process model airplane
animation video, three-dimensional simulation of the total assembly process Solidworks FIG source and
the two storage formats airplane model image, and making final assembly of the aircraft model animation
video, the fit between the model aircraft final assembly and schematic process chart of adjacent sub-
assembly step a schematic process chart;

[0033] Step 7: The materials and tools according to the content of each sub-assembly step required in the
process of making the assembly process card list of materials and tools, materials and process card bill of
tools comprising: a schematic view of the assembly of the sub-assembly, the instructions, aircraft parts
model code, name and number;
[0034] Step Eight: The number of sub-assembly is determined in step two of the six groups set operators,
each operator having seven members, the warehouse and a part of it is common among the set of sub-
assembly step the operator, the operator in accordance with assembly animation video subassembly step
three produced, and with reference to the steps made of materials and tools list process card seven
selected aircraft model parts entity assembly process sub-assembly from the box, get six group
subassembly; parts on the aircraft model has the advantage that the box is easy to carry, to prevent loss
of parts, can be reused, saving before assembly assembling method of learning and training costs;

[0035] Step 9: operator according Animations video final assembly process of model aircraft Step six
production, sub-assemblies utilizing step VIII was carried out the entire aircraft model assembly, and
record delivery time after the first aircraft model assembled and the last one plus the aircraft model
assembled delivery times;

[0036] Step 10: The operator six groups each assigned sub-assembly step of the assembly operation is
repeated eight steps 3-5 to Step 9 wheels.

DETAILED DESCRIPTION [0037] II:

[0038] and a different specific embodiment, the method of assembling aircraft model according to the
present embodiment for lean manufacturing step of a three-dimensional simulation model aircraft is
specifically:

[0039] Step eleven: Measure caliper specific aircraft model parts with the cursor;

[0040] Step twelve: three-dimensional simulation model of the aircraft part by Solidworks simulation
software interface according to the size measurement, model airplanes and parts are rendered in the
material after the actual determination of the physical perspective;

[0041] Step thirteen: taking four principles encoding encodes each three-dimensional simulation model
aircraft FIG part, such as yellow rubber pad 1402 is coded.

DETAILED DESCRIPTION [0042] III:

[0043] DETAILED DESCRIPTION with one or two are different, a method of assembling aircraft model
according to the present embodiment for leanmanufacturing, the step of balancing the five methods: a
step to identify bottlenecks and adjacent to the smallest sub-assembly work step , and the work done to
identify bottlenecks and averaging step, and then a step of decomposing the bottleneck process, the
average value of the assembly process more work given to the smallest sub-assembly work steps, the
overall balance of the production process of the assembly path, a balance each sub-assembly after the
step shown in FIG 6 hours trend effects.

DETAILED DESCRIPTION [0044] IV:

[0045] DETAILED with Embodiment 3 except that the embodiment of the present method of assembling
an aircraft model for lean manufacturing embodiment, the step of allocating eight sub-assembly of step 7
into an operator the operator, a picking member, a transport member, an inspector, a warehouse
operator, an observer and an observer for a two; each sub-assembly as shown in step 1 in table operator
and the task allocation table,

[0046] Table 1 the operator of the respective sub-assembly step and task allocation table

[0047]
The assembly process [0048] for the eight sub-assembly process steps are:

[0049] Step eighty-one: all members of each sub-assembly process of the step of assembling a sub-
assembly view video;

[0050] Step eighty-two: each sub-assembly according to the material and the process list of props, props
present materials and receive channel sub-assembly step required within 5-8 minutes by a picking
member;

[0051] Step eighty-three: completion of the track sub-assembly step by an operator independently of all
the assembly operations, and after completion of shell material into the cartridge assembly process
required to wait five minutes to complete the heat treatment process, if the lack of assembly during
assembly providing a workpiece by a spare parts warehouse operator and props keeping track of the
present sub-assembly step;

[0052] Step eighty-four: QA sub-assembly of the channel in the article by a process of the inspector,
particularly as compared with the hands of the proof mass sub-assembly step-like member;
[0053] Step eighty-five: the observers a and observers II, respectively by using a stopwatch data present
track sub-assembly step, waste point present track sub-assembly step by the observer two observations,
the other members of the auxiliary observers second recording data;

[0054] Step eighty-six: the quality inspection, by a member of the transport path of the present sub-
assembly step in assembling the article conveyed to the next process;

[0055] Step eighty-seven: when the assembly quality problems arise procedure performed by the
communication quality inspector and two adjacent sets of transport members for communication.

DETAILED DESCRIPTION [0056] V:

Four different [0057] and the exemplary embodiment is a method of assembling aircraft model according
to the present embodiment for lean manufacturing, materials and the step of eighty-two props including
aircraft model parts, a schematic view of the card assembly process sub-assembly, a list of materials and
tools process card, stopwatch, marker pen, questionnaire, and each step-like sub-assembly.

DETAILED DESCRIPTION [0058] VI:

[0059] with the description, four or five different, the data sub-assembly step of the eighty-five model
aircraft assembly method of the present embodiment for leanmanufacturing step includes assembling
process of the present track sub-assembly used time and the first frame, after the end of the model
aircraft assembled delivery times.

DETAILED DESCRIPTION [0060] VII:

[0061] DETAILED DESCRIPTION six different and is a method of assembling aircraft model according to
the present embodiment for lean manufacturing, the step of sixteen sub-assembly step of the group
assigned to each operator assembly operation steps is repeated eight to nine-step when four, operation
proceeds to the fourth round of the assembly, each operator of each path assigned sub-assembly step
has been decreased from six to three, by reducing the benefits of having an operator assembling the
assembly operation to reduce input costs.

Claims (7)

translated from Chinese

1. 1. A method for assembling an aircraft model of lean production, wherein: said aircraft

assembly method implemented by the following steps: Step a: three-dimensional simulation
model of the selected entity model aircraft parts Solidworks using simulation software, and
each a part airplane model entities encoded, and image files and source Solidworks to the two
storage formats aircraft model three-dimensional simulation of FIG part; step 2: step a part
airplane model obtained Solidworks source files different functions, different operating
difficulty and principle can be independently assembled integrally into six groups of sub-
assembly step: step of assembling the propeller, the frame assembly step, assembling step
head, the seat assembly process, assembling process and a base shell assembly process,
and stores the six source file format Solidworks group sub-assembly step; wherein the
number of parts six groups of sub-assembly step without comprise screws and nuts differ less
than 10; step three: on the six sub-assembly step Solidworks source file step two is
determined and using simulation software Solidworks per pass sub-assembly step 3D solid
assembly, are performed after each channel sub-assembly process is completed assembly
rendering, to give each of the three - dimensional simulation of FIG sub-assembly step to
store image format above six groups of the sub-three-dimensional simulation of FIG assembly
step; then according to each of said channel subassemblies body step after assembly saved
image made into a sub-assembly fitted schematic process card; step four: the propeller
mounting step six sets of sub-assembly step of step II was in the point a represents the rack
mounting step to the point B represents, head mounting step C represents a point, the seat
point D represents the assembly process, the assembling process shells point E represents
the base point F represents the assembly process, from the start point A, passes through the
point B, C, D, E the total mounting path and ending point F of the model aircraft; wherein the
point a, B, C the line segment AC, points D, E, F on the line segment DF, points C, D
segments forming the CD, and the segment AC and the line segment DF parallel and
perpendicular to both the CD and the line segment; step five: after the step of mounting four
general path determination, assembly man-hours for each channel sub-assembly step count
six times, each channel is determined sub-assembly process of the group average After a
schematic view of the assembly according to process card sub-assembly step of determining
three, five balance production step: Step six; means work, work to find the maximum sub-
assembly is determined to be the bottleneck process steps, and find a balance balance
production process implemented method step the final model aircraft final assembly path,
using image processing software Photoshop, Solidworks simulation software demo video
animation model aircraft final assembly process, Solidworks source files and pictures to the
two storage format of three-dimensional simulation model aircraft final assembly process
diagram, and the total production of animated video model aircraft assembly, the assembly
diagrams illustrating a process model aircraft final assembly of the card between the card and
a schematic view of the process step of the adjacent subassembly; step 7: the materials and
tools required for the respective sub-assembly step in the assembly process and mass
production tool list described process card, process card list of materials and tools include: a
schematic view of the assembly of the sub-assembly, the instructions, the coding model
aircraft parts, and the number of names; step eight: the number of sub-assembly step of
determining two set six group operating personnelEach operator having seven members,
video animation and fitted therein a warehouse operator groups between a common sub-
assembly step of the operator, the operator prepared following the procedure of three sub-
assembly, and with reference to step seven produced materials and tool inventory process
card, select from box aircraft model parts entity assembly process sub-assembly, to obtain six
sets of sub-assembly; step 9: animation operator overall assembly process according to the
model aircraft step six making demo video, the use of sub-assembly step VIII was carried out
the entire aircraft model assembly, and record the first aircraft delivery time after the model
aircraft assembled and the last one plus aircraft models assembled delivery times; step 10: six
groups of sub-assembly process each operator assigned to eight assembly operation repeat
steps 3-5 step 9 wheels.
2. According to the claim 1 for the lean model aircraft assembly produced by the method,
wherein: the step of a three-dimensional simulation model aircraft specifically: Step
eleven: specific dimensions measured with a vernier caliper model airplane parts; a
step II: according to the size measured in the three-dimensional simulation software
interface Solidworks simulation model aircraft parts, and the parts are rendered in the
actual material of the aircraft model in the determination of the physical perspective;
thirteen steps: taking four principles coding model for each aircraft parts FIG encoded
3D simulation.
3. 1 or 2 according to the assembling method for model aircraft Lean claim, wherein: the
step of balancing the five methods: a step to identify bottlenecks and adjacent to the
smallest sub-assembly work steps, and will be found a bottleneck process to do work
and averaging, and then a step of decomposing the bottleneck process, more than the
average work during assembly work given to the smallest sub-assembly step, to
complete the final assembly process of balancing the production path.
4. 3 according to the method for assembling airplane model Leanclaim, wherein: the
assembly process of the eight sub-assembly steps: Step eighty-one: all members of
each sub-assembly process of the sub-assembly viewed video assembling step; step
eighty-two: each sub-assembly according to the material and the process list of props,
 props present materials and receive channel sub-assembly step required within 5-8
minutes by a picking member; eighty-three steps: by a separate operator completes the
sub-assembly step of the present channel for all assembly operations, and after
completion of shell material into the cartridge assembly process required to wait five
minutes to complete the heat treatment process, if the lack of fitting the workpiece
during assembly by a warehouse members provide spare parts and props keeping
track of the present sub-assembly step; step eighty-four: QA sub-assembly of the
channel in the article by a process of the inspector, in particular with sub-assemblies
hands sample step contrast detection mass; eighty-five steps: the observers are two
observers using a stopwatch and recorded data track sub-assembly of the present
step, then the observer Two observation points waste recording track present in the
subassembly step, two other members of the auxiliary observers recorded transactions;
eighty-six Step: After quality inspection by a transport member to transport to the next
step of the present channel subassembly assembled in the article step; eighty-seven
steps: when the assembly quality problems arise procedure performed by the
communication quality inspector and two adjacent sets of transport members for
communication.
5. 4 according to the method for assembling airplane model Leanclaim, wherein: said step
of eighty-two materials and props including aircraft model parts, sub-assembly
schematic card assembly process, process card bill of tools and materials, stopwatch ,
marker pen, questionnaire, and each sample sub-assembly step.
6. 4 or 5, according to the assembling method for the aircraft model Lean claim, wherein:
data of said sub-assembly step of the assembly process of the present eighty-five
channel comprises the step of sub-assembly of the first aircraft and used time, tailstock
delivery time after the aircraft model assembled.
7. 6 according to the method for assembling airplane model Leanclaim, wherein: said step
of sixteen sub-assembly step of the group assigned to each operator assembling
operation repeats Step 4 to Step 9 of eight.

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