【摘要】：在訂單充足塢期緊張的情況下,分段制造往往會(huì)成為造船廠高效生產(chǎn)的約束瓶頸。絕大多數(shù)船廠都會(huì)忽視提高自身產(chǎn)能而采取外包的方式欲以緩解分段供給壓力。在分段的整個(gè)制造流程中胎架利用率的高低與胎架周期的長(zhǎng)短是決定分段能否高效生產(chǎn)的關(guān)鍵因素,也是分段制造的瓶頸所在。實(shí)現(xiàn)分段的流水化制造可以從根本上消除分段制造對(duì)整個(gè)船舶建造周期的影響,提高船廠的競(jìng)爭(zhēng)能力,具有重大的生產(chǎn)指導(dǎo)意義。本文正是基于約束理論的相關(guān)原理通過(guò)對(duì)中海江蘇造船基地流水化分段制造瓶頸的深入分析,從全局著眼找出一直以來(lái)影響分段高效產(chǎn)出的幾大原因,并提出質(zhì)量管控前移、DBR對(duì)預(yù)制件集配的管理、鋼材的微庫(kù)存管理、分段制造營(yíng)運(yùn)成本的精細(xì)化管理等方法從產(chǎn)銷率、庫(kù)存、經(jīng)營(yíng)成本3個(gè)方面入手,松綁約束瓶頸實(shí)現(xiàn)分段產(chǎn)銷率的大幅提升。首先,文章將對(duì)課題的來(lái)源,研究的目的與意義進(jìn)行闡述,對(duì)分段流水化制造國(guó)內(nèi)外研究的現(xiàn)狀進(jìn)行總結(jié),并對(duì)中海江蘇造船基地的分段制造現(xiàn)狀進(jìn)行介紹,提出分段流水化制造的必要性。其次,文章將對(duì)約束理論的原理及其提供的5步聚焦法、思維流程分析法、物流分析法、DBR生產(chǎn)管理模型進(jìn)行介紹。第三,通過(guò)對(duì)公司分段制造流程的再梳理,利用約束理論提供的相關(guān)方法應(yīng)用總結(jié)出中海江蘇造船基地分段流水化制造的瓶頸。這些瓶頸主要包括:分段制造產(chǎn)銷率低的瓶頸、預(yù)制件集配供應(yīng)混亂的瓶頸、鋼材庫(kù)存管理的瓶頸以及分段制造營(yíng)運(yùn)成本過(guò)高的瓶頸。第四,利用約束理論提供的相關(guān)方法分別對(duì)這些主要瓶頸進(jìn)行深入分析并提出應(yīng)對(duì)措施。通過(guò)分段制造質(zhì)量管控的前移與組織機(jī)構(gòu)的約束調(diào)整來(lái)實(shí)現(xiàn)分段產(chǎn)銷率的提高;通過(guò)分段預(yù)制件集配的DBR管理、用工模式的轉(zhuǎn)變、集配與質(zhì)量管控的結(jié)合實(shí)現(xiàn)預(yù)制集配的高效管理;通過(guò)鋼材的先進(jìn)先出管理和鋼材的預(yù)估與采購(gòu)實(shí)現(xiàn)鋼材的微庫(kù)存管理;通過(guò)分段生產(chǎn)耗材的合理控制與生產(chǎn)現(xiàn)場(chǎng)的5S管理實(shí)現(xiàn)分段制造運(yùn)營(yíng)成本的精細(xì)化管理。第五,通過(guò)應(yīng)對(duì)措施的實(shí)行檢驗(yàn)中海江蘇造船基地64000T散貨船分段流水化制造的效果。根據(jù)基地現(xiàn)有的分段制造場(chǎng)地與配套設(shè)施以及64000T散貨船分段制造的特點(diǎn)提出平直分段、曲面分段、上建桅屋類分段的流水化制造方案,實(shí)現(xiàn)全船分段的流水化制造。最后,文章將會(huì)對(duì)實(shí)施流水化制造的效果進(jìn)行評(píng)價(jià),對(duì)過(guò)程中出現(xiàn)的問(wèn)題進(jìn)行總結(jié),對(duì)文章的不足之處提出進(jìn)一步優(yōu)化的方向。
[Abstract]:In the case of tight docking period, piecewise manufacturing often becomes the constraint bottleneck of shipyard's efficient production. Most shipyards neglect to increase their own capacity and adopt outsourcing to ease the pressure on segmented supply. In the whole manufacturing process of the segment, the utilization ratio of the tire frame and the length of the cycle are the key factors to determine whether the segment can be produced efficiently, and also the bottleneck of the segmented manufacturing. The realization of piecewise flow manufacturing can fundamentally eliminate the influence of subsection manufacturing on the whole ship construction cycle and improve the competitiveness of shipyards. It has great guiding significance in production. This paper is based on the relevant principles of constraint theory, through the in-depth analysis of the bottleneck of subsection manufacturing in China Shipping Jiangsu Shipbuilding Base, from the overall point of view to find out the main reasons that have been affecting the high efficiency of segment production, and put forward the quality control forward. The methods of DBR, such as the management of preform assembly, the micro-inventory management of steel, the fine management of the operating cost of segmented manufacturing, etc., start from three aspects: production and sale rate, inventory and operating cost. The bottleneck of loosening constraints can greatly improve the production and marketing rate of segment production and marketing. First of all, the article will explain the source of the subject, the purpose and significance of the study, and summarize the domestic and foreign research status of subsection flow manufacturing, and introduce the current situation of subsection manufacturing in China Shipping Jiangsu Shipbuilding Base. The necessity of piecewise flow manufacturing is put forward. Secondly, the paper introduces the principle of constraint theory and the five-step focusing method, thought flow analysis, logistics analysis and DBR production management model. Thirdly, through the re-combing of the segmented manufacturing process of the company, the bottleneck of segmented flow manufacturing of China Shipping and Jiangsu Shipbuilding Base is summarized by using the relevant methods provided by the constraint theory. These bottlenecks mainly include: the bottleneck of low production and marketing rate of piecewise manufacturing, the bottleneck of confusion of prefabricated assembly and supply, the bottleneck of steel inventory management and the bottleneck of high operating cost of piecewise manufacturing. Fourth, using the relevant methods provided by constraint theory to analyze these main bottlenecks in depth and put forward countermeasures. The improvement of production and marketing rate can be realized by moving forward of the quality control of segmented manufacturing and adjusting the constraint of the organization. Through the DBR management of piecewise prefabricated parts, the transformation of employment mode, the combination of assembly and quality control, the efficient management of precast assembly is realized, and the micro-inventory management of steel is realized through the first-in-first-out management of steel products and the prediction and purchase of steel products. Through the reasonable control of the consumable material and the 5S management of the production site, the fine management of the operation cost of the piecewise manufacturing is realized. Fifthly, the effect of 644000T bulk carrier subsection flow manufacturing in China Shipping Jiangsu Shipbuilding Base is tested through the implementation of countermeasures. According to the existing subsection manufacturing site and supporting facilities of the base as well as the characteristics of 64000T bulk cargo ship segment manufacturing, this paper puts forward a flow manufacturing scheme of straight section, curved surface segment and upper mast house segment to realize the whole ship segment flow manufacturing. Finally, the article will evaluate the effect of the implementation of pipelined manufacturing, summarize the problems in the process, and put forward the further optimization direction for the shortcomings of the article.
【學(xué)位授予單位】：上海交通大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2015
【分類號(hào)】：U673

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本文編號(hào)：2344591