Layout design of a mixed-flow production line based on processing energy consumption and buffer configuration

doi:10.1007/s40436-021-00354-1

Advances in Manufacturing ›› 2021, Vol. 9 ›› Issue (3): 369-387.doi: 10.1007/s40436-021-00354-1

Layout design of a mixed-flow production line based on processing energy consumption and buffer configuration

Cai-Xia Zhang^1,2, Shu-Lin Dong^1,2, Hong-Yan Chu^1,2, Guo-Zhi Ding^3,4, Zhi-Feng Liu^1,2, Shi-Yao Guo³, Chong-Bin Yang^1,2

1 Institute of Advanced Manufacturing and Intelligent Technology, Beijing University of Technology, Beijing 100124, People's Republic of China;
2 Beijing Key Laboratory of Advanced Manufacturing Technology, Beijing University of Technology, Beijing 100124, People's Republic of China;
3 Beijing Xinghang Electromechanical Equipment Co., Ltd., Beijing 100074, People's Republic of China;
4 School of Mechanical Engineering and Automation, Beihang University, Beijing 100191, People's Republic of China

收稿日期:2020-11-16 修回日期:2021-01-19 出版日期:2021-09-25 发布日期:2021-09-13
通讯作者: Hong-Yan Chu E-mail:chuhongyan@bjut.edu.cn
基金资助:
The authors gratefully acknowledge the financial support from the National Science and Technology Major Project of China (Grant No. 2019ZX04024001), the Natural Science Foundation of Beijing Municipality (Grant No.3192003), the General Project of Science and Technology Plan from Beijing Educational Committee (Grant No. KM201810005013), the Tribology Science Fund of State Key Laboratory of Tribology (Grant Nos.STLEKF16A02, SKLTKF19B08), and the Training Program of Rixin Talent and Outstanding Talent from Beijing University of Technology.

Layout design of a mixed-flow production line based on processing energy consumption and buffer configuration

Cai-Xia Zhang^1,2, Shu-Lin Dong^1,2, Hong-Yan Chu^1,2, Guo-Zhi Ding^3,4, Zhi-Feng Liu^1,2, Shi-Yao Guo³, Chong-Bin Yang^1,2

1 Institute of Advanced Manufacturing and Intelligent Technology, Beijing University of Technology, Beijing 100124, People's Republic of China;
2 Beijing Key Laboratory of Advanced Manufacturing Technology, Beijing University of Technology, Beijing 100124, People's Republic of China;
3 Beijing Xinghang Electromechanical Equipment Co., Ltd., Beijing 100074, People's Republic of China;
4 School of Mechanical Engineering and Automation, Beihang University, Beijing 100191, People's Republic of China

Received:2020-11-16 Revised:2021-01-19 Online:2021-09-25 Published:2021-09-13
Supported by:
The authors gratefully acknowledge the financial support from the National Science and Technology Major Project of China (Grant No. 2019ZX04024001), the Natural Science Foundation of Beijing Municipality (Grant No.3192003), the General Project of Science and Technology Plan from Beijing Educational Committee (Grant No. KM201810005013), the Tribology Science Fund of State Key Laboratory of Tribology (Grant Nos.STLEKF16A02, SKLTKF19B08), and the Training Program of Rixin Talent and Outstanding Talent from Beijing University of Technology.

摘要/Abstract

摘要： Green manufacturing is a growing trend, and an effective layout design method for production lines can reduce resource wastage in processing. This study focuses on existing problems such as low equipment utilization, long standby time, and low logistics efficiency in a mixed-flow parallel production line. To reduce the energy consumption, a novel method considering an independent buffer configuration and idle energy consumption analysis is proposed for this production line's layout design. A logistics intensity model and a machine tool availability model are established to investigate the influences of independent buffer area configuration on the logistics intensity and machine tool availability. To solve the coupling problem between machine tools in such production lines, a decoupling strategy for the relationship between machine tool processing rates is explored. An energy consumption model for the machine tools, based on an optimized configuration of independent buffers, is proposed. This model can effectively reduce the idle energy consumption of the machine tools while designing the workshop layout. Subsequently, considering the problems encountered in workshop production, a comprehensive optimization model for the mixed-flow production line is developed. To verify the effectiveness of the mathematical model, it is applied to an aviation cabin production line. The results indicate that it can effectively solve the layout problem of mixed-flow parallel production lines and reduce the idle energy consumption of machine tools during production. The proposed buffer configuration and layout design method can serve as a theoretical and practical reference for the layout design of mixed-flow parallel production lines.

The full text can be downloaded at https://link.springer.com/article/10.1007%2Fs40436-021-00354-1

关键词: Layout design, Energy consumption, Mixed flow production line, Independent buffer configuration

Abstract: Green manufacturing is a growing trend, and an effective layout design method for production lines can reduce resource wastage in processing. This study focuses on existing problems such as low equipment utilization, long standby time, and low logistics efficiency in a mixed-flow parallel production line. To reduce the energy consumption, a novel method considering an independent buffer configuration and idle energy consumption analysis is proposed for this production line's layout design. A logistics intensity model and a machine tool availability model are established to investigate the influences of independent buffer area configuration on the logistics intensity and machine tool availability. To solve the coupling problem between machine tools in such production lines, a decoupling strategy for the relationship between machine tool processing rates is explored. An energy consumption model for the machine tools, based on an optimized configuration of independent buffers, is proposed. This model can effectively reduce the idle energy consumption of the machine tools while designing the workshop layout. Subsequently, considering the problems encountered in workshop production, a comprehensive optimization model for the mixed-flow production line is developed. To verify the effectiveness of the mathematical model, it is applied to an aviation cabin production line. The results indicate that it can effectively solve the layout problem of mixed-flow parallel production lines and reduce the idle energy consumption of machine tools during production. The proposed buffer configuration and layout design method can serve as a theoretical and practical reference for the layout design of mixed-flow parallel production lines.

The full text can be downloaded at https://link.springer.com/article/10.1007%2Fs40436-021-00354-1

Key words: Layout design, Energy consumption, Mixed flow production line, Independent buffer configuration

Cai-Xia Zhang, Shu-Lin Dong, Hong-Yan Chu, Guo-Zhi Ding, Zhi-Feng Liu, Shi-Yao Guo, Chong-Bin Yang. Layout design of a mixed-flow production line based on processing energy consumption and buffer configuration[J]. Advances in Manufacturing, 2021, 9(3): 369-387.

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Layout design of a mixed-flow production line based on processing energy consumption and buffer configuration

Layout design of a mixed-flow production line based on processing energy consumption and buffer configuration

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