破解智能制造落地瓶颈：基于精益的生产工艺设计方法及案例

Overcoming the Implementation Bottleneck in Intelligent Manufacturing: A Lean-Based Production Process Design Method with Case Studies

摘要

本研究旨在破解智能制造在复杂装备制造领域落地难的核心瓶颈，即生产工艺缺乏精益设计与标准化的问题。为此，提出并深入探讨基于精益的生产工艺设计方法，聚焦产品工艺向生产工艺转化的 3 个关键过程：工序向要素作业的细化、工序向工位的重组以及生产工艺的深度优化。通过 A 公司包装工序与 B 企业光学装备装配线的实例分析，采用作业测时、标准作业组合票及改进型工艺流程图等方法，系统验证了该方法的有效性。研究结果表明，该方法可显著提升生产效率与工艺标准化水平：在未增加自动化设备的情况下，使包装工序必要人工数降低19%、装配线人均效率提升 420%，并生成可直接支撑智能制造运行的制造物料清单与精细化工艺流程模型。本文所构建的生产工艺精益设计流程，为智能制造的系统化落地提供了可操作的方法依据，突出了通过工艺前端精益化实现制造系统高效化、数字化与智能化的重要路径。

Abstract

This study aims to address the core bottleneck impeding the implementation of intelligent manufacturing in complex equipment manufacturing-namely, the lack of lean design and standardization of production processes. To this end, a lean-based production process design method is proposed and investigated, focusing on three key transformations from product process planning to production: refining operations into elemental tasks, reorganizing operations into workstations, and optimizing the production process in depth. The effectiveness of the proposed method is systematically validated using case studies at Company A's packaging operation and Company B's optical equipment assembly line, where work measurement, standard work combination charts, and improved process flow diagrams are applied. Results demonstrate that the proposed method significantly enhances production efficiency and process standardization. Specifically, without introducing additional automated equipment, the required labor for the packaging operation is reduced by 19%, and the per-capita efficiency of the assembly line is increased by 420%. Moreover, a manufacturing bill of materials and a refined process flow model that can directly support intelligent manufacturing operation are generated. The lean production process design framework established in this study provides an applicable methodological basis for the systematic implementation of intelligent manufacturing, highlighting a critical path toward achieving high efficiency, digitalization, and intelligence in manufacturing systems through front-end lean process design.

关键词

生产工艺 / 精益设计 / 要素作业 / 智能制造

Key words

production process / lean design / elemental operations / intelligent manufacturing

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