Controlling and Optimization of Maintenance Production System for EMU Bogies

Abstract

Aiming to increase production capacity and efficiency, also avoid production imbalance, bogie of Electric Multiple Unit (EMU) maintenance production line was optimized. The 5th level wheel set maintenance line was analyzed and its process flow chart was drawn. Then use Plant-simulation software to model and simulate. The results showed that there are five bottlenecks and three blocks in the production line currently. The reasons were analyzed combination with the industrial engineering theories. The process layout adjustment was carried out on eight procedures respectively. The working hour of single train reduces by 13.3% after optimization. In order to further improve the production efficiency, the longest CRH380A wheel set maintenance line was simulated with mixed-flow production scheduling. Two scheduling methods were conducted, one was the motor trucks (D) and tow trucks (T), and the other was the 3rd, 4th and 5th level of maintenance. When the quantity ratio of the three levels of maintenance is 1:1:1, the optimal scheduling order is five-four-three. Considering single 5th level maintenance, the best order of trains is TDDDTDDD, the working hour of the maintenance decreases by 3.8%. The research accomplishments above provide technical support for process layout optimization, mixed-flow scheduling of EMU bogie maintenance and production controlling.