After the automation transformation of the gas turbine production line, the production efficiency can be improved by 30% -55%. The core of this improvement comes from three dimensions: reducing manual intervention, improving production coordination accuracy, and reducing unplanned downtime. The specific extent of the improvement depends on the scale of the production line and the depth of the transformation.
1, Direct efficiency improvement in core production processes
(1) Machining process
By adopting automatic loading and unloading and CAM system linkage, the auxiliary time for production change has been reduced from 1.2-1.8 hours manually to 0.15-0.25 hours, and the utilization rate of machine time has been increased by 25% -35%;
Automatic adaptation of cutting parameters, avoiding manual adjustment errors, and increasing the output of a single machine by 10% -15%.
(2) Assembly process
Automated positioning, tightening, and docking stations replace manual repetitive labor, reducing the assembly cycle of a single unit from 6.5-8.5 hours to 5-6 hours and improving assembly efficiency by 22% -30%;
The error and omission rate has decreased from 0.7% -1.2% to below 0.1%, reducing rework time and indirectly improving production capacity.
(3) Testing process
Online non-destructive testing and automatic size detection replace manual visual inspection and manual detection, improving detection efficiency by 40% -50%, and reducing the single detection cycle from 0.8 hours to 0.3 hours;
The detection data is automatically synchronized to MES to avoid manual input errors and shorten the waiting time in subsequent stages.
2, Indirect efficiency gains brought by collaboration and operation and maintenance
The AGV automatic material distribution system replaces manual transportation, reducing the proportion of material downtime from 10% -15% to 2% -4%, eliminating production capacity losses caused by delayed materials;
IoT real-time monitoring of device operation status, predicting failure time in advance, reducing unplanned downtime from 7% -10% to 2% -3%, and increasing annual effective production time by about 8% -12%;
The automated energy dispatch system optimizes the use of compressed air and cutting fluid, reducing energy consumption per unit product by 10% -15% and avoiding the risk of capacity interruption caused by energy waste.
3, Limitations on the extent of efficiency improvement
Only applicable to standardized production lines with a batch size of ≥ 5 units/month, the efficiency improvement after customized small batch (<2 units/month) transformation is only 15% -25%;
The upper limit of the impact of the transformation depth: Only single machine automation (without system linkage) can be increased by 20% -30%, and the linkage between the entire process and MES and ERP can reach an upper limit of 35% -55%;
A team with automated operation and maintenance capabilities is required, otherwise the equipment idle rate will increase by 5% -10%, offsetting some efficiency gains.
