Chng 1

NHNG KHI NIM C BN

1.1.QU TRNH SN XUT V QU TRNH CNG NGH
1.1.1 Qa trnh sn xut
Qu trnh sn xut l qu trnh con ngi tc ng vo ti nguyn thin nhin
bin n thnh sn phm phc v li ch ca con ngi.
Theo ngha rng, v d, c mt sn phm c kh th con ngi phi thc
hin cc qu trnh nh khai thc qung, luyn kim, gia cng c, gia cng nhit,
ho, lp rp, kim tra, .
Theo ngha hp, v d trong mt nh my c kh th qu trnh sn xut l qu
trnh tng hp cc hot ng c ch ca con ngi bin nguyn liu v thnh
phm thnh sn phm ca nh my. Qu trnh tng hp bao gm: ch to phi,
gia cng ct gt, gia cng nhit, ho, kim tra, lp rp v hng lot cc qu trnh
ph khc nh ch to dng c, ch to g, vn chuyn, sa cha my, chy th,
iu chnh, sn lt, bao b, ng gi, bo qun trong kho, .
1.1.2 Qu trnh cng ngh
Qu trnh cng ngh l mt phn ca qu trnh sn xut trc tip lm thay
i trng thi v tnh cht ca i tng sn xut. Thay i trng thi v tnh cht
bao hm: thay i hnh dng, thay i kch thc, thay i tnh cht c l ho ca
vt liu v thay i v tr tng quan gia cc b phn ca chi tit.
Qu trnh cng ngh gia cng c l qu trnh ct gt phi lm thay i
kch thc v hnh dng ca n.
Qu trnh cng ngh nhit luyn l qu trnh lm thay i tnh cht vt l v
ho hc ca vt liu chi tit.
Qu trnh cng ngh lp rp l qu trnh to thnh nhng quan h tng quan
gia cc chi tit thng qua cc loi lin kt mi lp ghp.
Ngoi ra cn c cc qu trnh cng ngh ch to phi nh qu trnh c (cng
ngh c), qu trnh gia cng p lc,
Xc nh qu trnh cng ngh hp l ri ghi thnh vn kin cng ngh th
cc vn kin cng ngh c gi l quy trnh cng ngh.
Qu trnh cng ngh hp l l qu trnh cng ngh tho mn c cc yu
cu ca chi tit nh chnh xc gia cng, nhm b mt, v tr tng quan gia
cc b mt, chnh xc hnh dng hc,
Qu trnh cng ngh c thc hin ti cc ch lm vic.
1.1.3 Ch lm vic
Ch lm vic l mt phn ca xng sn xut c dng thc hin cng
vic bng mt hoc mt nhm cng nhn. Ti y c b tr cc loi dng c,
g, my ct gt, thit b nng h, gi phi, chi tit hoc n v lp rp.
1.2 THANH PHN SN XUT CA NH MY CH TO MY
Cc nh my ch to my bao gm cc n v sn xut ring bit c gi l
cc phn xng v cc c cu khc.
Thnh phn ca cc phn xng v cc c cu c xc nh bng sn lng
ca sn phm, c tnh ca qui trnh cng ngh, yu cu i cht lng sn phm

v cc yu t sn xut khc, ng thi bng mc chuyn mn ha sn xut v

s hp tc ca nh my vi cc x nghip khc trong ngnh cng nh ngoi
ngnh .
Chuyn mn ha i hi phi tp trung sn xut mt khi lng ln hng ha
( ca mt dng sn phm nht nh) trong tng nh my.
S hp tc i hi cung cp phi (phi c, phi rn, phi dp) v thit b
(hoc c cu) khc t nh my chuyn mn ha.
Nu mt nh my c thit k s nhn phi c t nh my khc th trong
thnh phn ca nh my ny khng c phn xng c. V d, mt s nh my
ch to my cng c nhn phi c t mt nh my c phi chuyn mn ha,
nh my ny c kh nng cung cp cc loi phi c cho tt c cc khch hng
theo mt trnh t tp trung ha cao .
Thnh phn ca thit b cung cp nng lng ca nh my cng rt a dng,
tu thuc vo kh nng hp tc vi cc x nghip cng nghip khc i vi vic
cung cp nng lng in, ga, hi nc,
Trong sn xut ln c rt nhiu nh my bit hp tc vi cc nh my
chuyn mn ha c cung cp cc b phn sn phm dng cho sn phm
c ch to ti nh my, v d, cc nh my ch to t v ch to my ko
t hng cc ng c t cc nh my khc.
Thnh phn ca mt nh my ch to my c chia ra cc nhm sau y:
1) Cc phn xng chun b phi: c thp, c gang, c hp kim mu, rn
dp
2) Cc phn xng gia cng: gia cng c, nhit luyn, dp ngui, sn, m,
lp rp
3) Cc phn xng ph: dng c, ch th, ch to khun mu, th nghim,
sa cha c kh, sa cha in
4) Cc kho cha: vt liu, dng c, khun mu, nhin liu, sn phm
5) Cc trm cung cp nng lng: in , nhit, hi p v kh nn, nc...
6) Cc c cu vn chuyn.
7) Cc thit b v sinh-k thut: si m, thng gi, ng ng cp nc, h
thng cng rnh...
8) Cc b phn chung ca nh my: phng th nghim trung tm, phng th
nghim cng ngh, phng th nghim o lng trung tm, cc vn phng, trm x,
nh n, h thng lin lc
1.3. CC THNH PHN CA QUY TRNH CNG NGH
Quy trnh cng ngh gia cng c c chia ra cc thnh phn: nguyn
cng, g, v tr, bc, ng chuyn dao cng tc.
1.
Nguyn cng.
Nguyn cng l mt phn ca quy trnh cng ngh c hon thnh lin
tc ti mt ch lm vic do mt hay nhiu nhm cng nhn thc hin gia cng
mt hay mt s chi tit cng lc (khi khng c cng nhn no phc v th l
nguyn cng c t ng ho hon ton).

Nu thay i mt trong nhng iu kin nh: tnh lm vic lin tc hoc

ch lm vic th ta chuyn sang mt nguyn cng khc. Ta xt trng hp gia
cng trc bc trn hnh 1.1.
Nu ta tin mt u ri tr u ngay tin u kia th vn thuc mt
nguyn cng. Nhng nu tin mt u cho c lot chi tit ri mi tin u kia cho
c lot chi tit th ta c hai nguyn cng. Hoc l trn mt my ch tin mt u,
cn u kia c tin trn my khc th ta cng c hai nguyn cng.
Sau khi tin xong mt (hay hai my tin) tin hnh phay rnh then H
trn my phay th s c nguyn cng khc (nguyn cng phay).
Nguyn cng l n v c bn ca quy trnh cng ngh. Phn chia quy
trnh cng ngh ra thnh cc nguyn cng c ngha k thut v ngha kinh t.
ngha k thut l ch tu theo yu cu k thut ca chi tit m phi
gia cng b mt no bng phng php bo, phay hay mi.
ngha kinh t (v d, trng hp gia cng trc bc trn hnh 1.1) l ch
tu theo sn lng v iu kin c th m chia quy trnh cng ngh ra lm nhiu
nguyn cng (phn tn nguyn cng) hoc tp trung mt vi nguyn cng (tp
trung nguyn cng) nhm m bo s cn bng ca nhp sn xut. Hoc trn mt
my chnh xc khng nn lm c vic th v vic tinh m phi chia thnh hai
nguyn cng: th v tinh cho hai my (my th v my chnh xc).
2.
G.
G l mt phn ca nguyn cng c hon thnh trong mt ln g t mt
hoc nhiu chi tit cng lc. V d, trn mt u ca chi tit ( hnh 1.1) ri g li
chi tit u kia l hai ln g t. Mt nguyn cng c th c mt hoc nhiu ln
g.
3.
V tr.
V tr l mt phn ca nguyn cng c xc nh bi mt v tr tng quan
gia chi tit gia cng v my hoc gia chi tit gia cng v g hay dng c ct.
V d, mi ln phay mt cnh hoc khoan mt l trn chi tit c nhiu l c gi
l mt v tr. Trng hp gia cng mt l nhng qua nhiu bc khc nhau mh
khoan, khot, doa (hnh 1.2) cng c xem l chi tit c nhiu v tr.
Khi thit k qu trnh cng ngh cn lu l gim qu trnh g t (trong
khi vn gi c s v tr cn thit) bi v trong mi ln g t s gy ra sai s gia
cng.
Khi lp rp, i tng lp cng vi g(v d, g v tinh) trn bng ti
xch c th dch chuyn ti v tr mi thc hin nguyn cng lp rp.
4) Bc.
Bc l mt phn ca nguyn cng tin hnh gia cng mt b mt (hoc
nhiu b mt) bng mt dao hoc nhiu dao vi ch ct khng thay i. Nu
thay i mt trong cc iu kin nh: b mt gia cng hoc ch ct (tc ,
lng chy dao hoc chiu su ct) th ta chuyn sang mt bc khc. V d,
tin ba on A, B, C (hnh 1.1) l ba bc khc nhau. tin bn mt u D, E, F, G
(hnh 1.1) l bn bc c lp vi nhau. Sau khi tin ngoi ta thay dao, thay i
tc v bc tin dao (lng chy dao) tin ren l hai bc khc nhau. Hoc

khi gia cng l chnh xc ln lt bng cc phng php khoan, khot, doa th c
ba bc khc nhau.
Bc c th l bc n gin v bc phc tp. V d, khi tin mt trc bc
gm ba on vi ng knh khc nhau (bng mt dao) th ta phi thc hin ba
bc n gin. Cn khi tin trc bc ng thi bng nhiu dao th ta c mt
bc phc tp.
Khi lp rp cc bc c xem l mt qu trnh ni ghp cc chi tit li vi
nhau t chnh xc cn thit hoc cc qu trnh khc nhau nh co sa then
lp n vo v tr, lp mt vng bi trn trc,.
Mt nguyn cng c th c mt hoc nhiu bc.
5) ng chuyn dao.
ng chuyn dao l mt phn ca bc ht i mt lp vt liu c cng
ch ct v bng cng mt dao.
V d, tin mt tr ngoi ta c th dng mt dao vi cng mt ch ct
ht lm nhiu ln, mi ln l mt ng chuyn dao, hoc khi mi mt b mt
no ta phi thc hin nhiu ng chuyn dao. Nh vy, mi bc c th c
mt hoc nhiu ng chuyn dao.
6) ng tc.
ng tc l mt hnh ng ca ngi cng nhn iu khin my khi gia
cng hoc lp rp. V d: bm nt, quay dao, y ng, thay i ch ct,
cn i vi lp rp th ng tc l ly chi tit, lau sch chi tit, bi m trn chi tit,
cm cl, sit ai c,...
Vic phn chia thnh ng tc rt cn thit nh mc thi gian kh i gia
cng v lp rp, ng thi nghin cu nng sut lao ng v t ng ho
nguyn cng.
1.4. SN LNG V SN LNG HNG NM
Sn lng l s my, chi tit hoc phi c ch to ra trong mt n v
thi gian (nm, qu, thng).
Sn lng hng nm ca chi tit c xc nh theo cng thc:

N = N1.m1 +

100

y: N- s chi tit c sn xut trong mt nm;

N1- s sn phm ( s my) c sn xut trong mt nm;
m- s chi tit trong mt sn phm (s my);
- s chi tit c ch to thm d phng ( = 57%)
Nu tnh n s % chi tit ph phm (ch yu trong cc phn xng c
v rn) th ta c cng thc xc nh N nh sau:
+
N = N1.m1 +

100

Trong : = 36%
S lng my, chi tit hoc phi c ch to theo mt bn v nht nh
c gi l xeri (lot). Mi mt loi my mi ra i u nh s xeri (s lot)

1.5. CC DNG SN XUT

Qui trnh cng ngh m ta thit k phi m bo c chnh xc v cht
lng gia cng, ng thi phi m bo tng nng xut lao ng v gim gi
thnh. Qui trnh cng ngh ny phi m bo c sn lng t ra. t c
cc ch tiu trn y th qui trnh cng ngh phi c thit k thch hp vi dng
sn xut.
Tu theo sn lng hng nm v mc n nh ca sn phm m ngi ta
chia ra ba dng sn xut : sn xut n chic, sn xut hng lot v sn xut hng
khi.
1.5.1 sn xut n chic
Sn xut n chic l sn xut c s lng sn phm hng nm rt t
(thng t mt n vi chc chic), sn phm khng n nh do chng loi nhiu,
chu k ch to li khng c xc nh.
Sn xut n chic c nhng c im sau:
-Ti mi ch lm vic c gia cng nhiu loi chi tit khc nhau (tuy nhin
cc chi tit ny c hnh dng hnh hc v c tnh cng ngh tng t).
- Gia cng chi tit v lp rp sn phm c thc hin theo tin trnh cng
ngh (qui trnh cng ngh s lc).
- S dng cc thit b v dng c vn nng. Thit b (my) c b tr theo
tng loi v theo tng b phn sn xut khc nhau.
- S dng cc g vn nng. g chuyn dng ch c s dng gia
cng nhng chi tit thng xuyn c lp li.
- Khng thc hin c vic lp ln hon ton, c ngha l phn ln cng
vic lp rp u c thc hin bng phng php co sa. y vic lp ln
hon ton ch c m bo i vi mt s mi ghp nh ren, mi ghp then hoa,
cc b phn truyn bnh rng v cc b phn truyn xch.
- Cng nhn phi c trnh tay ngh cao.
- Nng sut lao ng thp, gi thnh sn phm cao. V d, dng sn xut
n chic l ch to cc my hng nng hoc cc sn phm ch th, cc sn phm
c ch to theo n t hng.
1.5.2 Sn xut hng lot
- Sn xut hng lot l sn xut c sn lng hng nm khng qu t, sn
phm c ch to theo tng lot vi chu k xc nh, sn phm tng i n
nh.
- Sn xut hng lot l sn xut ph bin nht trong ngnh ch to my
(7080% sn phm ca ngnh ch to my c ch to theo tng lot).
Sn xut hng lot c nhng c im sau y:
- Ti cc ch lm vic c thc hin mt s nguyn cng c chu k lp li
n nh.
- Gia cng c v lp rp c thc hin theo quy trnh cng ngh (quy trnh
cng ngh c chia ra cc nguyn cng khc nhau).
- S dng cc my vn nng v chuyn dng.
- Cc my c b tr theo quy trnh cng ngh.

- S dng nhiu dng c v g chuyn dng.

- m bo nguyn tc lp ln hon ton.
- Cng nhn c trnh tay ngh trung bnh.
Tu theo sn lng v mc n nh ca sn phm m ngi ta chia ra:
sn xut hng lot nh, sn xut hng lot va v sn xut hng lot ln.
Sn xut hng lot nh rt gn vi sn xut n chic, cn sn xut hng
lot ln rt gn vi sn xut hng khi.
V d, dng sn xut hng lot c th l ch to my cng c, ch to my
nng nghip,
Trong dng sn xut hng lot va c th t chc cc dy chuyn sn xut
linh hot (dy chuyn sn xut thay i). iu ny c ngha l sau mt khong
thi gian nht nh (2-3 ngy) c th tin hnh gia cng lot chi tit khc c kt
cu v qui trnh cng ngh tng t.
1.5.3 Sn xut hng khi
Sn xut hng khi l dng sn xut c sn lng rt ln, sn phm n nh
trong thi gian di (c th t 1 n 5 nm).
Sn xut hng khi c nhng c im sau y:
- Ti mi v tr lm vic (ch lm vic) c thc hin c nh mt nguyn
cng no .
- Cc my c b tr theo quy trnh cng ngh rt cht ch.
- S dng nhiu my t hp, my t ng, my chuyn dng v ng dy
t ng.
- Gia cng chi tit v lp rp sn phm c thc hin theo phng php
dy chuyn lin tc.
- S dng g chuyn dng, dng c chuyn dng v cc thit b o t
ng ho.
- m bo nguyn tc lp ln hon ton.
- Nng sut lao ng cao, gi thnh sn phm h.
- Cng nhn ng my c trnh tay ngh khng cao nhng th iu chnh
my li c trnh tay ngh cao.
-V d, dng sn xut hng khi c th l ch to t, ch to my ko, ch
to vng bi, ch to cc thit b o lng, Sn xut hng khi ch c th mang
li hiu qu kinh t i vi sn lng ca chi tit (hoc ca sn phm) ln, khi
m tt c mi chi ph cho vic t chc sn xut hng khi c hon li v gi
thnh mt n v sn phm nh hn so vi sn xut hng lot.
Hiu qu kinh t khi ch to s lng ln sn phm c tnh theo cng thc:
c

n S S
l
k
y: N s n v sn phm:
C chi ph cho vic thay i t dng sn xut hng lot sang dng sn
xut hng khi;
Sl gi thnh ca mt n v sn phm trong sn xut hng lot;
Sk - gi thnh ca mt n v sn phm trong sn xut hng khi.

iu kin xc nh hiu qu ca sn xut hng khi trc ht l sn lng

v mc chuyn mn ho ca nh my i vi tng loi sn phm c th.
Nhng iu kin thch hp nht ca sn xut hng khi l ch ch to mt lot sn
phm vi mt kt cu duy nht.
Tuy nhin, vi s pht trin ca khoa hc v k thut th kt cu ca sn
phm cng cn c thay i c cht lng hon thin hn. Trong nhng
trng hp nh vy quy trnh cng ngh cng cn c hiu chnh li.
1.6 NHP SN XUT
Trong sn xut hng lot ln v hng khi thng s dng phng php
sn xut dy chuyn ( c gia cng ln lp rp). Theo phng php ny th cc my
c b tr theo th t cc nguyn cng. S v tr (ch lm vic) v nng sut phi
c tnh ton sao cho ng b ( khng b nh n gia cc nguyn cng). Mun
cho dy chuyn sn xut ng b phi tun theo nhp sn xut nht nh.
Nhp sn xut l khong thi gian lp li chu k gia cng ( hoc lp rp) v c
tnh bng cng thc:
t=

F
q

y: t nhp sn xut (pht);

F thi gian lm vit tnh theo ca, thng, nm (pht );
q s lng sn phm (hoc chi tit) c ch to ra trong thi gian F.
V d, trong mt ngy lm vic 8 gi, ta c: F = 8 x 60 pht = 480 pht.Gia
cng c q = 160 chi tit. Nh vy nhp xn xut t =

480
= 3 pht. Co ngha l
160

thi gian ca mi nguyn cng l 3 pht (k c vn chuyn) hoc l bi s ca 3

(v d, nguyn cng ct rng cn c 4 my lm vic mi kp cho nguyn cng
trc bi v mi my ct mt chi tit mt 12 pht tc l bi s ca 3).
1.7. XC NH DNG SN XUT
Sau khi xc nh c sn lng hng nm N ca chi tit theo cng thc
(1.2) ta phi xc nh khi lng ca chi tit. Khi lng Q ca chi tit c xc
nh theo cng thc :
Q = V.
y: V- th tch ca chi tit (dm3);
-khi lng ring ca vt liu ( ca thp l 7,852kg/dm3; ca gang
do l 7,2kg/dm3; ca gang xm l 7kg/dm3 ; ca nhm l 2,7kg/dm3 v ca
ng l 8,72kg/dm3 ).
Khi c N v Q da vo bng 1.1 chn dng sn xut ph hp .
Khi thit b n mn hc v n tt nghip cng ngh ch to my
sinh vin thng gp cc dng sn xut hng lot va, hng lot ln v hng lot
khi thit k quy trnh cng ngh vi cc g chuyn dng , my chuyn
dng , my bn t ng , dao c chng v,v..
Bng 1.1 .xc nh dng sn xut
Dng sn xut
Q - khi lng ca chi tit
> 200kg
4 -200kg
< 4kg

n chic
Hng lot nh
Hng lot va
Hng lot ln
Hng khi

Sn lng hng nm ca chi tit (chic )

<5
< 10
< 100
55 -100
10 - 200
100 - 500
100 - 300
200 - 500
500 - 5000
300 -1000
500 -1000
5000 - 50000
> 1000
> 5000
> 50000

1.8. TP TRUNG V PHN TN NGUYN CNG

Trong sn xut hng lot ln v hng lot khi gia cng chi tit c th c
thc hin theo phng php tp trung nguyn cng hoc theo phng php phn
tn nguyn cng .
1.8.1. Phng php tp trung nguyn cng
Tp trung nguyn cng c ngha l b tr nhiu bc cng ngh vo mt
nguyn cng v c thc hin trn mt my. Thng thng tp trung nguyn
cng c thc hin vi cc bc cng ngh gn ging nhau nh : khoan, khot,
doa, ct ren hoc tin ngoi, tin trong, v,v.
phng php tp trung nguyn cng c ng dng cho nhng chi tit phc
tp c nhiu b mt gia cng. gia cng cc loi chi tit ny ngi ta phi dng
my c nng sut cao. l cc my t hp, my nhiu trc chnh (gia cng c
tin hnh tun t trn tng trc chnh v ng thi trn nhiu v tr khc nhau).
Trong trng hp ny thi gian gia cng mt chi tit bng thi gian gia cng trn
mt trc chnh. Nng sut gia cng tng nh gia cng song song v s trng hp
ca thi gian my. Thi gian ph bng thi gian quay ca bn my i mt v tr.
Ngoi cc my t hp v my nhiu trc chnh ra ngi ta cn dng cc my
nhiu dao thc hin gia cng theo phng php tp trung nguyn cng.
Ngoi nng sut cao ra, phng php tp trung nguyn cng cn cho php
nng cao h s s dng mt bng sn xut. Tuy nhin phng php ny c nhc
im l dng my c phc tp cao v iu chnh my cng rt kh khn.
1.8.2.phng php phn tn nguyn cng
phng php phn tn nguyn cng c ngha l chia quy trnh cng ngh ra
nhiu nguyn cng nh, mi nguyn cng c thc hin trn mt my. Trong
trng hp ny ngi ta s dng cc my thng dng, cc dng c tiu chun v
cc trang b cng ngh n gin. Nh nhng nt c trng m phng php
phn tn nguyn cng c tnh linh hot cao, c th l qu trnh chuyn i i
tng gia cng c thc hin rt nhanh chng v chi ph khng ng k.
Hin nay trong lnh vc ch to my, nhn chung ngi ta c xu hng p
dng phng php tp trung nguyn cng trn c s t ng ho sn xut nhm
tng nng sut lao ng, rt ngn chu k sn xut gim chi ph iu hnh v lp k
hoch sn xut. Cn phng php phn tn nguyn cng ch p dng quy m sn
xut ln nu trnh sn xut km nhn t gc k thut sn xut.