混流制造车间物料配送调度优化研究
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摘要
随着科学技术的飞速发展,生产力的提高以及顾客消费水平的提高,需求日益多样化,企业开始更多的关注如何利用现有技术缩短生产周期、提高应变能力以快速响应市场需求。而制造环节中的车间物料供给,又是保障生产平顺进行的重要环节。学术界和企业界一直在从减少物料存储和搬运时间、提高配送服务质量、快速的将物料流转化为资金流的方向去挖掘生产物流中蕴藏的提升空间。本文以混流制造车间为研究对象,以准时化生产管理(JIT)为指导思想,以先进制造理论为支撑技术,研究企业车间生产过程中物料配送调度作业方法。从配送的流程分析方面、模型建立方面、算法设计方面、关联计划调度方面、执行监控管理方面分别探讨如何合理安排生产计划、合理调度配送车辆、加强抵御现场作业不确定干扰的能力,实现应对生产线物料的弹性需求。对企业的物流现场管理改善和降低运作成本有指导意义。首先,本文综述并总结了混流制造车间物料配送中存在的主要问题。分析了典型的混流制造生产模式和JIT生产模式下的物料配送特点。根据理论研究点对物料配送调度优化问题进行了分类,划定了本文重点解决的范围。接着,围绕着混流制造车间物料配送优化的核心问题,从相关优化内容、技术和优化算法等方面进行了深入研究,具体包括：(1)针对物料配送中理论模型与实际脱节的问题,分析混流制造模式的特点,研究带时间窗约束、车辆容量约束、车辆等待时间和服务时间受限条件下的物料配送问题。在此过程中,以提高车辆的满载率为目的,讨论了可拆分模式下的物料配送路径规划模型。利用庞加莱双曲几何理论降低大规模物料配送问题的复杂度。并设计了一种改进遗传算法较好的求解该类问题。(2)研究模糊型多目标物料配送优化问题。利用模糊理论将工位物料需求量不确定、工位之间车辆行车时间不确定和工位物料需求时间窗不确定量化为模糊数。建立了含多种不确定因子的模糊机会约束规划多目标模型。在模型求解上,引入相邻目标相对优属度确定各个目标之间的权衡关系,并设计了一种基于“六度分离”理论的小世界优化算法求解该模型。该方法能够快速求解并得到具备一定抗干扰能力的物料配送方案。(3)从计划排序与物料配送联动优化的角度,研究“计划排序——线边库存控制——车辆调度”全局优化方法。在计划排序上,建立了以物料平准化为评价体系的物料供应数学模型。以线边消耗速度为输入,设计一种线边库存控制策略优化物料配送需求。以此为需求的车辆调度优化可实现整体提高配送效率的目的。在此基础上,研究如何利用多通道式缓存区实现混流线的计划排序优化,使本文理论能够更好的应用在自动化控制线上,保证线边库存物料消耗的均衡性。(4)自主设计并开发了安徽江淮汽车股份有限公司的MES。介绍系统的架构和物料配送功能模块设计方法及特点,并对本项目应用效果进行了演示。最后,对全文进行了总结概括,指出了需要进一步研究的方向。
With the development of science and technology, the improvement of productivity and consumption standard, the customers'demands is becoming diversity. It makes that the enterprises take more consideration on how to shorten the production period using the current technology and improve the response to the demand of market rapidly. The delivery of logistics is the key point in the production process to guarantee production.In this dissertation, the manufacturing workshop as the study object, the JIT management as guidelines, and the advanced manufacturing theories as crucial technology, the material delivery scheduling method in the manufacturing process of workshops is researched. With the methods of material delivery flow analysis, model construction, algorithm designing, associated schedule plans and the implementation and monitory of management, how to arrange the production plans reasonably, schedule the vehicles legitimately, and strengthen the ability of uncertain interference against field operations are discussed in order to meet the flexible requests of materials along the production lines. It has the contribution to improve the field material management and reduce the cost of operation.First of all, the main problem in the mixed-model manufacturing shop on material delivery is introduced, and the characteristic of material delivery under typical mixed-model production patterns and JIT patterns is analyzed. According to the theoretical researches, the different types of material distribution problems have been classified, and the scope of our researches has been defined.Secondly, surrounding the core problem of material delivery optimization in mixed-model manufacturing workshop, related optimization scopes, technology and optimization algorithms are studied in deep going way as follows.(1) According to the problem of theory detached from practice in the material delivery, the characteristic of mixed-model manufacturing is analyzed, and the problems of material delivery with the constraint conditions of time window, vehicle capacity, restricted vehicle waiting time and service time are researched. In this process, the path planning model under the decomposable condition is discussed to increase the vehicle capacity rate. The theory of Poincare hyperbolic geometry is used to reduce the complexity of the large scale material delivery problem. In addition, a modified genetic algorithm is designed to resolve this kind of problem.(2) Fuzzy multi-objective optimization of material delivery has been studied in this dissertation. The fuzzy numbers in fuzzy theory are used to describe the uncertainties of material requirements in every workstation, vehicle scheduling between workstations and material requirement time window. The multi-objective fuzzy chance constrained programming model involving multiple uncertain factors is built. To solve the model, the relative membership degree of adjacent objectives is introduced to determine the trade-off between objectives, and a small optimization algorithm based on "six degree of separation" is designed which can quickly get the robust material delivery solutions.(3) The global optimization method of material delivery scheduling including optimization of plan sequencing, assembly line inventory and vehicle scheduling is researched. A level scheduling material supply model is constructed according to production plan sequencing. A line inventory control strategy is designed to optimize the material delivery requirement with the material consumption rate of line. The goal of improving distribution efficiency can be achieved with the optimization of vehicle scheduling. On the basis, how to optimize the plan sequencing of mix-model line is investigated using multichannel buffer. And the theory could be applied on the automation lines to guarantee the proportionality of line inventory material consumption.(4) The MES of the business car assembly line in JAC is designed and developed independently. The system architecture, and the design method and characteristic of material delivery functional module are introduced. Demonstrates and the application effects of the project has been shown in the final section.Finally, the whole work in this dissertation is summarized and the research work in the future is pointed out.
With the development of science and technology, the improvement of productivity and consumption standard, the customers'demands is becoming diversity. It makes that the enterprises take more consideration on how to shorten the production period using the current technology and improve the response to the demand of market rapidly. The delivery of logistics is the key point in the production process to guarantee production.In this dissertation, the manufacturing workshop as the study object, the JIT management as guidelines, and the advanced manufacturing theories as crucial technology, the material delivery scheduling method in the manufacturing process of workshops is researched. With the methods of material delivery flow analysis, model construction, algorithm designing, associated schedule plans and the implementation and monitory of management, how to arrange the production plans reasonably, schedule the vehicles legitimately, and strengthen the ability of uncertain interference against field operations are discussed in order to meet the flexible requests of materials along the production lines. It has the contribution to improve the field material management and reduce the cost of operation.First of all, the main problem in the mixed-model manufacturing shop on material delivery is introduced, and the characteristic of material delivery under typical mixed-model production patterns and JIT patterns is analyzed. According to the theoretical researches, the different types of material distribution problems have been classified, and the scope of our researches has been defined.Secondly, surrounding the core problem of material delivery optimization in mixed-model manufacturing workshop, related optimization scopes, technology and optimization algorithms are studied in deep going way as follows.(1) According to the problem of theory detached from practice in the material delivery, the characteristic of mixed-model manufacturing is analyzed, and the problems of material delivery with the constraint conditions of time window, vehicle capacity, restricted vehicle waiting time and service time are researched. In this process, the path planning model under the decomposable condition is discussed to increase the vehicle capacity rate. The theory of Poincare hyperbolic geometry is used to reduce the complexity of the large scale material delivery problem. In addition, a modified genetic algorithm is designed to resolve this kind of problem.(2) Fuzzy multi-objective optimization of material delivery has been studied in this dissertation. The fuzzy numbers in fuzzy theory are used to describe the uncertainties of material requirements in every workstation, vehicle scheduling between workstations and material requirement time window. The multi-objective fuzzy chance constrained programming model involving multiple uncertain factors is built. To solve the model, the relative membership degree of adjacent objectives is introduced to determine the trade-off between objectives, and a small optimization algorithm based on "six degree of separation" is designed which can quickly get the robust material delivery solutions.(3) The global optimization method of material delivery scheduling including optimization of plan sequencing, assembly line inventory and vehicle scheduling is researched. A level scheduling material supply model is constructed according to production plan sequencing. A line inventory control strategy is designed to optimize the material delivery requirement with the material consumption rate of line. The goal of improving distribution efficiency can be achieved with the optimization of vehicle scheduling. On the basis, how to optimize the plan sequencing of mix-model line is investigated using multichannel buffer. And the theory could be applied on the automation lines to guarantee the proportionality of line inventory material consumption.(4) The MES of the business car assembly line in JAC is designed and developed independently. The system architecture, and the design method and characteristic of material delivery functional module are introduced. Demonstrates and the application effects of the project has been shown in the final section.Finally, the whole work in this dissertation is summarized and the research work in the future is pointed out.
引文
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