混合流水线生产计划与调度问题研究
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摘要
21世纪人类进入了信息化的时代,经济的全球化、一体化、市场化和信息化,使全球市场竞争也越来越激烈,促使企业的生产方式发生了巨大的变化。利用现代各种先进的方法和技术,优化生产经营和生产操作,优化资源分配的生产计划和调度已经越来越重要,是实现精细化生产,增强企业竞争力的一个重要方面。随着生产方式的改进,对生产计划与调度的研究也具有越来越重要的现实意义和理论价值。
本文根据汽车生产企业的生产流程,对混合流水型生产方式的生产计划、投产序列优化调度、生产过程的监测和控制、生产中的物料需求几方面的应用,结合汽车部件生产和整车装配生产计划与调度过程进行了深入的研究。主要工作内容及创新点如下:
(1)提出了混流装配生产计划与生产排程制定方法。以订单需求与企业生产能力为依据制定生产计划和工作班次。为保证产品生产序列满足负荷平衡和物料消耗平准化,设计了加权决策的多目标模型,采用免疫优化算法,设计了一种新的抗体浓度表示方法,能够以很快的收敛速度获得优化结果。计算结果表明,按照该序列进行生产日程安排,可以满足交货日期要求,并能使库存最小化。
(2)根据混流生产产品的特点,提出了以状态路径或状态网络图表达产品装配生产过程的方法,并由此建立产品状态之间的转化路径,以此为依据,可以实现产品个性化的生产活动往后推迟,同时可以实现在制品的在线动态调整。
(3)构建了基于产品控制和在制品动态调整的混流装配生产计划与调度体系结构,给出了生产监控的数学模型,提出了多个控制向量,实现了从生产计划的产品队列到在制品的状态跟踪和分析,以及对产品的调整等生产过程的动态描述。
(4)将产品装配工艺与产品物料清单结合形成装配工位物料需求,按照装配线物料供给特点,既可以得到按生产节拍的投料计划,也可以依据单元物料消耗和产品生产序列推导出不同时间段的物料需求。给出的物料需求的计算公式,可以获得不同时间精度的投料计划。
(5)在混合流水加工车间,生产调度目标是生产时间最小化与机器负荷平衡,为此建立了控制负荷差别的数学模型,以最小化的makespan为目标,运用免疫算法求解,可以加快算法的迭代速度,提高效率。对于加工和装配两阶段生产调度,利用分治方法将问题分解得到多个子问题并形成对应的Agent,然后采用合作博弈理论,进行多Agent之间的合作博弈,实现优化过程。
(6)为处理生产过程中的突发事件,设计了漏斗模型动态调度方法。以调度窗口里的生产任务为漏斗库存,以事件为驱动再调度的策略,按照策略选择任务进入调度窗口,保持任务总量与生产系统平衡;根据各种事件特点进行规则判断,选择重新调度与否。本方法采用较少的再调度次数保证生产的目标要求,即保持了生产过程平稳有序进行,又提高了生产的效率。
以江铃汽车集团全顺汽车厂的生产实际为背景,结合本论文所提出的理论,开发了具有实用价值的混合流水生产计划和调度系统。
With the onset of the information age of 21 century, the production methods of enterprises have been making some big changes because of the competitiveness of global market caused by economy globalization, integration, market and information directing. The production planning and scheduling become more and more important by using modern advanced technologies and methods. To optimize the production management, operating and resources distribution becomes the essential part to realize the lean manufacturing and increase the competitiveness of enterprises. With the improvement of production methods, the study of production planning and scheduling becomes more and more realistic and meaningful.
According to the producing flow of the cars enterprises, combined with production planning and scheduling of auto parts producing and the cars assembling, this dissertation conducts the deep research on mixed-model flow shop manufacturing, including the production plan, assembly sequencing optimal scheduling, the monitoring and controlling process and the application of products materials. The main tasks and innovations are the following:
1.It proposes the method of mixed-model flow shop production planning and assembly sequencing. According to the requirement of order and the production capacity of enterprise, it makes the production planning and working shifts. In order to guarantee the production sequence to satisfy the load balancing and the material supply leveling, it designs the weighted sum model with multiple objects optimization, by adopting optimal immune algorithm, to design a kind of new methods to show the density of immune body will get optimal results with the constringent fast speed. The results show that it can meet the need of delivery date and get the minimum stock by arranging the production scheduling in sequence.
2.It put forwards the method of status route and status network chart to show the assembling process according to the characteristics of the mixed-model flow shop manufacturing, so as to build a changeable route among products status and realize the delay of customized production activity, and meanwhile, to realize the dynamic adjustment on line of work in process.
3.It constructs a framework of mix-model assembly planning and scheduling system based on product controlling and dynamic adjustments of work in process, provides the mathematics model of production monitoring, put forwards the multi-controlling vectors and realizes the dynamic description from products alignments to status tracking and analysis of work in process, and the products adjustments as well.
4.Combining the production assembling process with the bill of materials to form the material requirement of assembling procedure. According to the features of the assembling line material supply, it not only can get material consumption planning according to the tact time, but also deduce material requirement in different times based on the unit material consumption and production sequence. It can gain material consumption planning with different time and precision by mathematic formula of material requirement.
5.During the hybrid flow shop, the scheduling goal is the minimum production time and the load balancing in machines, so as to establish mathematical model to control the load differences. Taking minimum makespan as the goal, it may speed up the algorithm iterative speed and get more efficiency by using the immunity algorithm. As to the production scheduling of processing and assembling, it forms the respective agent by dispatching the problems into many sub-problems, then using cooperation game theory to get it solved among those many agents to optimize the process.
6.To deal with the unexpected events, it designs the funnel model dynamic scheduling method. With the scheduling of production task as the funnel stock, using the strategic of event-driven rescheduling, according to the strategic task, it selects the optional tasks into the window of scheduling and keeps the balance of production output and production system; according to the characteristics of the events, it judges and selects rescheduling. It can not only guarantee the orderly production process, but also increase the production efficiency by using minimum rescheduling times to achieve the production target。
With the production process of Quan Shun Automobile Factory in Jiang Lin Automobile Group as the background, combined with the theory put forward in this dissertation, it opens up a valuable production planning and scheduling system of mixed-model flow shop manufacturing.
本文根据汽车生产企业的生产流程,对混合流水型生产方式的生产计划、投产序列优化调度、生产过程的监测和控制、生产中的物料需求几方面的应用,结合汽车部件生产和整车装配生产计划与调度过程进行了深入的研究。主要工作内容及创新点如下:
(1)提出了混流装配生产计划与生产排程制定方法。以订单需求与企业生产能力为依据制定生产计划和工作班次。为保证产品生产序列满足负荷平衡和物料消耗平准化,设计了加权决策的多目标模型,采用免疫优化算法,设计了一种新的抗体浓度表示方法,能够以很快的收敛速度获得优化结果。计算结果表明,按照该序列进行生产日程安排,可以满足交货日期要求,并能使库存最小化。
(2)根据混流生产产品的特点,提出了以状态路径或状态网络图表达产品装配生产过程的方法,并由此建立产品状态之间的转化路径,以此为依据,可以实现产品个性化的生产活动往后推迟,同时可以实现在制品的在线动态调整。
(3)构建了基于产品控制和在制品动态调整的混流装配生产计划与调度体系结构,给出了生产监控的数学模型,提出了多个控制向量,实现了从生产计划的产品队列到在制品的状态跟踪和分析,以及对产品的调整等生产过程的动态描述。
(4)将产品装配工艺与产品物料清单结合形成装配工位物料需求,按照装配线物料供给特点,既可以得到按生产节拍的投料计划,也可以依据单元物料消耗和产品生产序列推导出不同时间段的物料需求。给出的物料需求的计算公式,可以获得不同时间精度的投料计划。
(5)在混合流水加工车间,生产调度目标是生产时间最小化与机器负荷平衡,为此建立了控制负荷差别的数学模型,以最小化的makespan为目标,运用免疫算法求解,可以加快算法的迭代速度,提高效率。对于加工和装配两阶段生产调度,利用分治方法将问题分解得到多个子问题并形成对应的Agent,然后采用合作博弈理论,进行多Agent之间的合作博弈,实现优化过程。
(6)为处理生产过程中的突发事件,设计了漏斗模型动态调度方法。以调度窗口里的生产任务为漏斗库存,以事件为驱动再调度的策略,按照策略选择任务进入调度窗口,保持任务总量与生产系统平衡;根据各种事件特点进行规则判断,选择重新调度与否。本方法采用较少的再调度次数保证生产的目标要求,即保持了生产过程平稳有序进行,又提高了生产的效率。
以江铃汽车集团全顺汽车厂的生产实际为背景,结合本论文所提出的理论,开发了具有实用价值的混合流水生产计划和调度系统。
With the onset of the information age of 21 century, the production methods of enterprises have been making some big changes because of the competitiveness of global market caused by economy globalization, integration, market and information directing. The production planning and scheduling become more and more important by using modern advanced technologies and methods. To optimize the production management, operating and resources distribution becomes the essential part to realize the lean manufacturing and increase the competitiveness of enterprises. With the improvement of production methods, the study of production planning and scheduling becomes more and more realistic and meaningful.
According to the producing flow of the cars enterprises, combined with production planning and scheduling of auto parts producing and the cars assembling, this dissertation conducts the deep research on mixed-model flow shop manufacturing, including the production plan, assembly sequencing optimal scheduling, the monitoring and controlling process and the application of products materials. The main tasks and innovations are the following:
1.It proposes the method of mixed-model flow shop production planning and assembly sequencing. According to the requirement of order and the production capacity of enterprise, it makes the production planning and working shifts. In order to guarantee the production sequence to satisfy the load balancing and the material supply leveling, it designs the weighted sum model with multiple objects optimization, by adopting optimal immune algorithm, to design a kind of new methods to show the density of immune body will get optimal results with the constringent fast speed. The results show that it can meet the need of delivery date and get the minimum stock by arranging the production scheduling in sequence.
2.It put forwards the method of status route and status network chart to show the assembling process according to the characteristics of the mixed-model flow shop manufacturing, so as to build a changeable route among products status and realize the delay of customized production activity, and meanwhile, to realize the dynamic adjustment on line of work in process.
3.It constructs a framework of mix-model assembly planning and scheduling system based on product controlling and dynamic adjustments of work in process, provides the mathematics model of production monitoring, put forwards the multi-controlling vectors and realizes the dynamic description from products alignments to status tracking and analysis of work in process, and the products adjustments as well.
4.Combining the production assembling process with the bill of materials to form the material requirement of assembling procedure. According to the features of the assembling line material supply, it not only can get material consumption planning according to the tact time, but also deduce material requirement in different times based on the unit material consumption and production sequence. It can gain material consumption planning with different time and precision by mathematic formula of material requirement.
5.During the hybrid flow shop, the scheduling goal is the minimum production time and the load balancing in machines, so as to establish mathematical model to control the load differences. Taking minimum makespan as the goal, it may speed up the algorithm iterative speed and get more efficiency by using the immunity algorithm. As to the production scheduling of processing and assembling, it forms the respective agent by dispatching the problems into many sub-problems, then using cooperation game theory to get it solved among those many agents to optimize the process.
6.To deal with the unexpected events, it designs the funnel model dynamic scheduling method. With the scheduling of production task as the funnel stock, using the strategic of event-driven rescheduling, according to the strategic task, it selects the optional tasks into the window of scheduling and keeps the balance of production output and production system; according to the characteristics of the events, it judges and selects rescheduling. It can not only guarantee the orderly production process, but also increase the production efficiency by using minimum rescheduling times to achieve the production target。
With the production process of Quan Shun Automobile Factory in Jiang Lin Automobile Group as the background, combined with the theory put forward in this dissertation, it opens up a valuable production planning and scheduling system of mixed-model flow shop manufacturing.
引文
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