面向离散制造系统的管理过程设计研究
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摘要
面对激烈的市场竞争,敏捷制造提出企业需具备快速反应、重组资源、组织生产以最大可能满足客户“个性化产品”需求的制造战略。基于敏捷制造战略,本文提出敏捷制造体系的核心问题是如何进行产品设计和制造过程设计。接下来,本文提出管理过程设计的概念,完善了制造过程设计的内容体系。
在对国内外文献深入研究的基础上,本文分析了生产系统变动因素的多级分类。通过回顾各种管理过程设计方法,指出其应用上的局限性及建立制造过程数学模型的必要性。通过比较分析离散事件动态系统的多种建模方法:排队网络法、极大代数法和Petri网法,最终确定采用Petri网法建立制造过程的数学模型。本文详细分析了基于丰田生产方式的管理过程设计内容体系。
本文分别实现了刚性串联制造过程、推动式柔性串联制造过程、拉动式柔性串联制造过程的Petri网建模,推导了各模型的关联矩阵、三阶段状态方程和可达标识图,并对各模型进行了行为特性分析。本文实现了串并联和并串联制造过程的Petri网建模和相应的特性分析。
考虑到制造过程中事件的发生和状态的延续都与时间有关,本文分别建立了刚性串联制造过程、推动式柔性串联制造过程和拉动式柔性串联制造过程的TTPN模型,并针对各模型讨论了生产周期、生产率、生产提前期和设备利用率等动态性能参数。本文讨论了推动式柔性串联制造过程的在制品数量与作业时间的关系,提出一种通过调整作业时间实现在制品数量控制的方法。本文实现了复杂制造过程的SPN模型的化简和等价性能参数的计算,并研究了制造过程SPN模型化简方法在装配线布置问题上的应用。通过实例仿真分析验证了所提出方法的有效性。
本文将准时化生产(JIT)与制造执行系统(MES)作以比较分析,提出两者虽然实施方法各异,但实质相同的观点。在此基础上,本文提出广义制造执行系统的概念。最后,总结全文并展望了进一步的研究工作。
In face of the keen market competition, the agile manufacturing strategy is proposed that the agile manufacturing enterprises should have the capability of quick reaction, reconfigurating resources and organizing production to meet customers’individual needs. On the basis of this strategy, the core problem of the agile manufacturing system is brought forward that is how to make product design and manufacturing process design. Then, the concept of management process design is proposed, which perfects the manufacturing process design system.
Based on intensive study of literature home and abroad, the multi-hierarchy classification of production system change factors is analyzed. All kinds of methods of manufacturing process design are reviewed. Since the methods have limitations on manufacturing process design, it is necessary to build mathmatical model of manufacturing process. Many kinds of modeling methods of DEDS are analyzed, including Queuing Network, Maximal Algebra and Petri nets. In the end, it is determined to model the manufacturing process by Petri nets. Then, the management process design system based on Toyota Production System is analyzed detailedly.
Many kinds of manufacturing process’PN models are built, including inflexible manufacturing process in series, push-type flexible manufacturing process in series and pull-type flexible manufacturing process in series. Furthermore, all kinds of models’Incidence Matrix, three-phase State Equations and Reachable Mark Chart are deduced and Behavioral Performances of the models are analyzed. And Then, series-parallel manufacturing process and parallel-series manufacturing process’PN models are built and Behavioral Performances of the two models are analyzed.
In view of the events’occurrence and states’continuous in manufacturing process having relation with time, three kinds of manufacturing process’TTPN models are built, which are inflexible manufacturing process in series, push-type flexible manufacturing process in series and pull-type flexible manufacturing process in series. All models’dynamic parameters are discussed, including production period, productivity, lead time, equipment operating factor and so on. The relation between work-in-process quantity and operation time of push-type flexible manufacturing process in series is discussed, and a method is proposed which could control work-in-process quantity by adjusting the operation time.
Reducing complicated manufacturing process SPN model and computering the equivalent performance parameters are realized. Then, how to apply the reduction methods of the manufacturing process’SPN models for assembly lines layout problem is discussed. Demonstration and simulation study are used to estimate available of new methods.
This paper compares TPS and MES,and brings forward both of them have the same essence and different methods, which provides a base to expand MES into General Manufacturing Execution System(GMES). In the end, a summary is made and some further researches are pointed out.
在对国内外文献深入研究的基础上,本文分析了生产系统变动因素的多级分类。通过回顾各种管理过程设计方法,指出其应用上的局限性及建立制造过程数学模型的必要性。通过比较分析离散事件动态系统的多种建模方法:排队网络法、极大代数法和Petri网法,最终确定采用Petri网法建立制造过程的数学模型。本文详细分析了基于丰田生产方式的管理过程设计内容体系。
本文分别实现了刚性串联制造过程、推动式柔性串联制造过程、拉动式柔性串联制造过程的Petri网建模,推导了各模型的关联矩阵、三阶段状态方程和可达标识图,并对各模型进行了行为特性分析。本文实现了串并联和并串联制造过程的Petri网建模和相应的特性分析。
考虑到制造过程中事件的发生和状态的延续都与时间有关,本文分别建立了刚性串联制造过程、推动式柔性串联制造过程和拉动式柔性串联制造过程的TTPN模型,并针对各模型讨论了生产周期、生产率、生产提前期和设备利用率等动态性能参数。本文讨论了推动式柔性串联制造过程的在制品数量与作业时间的关系,提出一种通过调整作业时间实现在制品数量控制的方法。本文实现了复杂制造过程的SPN模型的化简和等价性能参数的计算,并研究了制造过程SPN模型化简方法在装配线布置问题上的应用。通过实例仿真分析验证了所提出方法的有效性。
本文将准时化生产(JIT)与制造执行系统(MES)作以比较分析,提出两者虽然实施方法各异,但实质相同的观点。在此基础上,本文提出广义制造执行系统的概念。最后,总结全文并展望了进一步的研究工作。
In face of the keen market competition, the agile manufacturing strategy is proposed that the agile manufacturing enterprises should have the capability of quick reaction, reconfigurating resources and organizing production to meet customers’individual needs. On the basis of this strategy, the core problem of the agile manufacturing system is brought forward that is how to make product design and manufacturing process design. Then, the concept of management process design is proposed, which perfects the manufacturing process design system.
Based on intensive study of literature home and abroad, the multi-hierarchy classification of production system change factors is analyzed. All kinds of methods of manufacturing process design are reviewed. Since the methods have limitations on manufacturing process design, it is necessary to build mathmatical model of manufacturing process. Many kinds of modeling methods of DEDS are analyzed, including Queuing Network, Maximal Algebra and Petri nets. In the end, it is determined to model the manufacturing process by Petri nets. Then, the management process design system based on Toyota Production System is analyzed detailedly.
Many kinds of manufacturing process’PN models are built, including inflexible manufacturing process in series, push-type flexible manufacturing process in series and pull-type flexible manufacturing process in series. Furthermore, all kinds of models’Incidence Matrix, three-phase State Equations and Reachable Mark Chart are deduced and Behavioral Performances of the models are analyzed. And Then, series-parallel manufacturing process and parallel-series manufacturing process’PN models are built and Behavioral Performances of the two models are analyzed.
In view of the events’occurrence and states’continuous in manufacturing process having relation with time, three kinds of manufacturing process’TTPN models are built, which are inflexible manufacturing process in series, push-type flexible manufacturing process in series and pull-type flexible manufacturing process in series. All models’dynamic parameters are discussed, including production period, productivity, lead time, equipment operating factor and so on. The relation between work-in-process quantity and operation time of push-type flexible manufacturing process in series is discussed, and a method is proposed which could control work-in-process quantity by adjusting the operation time.
Reducing complicated manufacturing process SPN model and computering the equivalent performance parameters are realized. Then, how to apply the reduction methods of the manufacturing process’SPN models for assembly lines layout problem is discussed. Demonstration and simulation study are used to estimate available of new methods.
This paper compares TPS and MES,and brings forward both of them have the same essence and different methods, which provides a base to expand MES into General Manufacturing Execution System(GMES). In the end, a summary is made and some further researches are pointed out.
引文
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