基于TOC和Conwip/pull的制造执行控制系统仿真与优化
|
摘要
制造系统的控制与优化是实现企业预期生产目标的关键,而其中瓶颈资源又是影响系统的负荷平衡及生产效率的主要因素。特别是在当前动态多变的市场环境下,对生产系统瓶颈设备、瓶颈工序的辨识和有效控制,是保证生产系统平稳顺畅运行、提高订单交货期满足率的重要任务。为此,本文分析了Conwip/pull控制系统在处理系统瓶颈存在的问题,提出了基于约束理论(TOC)的制造系统瓶颈资源和制造过程优化的控制方法,并在仿真研究的基础上,给出集成控制系统流通卡数量优化算法和基于改进模拟退火算法(VFSA)的瓶颈资源调度算法,为企业实施该系统提供了保障。
论文首先分析了Conwip/pull制造控制系统的特点和制造过程控制与优化问题的实际需求,提出了建立基于约束理论的Conwip/pull集成控制系统模型。在详细地分析该集成系统控制模型和运行机理的基础上,提出了基于TOC的Conwip/pull生产控制系统瓶颈工序的辨识方法。
针对Conwip/pull控制系统的仿真以及流通卡数量确定方法的研究还比较鲜见,建立了基于离散事件系统建模与仿真方法的集成控制系统及其内部各模块的仿真模型。给出了集成控制系统的流通卡数量、缓冲系数等参数最优配置的方法。
考虑到系统的仿真运行时间比较长,为了提高仿真系统的效率,采用了Ingber提出的快速模拟退火算法(VFSA)来取代传统模拟退火算法,将改进模拟退火算法嵌入到上述仿真系统中进行参数优化。
最后,在Witness仿真软件环境下,分别对Conwip系统、Conwip/pull控制系统、基于TOC的集成控制系统进行仿真研究与对比。
研究及仿真结果表明,利用TOC理论的确能够有效地解决系统的瓶颈问题,通过利用TOC理论来确立系统瓶颈的新颖方法和瓶颈工序调度机制大大地降低了订单等待时间。
Manufacturing system control and optimization is the key to achieve enterprises and their production goals, Bottleneck resources which are the main factors to affect system resources, load balancing and production efficiency. To identify and effective control bottlenecks equipment on the production system, which is the important task for ensuring a smooth production system and improving the rate of orders for delivery to meet. Therefore, this paper studied the bottlenecks problem on Conwip /pull control system, proposed a control method on manufacturing systems bottleneck resources and manufacturing process optimization based on the Theory of Constraints (TOC), on the basis of simulation studies, it is given the optimization algorithm about circulation cards number in the integrated control system and bottleneck resource scheduling algorithm based on improved simulated annealing algorithm (VFSA). It has provided an indemnification to implement the system foe enterprises.
Firstly, taking into account the problems in dealing with the system bottleneck in the Conwip / pull control system, the hybrid control system model is formulated with respect to DBR (Drum-Buffer-Rope) technique and a novel TOC based bottleneck resources discovery and scheduling mechanism is presented. After a detailed analysis of the integrated system control structure and operation mechanism, proposed Conwip / pull production control system based on TOC to identify bottlenecks processes.
Secondly, most of the literatures has merely introduced or explained the concept of the hybrid model, the system parameters optimization or other related problem have not yet been studied in-depth. It is established an integrated control system based on discrete event system modeling and simulation and its various modules of the integrated control system simulation model. The optimal parameters allocation method is given about the circulation cards number and buffering coefficient of the integrated control system.
Thirdly, taking into account the simulation system run-time is relatively long and in order to improve the efficiency of the simulation system, hence, it has adopted a fast simulated annealing algorithm (VFSA), which is proposed by Ingber to replace the traditional simulated annealing algorithm, make the improved simulated annealing algorithm embed into the simulation system, it greatly improved the efficiency of the system simulation and obtained the optimal solution.
Finally, for the purpose of verifying the validity of above methods, simulations under witness environment were done and the comparison among the Conwip, Conwip/pull and integrated control system was given. The simulation results showed that the proposed hybrid system can solve the bottleneck problem effectively and enhanced the productivity of the system and reduced the delay time greatly by the TOC based novel bottleneck resources discovery and scheduling mechanism.
论文首先分析了Conwip/pull制造控制系统的特点和制造过程控制与优化问题的实际需求,提出了建立基于约束理论的Conwip/pull集成控制系统模型。在详细地分析该集成系统控制模型和运行机理的基础上,提出了基于TOC的Conwip/pull生产控制系统瓶颈工序的辨识方法。
针对Conwip/pull控制系统的仿真以及流通卡数量确定方法的研究还比较鲜见,建立了基于离散事件系统建模与仿真方法的集成控制系统及其内部各模块的仿真模型。给出了集成控制系统的流通卡数量、缓冲系数等参数最优配置的方法。
考虑到系统的仿真运行时间比较长,为了提高仿真系统的效率,采用了Ingber提出的快速模拟退火算法(VFSA)来取代传统模拟退火算法,将改进模拟退火算法嵌入到上述仿真系统中进行参数优化。
最后,在Witness仿真软件环境下,分别对Conwip系统、Conwip/pull控制系统、基于TOC的集成控制系统进行仿真研究与对比。
研究及仿真结果表明,利用TOC理论的确能够有效地解决系统的瓶颈问题,通过利用TOC理论来确立系统瓶颈的新颖方法和瓶颈工序调度机制大大地降低了订单等待时间。
Manufacturing system control and optimization is the key to achieve enterprises and their production goals, Bottleneck resources which are the main factors to affect system resources, load balancing and production efficiency. To identify and effective control bottlenecks equipment on the production system, which is the important task for ensuring a smooth production system and improving the rate of orders for delivery to meet. Therefore, this paper studied the bottlenecks problem on Conwip /pull control system, proposed a control method on manufacturing systems bottleneck resources and manufacturing process optimization based on the Theory of Constraints (TOC), on the basis of simulation studies, it is given the optimization algorithm about circulation cards number in the integrated control system and bottleneck resource scheduling algorithm based on improved simulated annealing algorithm (VFSA). It has provided an indemnification to implement the system foe enterprises.
Firstly, taking into account the problems in dealing with the system bottleneck in the Conwip / pull control system, the hybrid control system model is formulated with respect to DBR (Drum-Buffer-Rope) technique and a novel TOC based bottleneck resources discovery and scheduling mechanism is presented. After a detailed analysis of the integrated system control structure and operation mechanism, proposed Conwip / pull production control system based on TOC to identify bottlenecks processes.
Secondly, most of the literatures has merely introduced or explained the concept of the hybrid model, the system parameters optimization or other related problem have not yet been studied in-depth. It is established an integrated control system based on discrete event system modeling and simulation and its various modules of the integrated control system simulation model. The optimal parameters allocation method is given about the circulation cards number and buffering coefficient of the integrated control system.
Thirdly, taking into account the simulation system run-time is relatively long and in order to improve the efficiency of the simulation system, hence, it has adopted a fast simulated annealing algorithm (VFSA), which is proposed by Ingber to replace the traditional simulated annealing algorithm, make the improved simulated annealing algorithm embed into the simulation system, it greatly improved the efficiency of the system simulation and obtained the optimal solution.
Finally, for the purpose of verifying the validity of above methods, simulations under witness environment were done and the comparison among the Conwip, Conwip/pull and integrated control system was given. The simulation results showed that the proposed hybrid system can solve the bottleneck problem effectively and enhanced the productivity of the system and reduced the delay time greatly by the TOC based novel bottleneck resources discovery and scheduling mechanism.
引文
[1]林勇,乐晓娟,付秋芳.Push/pull和CONWIP/PULL生产控制模式对比分析.工业工程,2006,9(2):1-5.
[2]汪定伟.MRP Ⅱ与JIT结合的生产管理方法.北京:科学出版社,1996,11-47.
[3]Wallace J H,Mark L S.Factory Physics:Foundation of Management.Second Edition.北京:清华大学出版社,2002:339-362.
[4]Hodgson T J,Wang D.Optimal hybrid push/pull strategies for a parallel multi-stage system.lnternation Journal of Production Research,1991,29(6):1279-1287.
[5]Pandey P C,Prontep Khokhajaikiat.Performance modeling of multistage production systems operating under hybrid push/pull control.International Journal of Production Economics,1996,43(1):17-28.
[6]Spearman M L,Woodruff D L,Hopp W J.CONWIP:A pull alternative to Kanban.International Journal of Production Research,1990,28(5):879-894.
[7]黄敏,汪定伟,王兴伟.CONWIP生产控制方法.控制与决策,1999,14(3):193-198.
[8]Bonvik AM,Couch C E,Gershwin S B.A comparison of production line control mechanism.International Journal of Production Research,1997,35(3):789-804.
[9]GOLDRATT E M.Computerized shop floor scheduling.International Journal of Production Research,1988,26(3):443-455.
[10]Rui Zhang,Cheng Wu.Bottleneck identification procedures for the job shop scheduling problem with application to genetic algorithms,Int J Adv Manuf Technol,2008,10(7):2-18.
[11]BALDERSTONE S J,MABIN J.A review of Goldratt's theory of constraints(TOC)-lessons from the international literature.Proceedings of 3 3~(rd) Annual Conference of the operational Research Society of New Zealand.New Zealand,1998:156-791.
[12]WU S,MORRIS J,GORRONT A.Sinmulation analysis of the effectiveness of drum-buffer-rope scheduling in furniture manufacturing.Computer&Industry Engineering,1994,26(4):757-764.
[13]王军强,孙树栋,王东成等.基于约束理论的制造单元管理与控制研究.计算机集成制造系统,2006,12(7):1108-1116.
[14]曹振新,张士杰.基于约束理论的制造单元瓶颈分析及对策.机械设计与制造,2004,4(3):109-111.
[15]郭永辉,钱省三.基于DBR理论的半导体品圆厂生产作业控制.工业工程与管理,2006,5(6):70-75.
[16]李黎,成晔,袁守华.基于瓶颈分析的优先权调度算法研究.计算机集成制造系统,2005,11(2):247-250.
[17]綦振法,王世德.MRP Ⅱ、JIT与TOC的集成模式研究.华东经济管理,2002,16(6):72-74.
[18]谌承正.运用系统仿真与基因算法执行限制理论于流线型:(博士学位论文).台北:国立台北科技大学,2001.
[19]谢忠志.DBR现场排程及管理决策支持系统之建构-运用基因算法及模糊理论:(博士学位论文).台北:国立台北科技大学,2001.
[20]田志章,龚哲君.流水型CONWIP生产控制系统研究:(硕士学位论文).武汉:武汉理工大学,2007.
[21]李士清.精益生产方式的机理与拉式系统建模研究:(博士学位论文).北京:北京航天航空大学,1995:32-35.
[22]Hopp W J,Roof M L.Setting WIP level with statistical throughput control(STC) in CONWIP production line.International Journal of Production Rearch,2001,36(4):867-882.
[23]John Geraghty,Cathal Heavey.A review and comparison of hybrid and pull-type production control strategies.International Journal of Production Rearch,2005,27(3):435-457.
[24]E.G.A.GAURY,H.PIERREVAL,J.P.C.KLEIJNEN.An evolutionary approach to select a pull system among Kanban,Conwip and Hybrid.Journal of Intelligent Manufacturing,2000,11(4):157-167.
[25]王静,刘明周.基于瓶颈分析的离散制造系统在制品库存控制研究:(硕士学位论文).合肥:合肥工业大学,2008.
[26]夏锐,吴伟,贺敏伟.基于TOC理论的瓶颈分析及作业调度方案的探讨.化工自动化及仪表,2006,33(4):21-24.
[27]徐学军.以瓶颈资源为基础的生产与库存控制系统的构建.制造业自动化,2001,23(1):21-24.
[28]王军强,孙树栋,余建军等.基于约束理论和免疫算法的产品组合优化研究.计算机集成制造系统,2006,12(12):2017-2046.
[29]余华,杨素英.基于TOC与计算智能的生产调度问题研究:(硕士学位论文).大连:大连理工大学,2005.
[30]戴建设,王书宁.约束理论:原理技术和应用.计算技术与自动化,1994,13(2):60-65.
[31]刘敏,鲁建厦.基于ERP和TOC的生产物流管理模式及其关键技术研究:(硕士学位论文).杭州:浙江工业大学,2004.
[32]潘爱香.试论约束理论及其现实运用.北京工商大学(社会科学版),2004,19(3):40-42.
[33]杨宏安,孙树栋,吴秀丽等.基于约束满足的Job-Shop调度算法研究.计算机工程与应用,2003,3(1):36-55.
[34]王红娟,刘东曜,明新国.基于约束理论的混合流水线车间生产调度及其应用:(硕士学位论文).上海:上海理工大学,2008.
[35]Seung Hyun Rhee,Nam Wook Cho,Hyerim Bae.Increasing the sfficiency of business process using a theory of constraints.Inf Syst Front,2008:78-96.
[36]叶涛锋,韩文民.“按订单”生产方式下瓶颈资源的确定.工业工程与管理,2003,8(6):51-54.
[37]张乔龄.TOC式扣件生产系统之仿真实例研究:(博士学位论文).台南:国立成功大学,2004.
[38]陈建宇.限制理论在印刷电路板排程之应用:(硕士学位论文).中坜:元智大学,1998.
[39]BECHTE W.Theory and practice of load-oriented manufacturing control.International Journal of Production Research,1988,26(3):375-395.
[40]MAShihua,CHEN Rongqiu,LI Zhicheng.The integrated planning and control system based on MRP and OPT.China Mechanical Engineering,1995,6(6):11-13.
[41]RONEN B,STAIR M K.Synchronized manufacturing as in OPT:from practice to theory.Computers Industrial Engineering,1990,18(4):585-600.
[42]YE Taofeng,HAN Wenmin.A method on determining bottleneck in make-to-order production.Industrial Engineering and Management,2003,8(6):51-54.
[43]王凤渊,杨云,李必强.对企业生产缓冲的分析与评价.中国管理科学,1998,6(1):32-39.
[44]徐学军,张红,叶广宇.生产进度的同步化方法研究.工业工程与管理,2001,2(4):38-41.
[45]吴鸿辉,李荣贵.限制驱导式现场排程与管理技术修订版:(硕士学位论文).台北:全华科技图书股份有限公司,2001.
[46]Eli Schragenheim,Boax Ronen.Drum-buffer-rope shop floor control.Production and Management Journal,1990,5(3):18-22.
[47]V.D.R.Guide.Scheduling using drum-buffer-rope in a remanufacturing environment.International Journal of Production Research,1996,34(4):1081-1091.
[48]Seung Hyun,Rhee Nam Wook Cho,Hyerim Bae.Increasing the efficiency of business process using a theory of constraints.Inf Syst Front,2008:79-96.
[49]北京威特尼斯科技中心.物流与供应链仿真系统WITNESS操作指南及案例,2006.
[50]李士清.精益生产方式的机理与拉式系统建模研究:(博士学位论文).北京:北京航天航空大学,1995:32-35.
[51]TANG ChunMing,PEI DingYi,Wang XiaoFeng.Delegateable signatures based on noninteractive witness indistinguishable and noninteractive witness hiding proofs.Science in China Series F:Information Science,2008,51(2):128-144.
[52]杨棖,王志斌.基于Witness仿真的分组装配拉动生产系统研究:(硕士学位论文).上海:上海交通大学,2007.
[53]鄢长文,冯刚.基于Witness的汽车销售物流配送中心规划与仿真:(硕士学位论文).大连:大连理工大学,2008.
[54]王建青,邵延君.基于WITNESS的制造系统优化.机械制造与研究,2008,37(4):36-45.
[55]Ingber L.Very fast simulated annealing,Math compute Modeling,1989,12:967-973
[56]王亚超,马汉武.生产物流系统建模与仿真-Witness系统及应用.北京:科学出版社,2006:241-247.
[2]汪定伟.MRP Ⅱ与JIT结合的生产管理方法.北京:科学出版社,1996,11-47.
[3]Wallace J H,Mark L S.Factory Physics:Foundation of Management.Second Edition.北京:清华大学出版社,2002:339-362.
[4]Hodgson T J,Wang D.Optimal hybrid push/pull strategies for a parallel multi-stage system.lnternation Journal of Production Research,1991,29(6):1279-1287.
[5]Pandey P C,Prontep Khokhajaikiat.Performance modeling of multistage production systems operating under hybrid push/pull control.International Journal of Production Economics,1996,43(1):17-28.
[6]Spearman M L,Woodruff D L,Hopp W J.CONWIP:A pull alternative to Kanban.International Journal of Production Research,1990,28(5):879-894.
[7]黄敏,汪定伟,王兴伟.CONWIP生产控制方法.控制与决策,1999,14(3):193-198.
[8]Bonvik AM,Couch C E,Gershwin S B.A comparison of production line control mechanism.International Journal of Production Research,1997,35(3):789-804.
[9]GOLDRATT E M.Computerized shop floor scheduling.International Journal of Production Research,1988,26(3):443-455.
[10]Rui Zhang,Cheng Wu.Bottleneck identification procedures for the job shop scheduling problem with application to genetic algorithms,Int J Adv Manuf Technol,2008,10(7):2-18.
[11]BALDERSTONE S J,MABIN J.A review of Goldratt's theory of constraints(TOC)-lessons from the international literature.Proceedings of 3 3~(rd) Annual Conference of the operational Research Society of New Zealand.New Zealand,1998:156-791.
[12]WU S,MORRIS J,GORRONT A.Sinmulation analysis of the effectiveness of drum-buffer-rope scheduling in furniture manufacturing.Computer&Industry Engineering,1994,26(4):757-764.
[13]王军强,孙树栋,王东成等.基于约束理论的制造单元管理与控制研究.计算机集成制造系统,2006,12(7):1108-1116.
[14]曹振新,张士杰.基于约束理论的制造单元瓶颈分析及对策.机械设计与制造,2004,4(3):109-111.
[15]郭永辉,钱省三.基于DBR理论的半导体品圆厂生产作业控制.工业工程与管理,2006,5(6):70-75.
[16]李黎,成晔,袁守华.基于瓶颈分析的优先权调度算法研究.计算机集成制造系统,2005,11(2):247-250.
[17]綦振法,王世德.MRP Ⅱ、JIT与TOC的集成模式研究.华东经济管理,2002,16(6):72-74.
[18]谌承正.运用系统仿真与基因算法执行限制理论于流线型:(博士学位论文).台北:国立台北科技大学,2001.
[19]谢忠志.DBR现场排程及管理决策支持系统之建构-运用基因算法及模糊理论:(博士学位论文).台北:国立台北科技大学,2001.
[20]田志章,龚哲君.流水型CONWIP生产控制系统研究:(硕士学位论文).武汉:武汉理工大学,2007.
[21]李士清.精益生产方式的机理与拉式系统建模研究:(博士学位论文).北京:北京航天航空大学,1995:32-35.
[22]Hopp W J,Roof M L.Setting WIP level with statistical throughput control(STC) in CONWIP production line.International Journal of Production Rearch,2001,36(4):867-882.
[23]John Geraghty,Cathal Heavey.A review and comparison of hybrid and pull-type production control strategies.International Journal of Production Rearch,2005,27(3):435-457.
[24]E.G.A.GAURY,H.PIERREVAL,J.P.C.KLEIJNEN.An evolutionary approach to select a pull system among Kanban,Conwip and Hybrid.Journal of Intelligent Manufacturing,2000,11(4):157-167.
[25]王静,刘明周.基于瓶颈分析的离散制造系统在制品库存控制研究:(硕士学位论文).合肥:合肥工业大学,2008.
[26]夏锐,吴伟,贺敏伟.基于TOC理论的瓶颈分析及作业调度方案的探讨.化工自动化及仪表,2006,33(4):21-24.
[27]徐学军.以瓶颈资源为基础的生产与库存控制系统的构建.制造业自动化,2001,23(1):21-24.
[28]王军强,孙树栋,余建军等.基于约束理论和免疫算法的产品组合优化研究.计算机集成制造系统,2006,12(12):2017-2046.
[29]余华,杨素英.基于TOC与计算智能的生产调度问题研究:(硕士学位论文).大连:大连理工大学,2005.
[30]戴建设,王书宁.约束理论:原理技术和应用.计算技术与自动化,1994,13(2):60-65.
[31]刘敏,鲁建厦.基于ERP和TOC的生产物流管理模式及其关键技术研究:(硕士学位论文).杭州:浙江工业大学,2004.
[32]潘爱香.试论约束理论及其现实运用.北京工商大学(社会科学版),2004,19(3):40-42.
[33]杨宏安,孙树栋,吴秀丽等.基于约束满足的Job-Shop调度算法研究.计算机工程与应用,2003,3(1):36-55.
[34]王红娟,刘东曜,明新国.基于约束理论的混合流水线车间生产调度及其应用:(硕士学位论文).上海:上海理工大学,2008.
[35]Seung Hyun Rhee,Nam Wook Cho,Hyerim Bae.Increasing the sfficiency of business process using a theory of constraints.Inf Syst Front,2008:78-96.
[36]叶涛锋,韩文民.“按订单”生产方式下瓶颈资源的确定.工业工程与管理,2003,8(6):51-54.
[37]张乔龄.TOC式扣件生产系统之仿真实例研究:(博士学位论文).台南:国立成功大学,2004.
[38]陈建宇.限制理论在印刷电路板排程之应用:(硕士学位论文).中坜:元智大学,1998.
[39]BECHTE W.Theory and practice of load-oriented manufacturing control.International Journal of Production Research,1988,26(3):375-395.
[40]MAShihua,CHEN Rongqiu,LI Zhicheng.The integrated planning and control system based on MRP and OPT.China Mechanical Engineering,1995,6(6):11-13.
[41]RONEN B,STAIR M K.Synchronized manufacturing as in OPT:from practice to theory.Computers Industrial Engineering,1990,18(4):585-600.
[42]YE Taofeng,HAN Wenmin.A method on determining bottleneck in make-to-order production.Industrial Engineering and Management,2003,8(6):51-54.
[43]王凤渊,杨云,李必强.对企业生产缓冲的分析与评价.中国管理科学,1998,6(1):32-39.
[44]徐学军,张红,叶广宇.生产进度的同步化方法研究.工业工程与管理,2001,2(4):38-41.
[45]吴鸿辉,李荣贵.限制驱导式现场排程与管理技术修订版:(硕士学位论文).台北:全华科技图书股份有限公司,2001.
[46]Eli Schragenheim,Boax Ronen.Drum-buffer-rope shop floor control.Production and Management Journal,1990,5(3):18-22.
[47]V.D.R.Guide.Scheduling using drum-buffer-rope in a remanufacturing environment.International Journal of Production Research,1996,34(4):1081-1091.
[48]Seung Hyun,Rhee Nam Wook Cho,Hyerim Bae.Increasing the efficiency of business process using a theory of constraints.Inf Syst Front,2008:79-96.
[49]北京威特尼斯科技中心.物流与供应链仿真系统WITNESS操作指南及案例,2006.
[50]李士清.精益生产方式的机理与拉式系统建模研究:(博士学位论文).北京:北京航天航空大学,1995:32-35.
[51]TANG ChunMing,PEI DingYi,Wang XiaoFeng.Delegateable signatures based on noninteractive witness indistinguishable and noninteractive witness hiding proofs.Science in China Series F:Information Science,2008,51(2):128-144.
[52]杨棖,王志斌.基于Witness仿真的分组装配拉动生产系统研究:(硕士学位论文).上海:上海交通大学,2007.
[53]鄢长文,冯刚.基于Witness的汽车销售物流配送中心规划与仿真:(硕士学位论文).大连:大连理工大学,2008.
[54]王建青,邵延君.基于WITNESS的制造系统优化.机械制造与研究,2008,37(4):36-45.
[55]Ingber L.Very fast simulated annealing,Math compute Modeling,1989,12:967-973
[56]王亚超,马汉武.生产物流系统建模与仿真-Witness系统及应用.北京:科学出版社,2006:241-247.