混合装配线过程平衡研究及仿真分析
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摘要
随着设备、工装夹具的柔性化,基于多品种、小批量的混流装配生产组织已成为可能,并逐渐推行到汽车、电子制造、食品加工等行业中。与单一品种装配线平衡问题相比,影响多品种混装生产线平衡的因素更多,这使得多品种混合装配线平衡问题求解难度加大,而且建立面向不确定条件下的混合装配过程平衡模型难度更大。
本文首先阐述了多品种产品混流装配线的研究意义,分析了装配线平衡问题国内外研究现状,就装配线平衡这一工程问题进行了数学描述。
在此基础上,本文分析了混合装配生产过程平衡影响因素,给出了混合装配生产过程平衡框架;并依据所给框架体系,分别给出了确定条件下的混装平衡建模和不确定条件下的混装平衡建模方法;同时考虑到混流装配线上,产品的不同投产序列可能带来的装配线平衡率差异,建立了旨在负荷均衡的混合生产操作分配数学模型,以及旨在最小化平均闲置时间的多种产品投产排序模型。
同时,针对封闭工作站,利用混装生产过程平衡模型的求解结果,结合工人熟练程度、工作疲劳变化等不确定性因素的影响,基于Flexsim软件进行建模及仿真分析,进行动态平衡调整,以得到新的平衡。仿真结果表明本文所建立的混合装配过程平衡框架体系、操作分配模型、投产序列模型的正确性与有效性。
研究结果表明数学建模和仿真技术相结合的方法,既能求解出近优甚至最优解,又能通过仿真技术模拟生产组织,预演生产过程中不确定影响,以协助得到不确定条件下的最优解,为解决多品种产品在混装生产过程中的平衡问题提供理论指导。
With the flexibility of the equipment and fixture, it’s possible for the mixed assembly production organizations based on multi-variety and small batch. And it’s gradually used to the automotive, electronics manufacturing, food processing and other industries. Compared with single product assembly line balancing problem, factors which affect multi-variety mixed production lines are more, and it makes more difficult to solve multi-variety mixed assembly line balancing problem. In addition, it is more difficult to establish models of mixed assembly process balancing under uncertain conditions.
First this article explains the significance of multi-variety mixed assembly line and analyses the recent status at home and abroad on the assembly line balancing problem, then describes this engineering issue in mathematical method.
This article analyses the factors that affect the mixed production process balancing, and presents the framework of it. And according to the given framework system, it presents the mixed assembly balancing modeling under certain and uncertain conditions. Besides, taking into account that different production sequences on the mixed assembly line will have different assembly line balancing rate, So not only does it establish a mathematical model with workload balance, but also gives multi-product sequencing model based on minimizing the average idle time.
Meanwhile, for the closed workstation, on the basis of the result from the mixed assembly production process balancing model, we consider the factors like the proficiency level of workers and working fatigue changes. In order to get a new balance, we build model and simulate based on Flexsim software and makes dynamic balancing adjustments. The simulation result shows the correction and effectiveness of the mixed assembly production balancing framework system, task allocation model and sequencing model.
The results demonstrate that the combination of mathematical modeling and simulation technology, not only get nearly optimal solution, but also can imitate the production organizations by simulation technology, preview the uncertain effects of the production process to get optimal solution under uncertainty. Therefore it provides theoretical guidance for solving multi-variety mixed assembly process balancing problem.
本文首先阐述了多品种产品混流装配线的研究意义,分析了装配线平衡问题国内外研究现状,就装配线平衡这一工程问题进行了数学描述。
在此基础上,本文分析了混合装配生产过程平衡影响因素,给出了混合装配生产过程平衡框架;并依据所给框架体系,分别给出了确定条件下的混装平衡建模和不确定条件下的混装平衡建模方法;同时考虑到混流装配线上,产品的不同投产序列可能带来的装配线平衡率差异,建立了旨在负荷均衡的混合生产操作分配数学模型,以及旨在最小化平均闲置时间的多种产品投产排序模型。
同时,针对封闭工作站,利用混装生产过程平衡模型的求解结果,结合工人熟练程度、工作疲劳变化等不确定性因素的影响,基于Flexsim软件进行建模及仿真分析,进行动态平衡调整,以得到新的平衡。仿真结果表明本文所建立的混合装配过程平衡框架体系、操作分配模型、投产序列模型的正确性与有效性。
研究结果表明数学建模和仿真技术相结合的方法,既能求解出近优甚至最优解,又能通过仿真技术模拟生产组织,预演生产过程中不确定影响,以协助得到不确定条件下的最优解,为解决多品种产品在混装生产过程中的平衡问题提供理论指导。
With the flexibility of the equipment and fixture, it’s possible for the mixed assembly production organizations based on multi-variety and small batch. And it’s gradually used to the automotive, electronics manufacturing, food processing and other industries. Compared with single product assembly line balancing problem, factors which affect multi-variety mixed production lines are more, and it makes more difficult to solve multi-variety mixed assembly line balancing problem. In addition, it is more difficult to establish models of mixed assembly process balancing under uncertain conditions.
First this article explains the significance of multi-variety mixed assembly line and analyses the recent status at home and abroad on the assembly line balancing problem, then describes this engineering issue in mathematical method.
This article analyses the factors that affect the mixed production process balancing, and presents the framework of it. And according to the given framework system, it presents the mixed assembly balancing modeling under certain and uncertain conditions. Besides, taking into account that different production sequences on the mixed assembly line will have different assembly line balancing rate, So not only does it establish a mathematical model with workload balance, but also gives multi-product sequencing model based on minimizing the average idle time.
Meanwhile, for the closed workstation, on the basis of the result from the mixed assembly production process balancing model, we consider the factors like the proficiency level of workers and working fatigue changes. In order to get a new balance, we build model and simulate based on Flexsim software and makes dynamic balancing adjustments. The simulation result shows the correction and effectiveness of the mixed assembly production balancing framework system, task allocation model and sequencing model.
The results demonstrate that the combination of mathematical modeling and simulation technology, not only get nearly optimal solution, but also can imitate the production organizations by simulation technology, preview the uncertain effects of the production process to get optimal solution under uncertainty. Therefore it provides theoretical guidance for solving multi-variety mixed assembly process balancing problem.
引文
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[2] Soumen CHosh,Roger J Gagnom. A Comprehensive literature review and analysis of the design.Balancing and scheduling of assembly lines[J].International Journal of Production Research,1989,27(4):637～670.
[3] MaCaskill J L C.Production-line balances for mixed-model lines[J].Management Science.1972,19:423～434.
[4] Graves S C,Lamar B W. An integer programming procedure for assembly system design problems[J].Operations Research.1983,31(3):522～545.
[5] Driscoll J, Thilakawardana.The definition of assembly line balancing difficulty and evaluation of balance solution quality[J].Robotics and Computer integrated Manufacturing.2001,17:81～86.
[6]贾大龙,韩玉启等.应用工业工程[M].第一版.北京:北京兵器工业出版社,1993:76～118
[7]王芸风,于宝证,赵韩,刘琼.混合遗传算法在生产线工艺路线排序中的应用[J].农业机械学报.2005,36(10):PP.168～170
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[10]朱传军,徐小平.东风车架装配线生产节拍研究[J].机电产品开发与创新.2007,20(5):PP.78～80
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[13]徐小强.泰勒科学管理理论在管理史上的地位及其评价[J].管理与财富.2007(1):PP.38～38
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[17] Bowman,E.H.Assembly line balancing by linear programming[J].Operations Research,1960,V01.8,385～389
[18] Roberts S D,Villa C D.On a multi product assembly line balancing problem [J].AIIE Transactions,1970,2,361-364.
[19] Marc Peeters,Zeger Degraeve.An linear Programming based lower bound for the simple assembly line balancing Problem[J].European journal of Operational Research,2004:716～73l
[20]杨本强等.汽车总成装配作业均衡编排问题的数学建模[J].电气传动自动化,2004
[21] Helgeson W.B,Birninie D.P. Assembly line balancing using the ranked positional weight techniques.Joumal of Industrial Engineering [J].196l. Voll 12:394～398.
[22] Hoffman,T.R.EUREKA. A Hybird System for Assembly Line Balancing ,Management Science[J].1992.V011(38):39～47
[23]宋华明,韩玉启,杨慧.多品种混流型装配流水线的平衡设计[J].中国机械工程,2003
[24] Thomo poluios N T.Mixed Model Line Balancing with Smoothed Station Assignments[J].Management Scinence,1970,16(9):593～603
[25] Joseph Bukchin,Ezey M.Dar-E1.Mixed modle assembly line design in a make·to-order environment[J].Computer & Industrial Engineering.2002(4 1):405-42l
[26]宋华明,韩玉启.多目标装配线平衡的优化算法[J].运筹与管理,2002,ll(3):55～62
[27]孟广耀,陈晓维,方绍欣.最大候选规则在鼓风机装配线平衡中的应用[J].青岛建筑上程学院学报,2002,23(2):52～54
[28] S.B.Liu AEH.L.Ong AEH.C.Huang.Two bi—directional heuristics for the assembly line type II problem Int Adv[J].Manuf.Techn01.2003(22):656～661
[29]皮兴忠,范秀敏,严隽琪.用基于作业序列的遗传算法求解装配线平衡问题[J].机械科学与技术,2003,22(1):35-38
[30] Sophie D.Lapierre,Angel Ruiz,Patric Soriano.Balancing assembly lines with tabu search[J].European Journal of Operational Research,2006(168):826～837
[31] Gregory Levitin,Jacob Rubinovitz,Boris Shnits.A genetic algorithm for robotic assembly line balancing[J].European Journal of Operational Research.2006(168):8ll～825
[32]郭伏,张困民.工作研究在流水线平整中的应用[J].工业工程与管理,2005(2):120～124
[33]刘广.运用流程程序分析法优化摊铺机装配流程[J].工程机械,2005
[34]鲁峥嵘,张玄.现代IE在汽车总装流水线中的应用[J].企业标准化,1999
[35]董建华等.遗传禁忌搜索算法在混流装配线排序中的应用[J].工业工程与管理.2003(2):14.17
[36]曹振新等.多目标遗传算法在混流装配线排序中的应用[J].计算机工程.2005,31
[37]宋华明等.考虑流水线平衡的混合装配线排序[J].中国机械工程.2006,17 (11):1138～1141
[38] Bard J F,Dar E,Shrub A.An analytic framework for sequencing mixed model assembly lines[J].International Journal of Production Research,1992,30(1):35～48.
[39] Yow Y L,Matheson LA.Sequencing mixed model assembly lines with genetic algorithms[J].Computers & Industry Engineering,1996,30(4):1027～1036.
[40] Chul J H,Kim Y.A genetic algorithm for multiple objective sequencing problems in mixed model assembly lines[J].Computers and Research,1998,25(7):675～690.
[41] JIN M Z,WU S D.A new heuristic method for mixed model assembly line balancing problem[J].Computers&Industrial Engineering,2003,44(1):159-169.
[42] Armin Scholl,Christian Becker.State-of-the art exact and heuristic solution procedures for simple assembly line balancing[J].European Journal of Operational Research.2006(168):669—693
[43]杜月普,杨月新.装配生产线的平衡问题研究[J].机械设计与制造,2003(2):104～106
[44]卫东等.给定序列的混合品种装配生产线平衡算法[J].机械工程学报,40(40):135.138
[45] Joaquin Bautista,Jordi Pereira.Ant algorithm for a time and space constrained assembly line balancing problem[J].European Journal of Operational Research.2007,177:2016—2032
[46]宋华明.基于遗传算法的装配线负荷平衡[J].机械设计与制造,2002(4):28-30
[47]曹振新.混流装配线负荷平衡与投产排序的优化研究[J].信息与控制,2004,33(6):660～664
[48]向玉琴,基于仿真的生产线系统优化设计及分析[D],上海交通大学硕士学位论文, 2000
[49]冯允成等离散系统仿真[M].北京:机械上业出版社,1998.1～21
[50]王红军.基于eM-Plant的FMs仿真建模技术研究[J].机械加工与自动化,2004,7,9～11
[51]邵立,严隽琪.生产线的虚拟集成设计[J].工业工程与管理,2000,6:1～4
[52]王永超.灌装线虚拟仿真建模的研究与应用[D].广东:广东工业大学,2002
[53]邵立.基于虚拟制造技术的自动线设计研究[D].上海:上海交通大学,2000
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[58]候东亮.汽车底盘总装配线平衡及人员的最佳化配置研究[D].哈尔滨:东北林业大学.2006
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[2] Soumen CHosh,Roger J Gagnom. A Comprehensive literature review and analysis of the design.Balancing and scheduling of assembly lines[J].International Journal of Production Research,1989,27(4):637～670.
[3] MaCaskill J L C.Production-line balances for mixed-model lines[J].Management Science.1972,19:423～434.
[4] Graves S C,Lamar B W. An integer programming procedure for assembly system design problems[J].Operations Research.1983,31(3):522～545.
[5] Driscoll J, Thilakawardana.The definition of assembly line balancing difficulty and evaluation of balance solution quality[J].Robotics and Computer integrated Manufacturing.2001,17:81～86.
[6]贾大龙,韩玉启等.应用工业工程[M].第一版.北京:北京兵器工业出版社,1993:76～118
[7]王芸风,于宝证,赵韩,刘琼.混合遗传算法在生产线工艺路线排序中的应用[J].农业机械学报.2005,36(10):PP.168～170
[8]李志豪,杨晓英,邓效忠.发动机装配线平衡问题的分析与改进[J].河南科技大学学报(自然科学版).2004,25(6):pp.28～31
[9]席忠民.汽车总装配线的作业时间研究[J].汽车研究与开发.1998(2):PP.45～47
[10]朱传军,徐小平.东风车架装配线生产节拍研究[J].机电产品开发与创新.2007,20(5):PP.78～80
[11]陈志祥.学习曲线及在工业生产运作研究中的应用综述[J].中国工程科学.2007,9(7):PP.82～88,94
[12] Patrick R.Mcmullen,Gregory V Frazier.Using Simulation and Data Envelopment Analysis to Compare Assembly Line Balancing Solutions[J].Journal of Productivity Analysis.1998(11):PP.149～168
[13]徐小强.泰勒科学管理理论在管理史上的地位及其评价[J].管理与财富.2007(1):PP.38～38
[14]郭玉春.春飞公司吸尘器装配线平衡研究[D].南京:南京理工人学经济管理学院,2004
[15] Klein Robert, Scholl Armin . Maximing the production rate in simple assemble line balance-A branch and bound procedure [J],European Journal of operationalResearch 1996,367～335
[16] SCHOLL A. Balancing and sequencing of assembly lines [M].2nd ed.Heidelberg:Physica-Verlag,1999.
[17] Bowman,E.H.Assembly line balancing by linear programming[J].Operations Research,1960,V01.8,385～389
[18] Roberts S D,Villa C D.On a multi product assembly line balancing problem [J].AIIE Transactions,1970,2,361-364.
[19] Marc Peeters,Zeger Degraeve.An linear Programming based lower bound for the simple assembly line balancing Problem[J].European journal of Operational Research,2004:716～73l
[20]杨本强等.汽车总成装配作业均衡编排问题的数学建模[J].电气传动自动化,2004
[21] Helgeson W.B,Birninie D.P. Assembly line balancing using the ranked positional weight techniques.Joumal of Industrial Engineering [J].196l. Voll 12:394～398.
[22] Hoffman,T.R.EUREKA. A Hybird System for Assembly Line Balancing ,Management Science[J].1992.V011(38):39～47
[23]宋华明,韩玉启,杨慧.多品种混流型装配流水线的平衡设计[J].中国机械工程,2003
[24] Thomo poluios N T.Mixed Model Line Balancing with Smoothed Station Assignments[J].Management Scinence,1970,16(9):593～603
[25] Joseph Bukchin,Ezey M.Dar-E1.Mixed modle assembly line design in a make·to-order environment[J].Computer & Industrial Engineering.2002(4 1):405-42l
[26]宋华明,韩玉启.多目标装配线平衡的优化算法[J].运筹与管理,2002,ll(3):55～62
[27]孟广耀,陈晓维,方绍欣.最大候选规则在鼓风机装配线平衡中的应用[J].青岛建筑上程学院学报,2002,23(2):52～54
[28] S.B.Liu AEH.L.Ong AEH.C.Huang.Two bi—directional heuristics for the assembly line type II problem Int Adv[J].Manuf.Techn01.2003(22):656～661
[29]皮兴忠,范秀敏,严隽琪.用基于作业序列的遗传算法求解装配线平衡问题[J].机械科学与技术,2003,22(1):35-38
[30] Sophie D.Lapierre,Angel Ruiz,Patric Soriano.Balancing assembly lines with tabu search[J].European Journal of Operational Research,2006(168):826～837
[31] Gregory Levitin,Jacob Rubinovitz,Boris Shnits.A genetic algorithm for robotic assembly line balancing[J].European Journal of Operational Research.2006(168):8ll～825
[32]郭伏,张困民.工作研究在流水线平整中的应用[J].工业工程与管理,2005(2):120～124
[33]刘广.运用流程程序分析法优化摊铺机装配流程[J].工程机械,2005
[34]鲁峥嵘,张玄.现代IE在汽车总装流水线中的应用[J].企业标准化,1999
[35]董建华等.遗传禁忌搜索算法在混流装配线排序中的应用[J].工业工程与管理.2003(2):14.17
[36]曹振新等.多目标遗传算法在混流装配线排序中的应用[J].计算机工程.2005,31
[37]宋华明等.考虑流水线平衡的混合装配线排序[J].中国机械工程.2006,17 (11):1138～1141
[38] Bard J F,Dar E,Shrub A.An analytic framework for sequencing mixed model assembly lines[J].International Journal of Production Research,1992,30(1):35～48.
[39] Yow Y L,Matheson LA.Sequencing mixed model assembly lines with genetic algorithms[J].Computers & Industry Engineering,1996,30(4):1027～1036.
[40] Chul J H,Kim Y.A genetic algorithm for multiple objective sequencing problems in mixed model assembly lines[J].Computers and Research,1998,25(7):675～690.
[41] JIN M Z,WU S D.A new heuristic method for mixed model assembly line balancing problem[J].Computers&Industrial Engineering,2003,44(1):159-169.
[42] Armin Scholl,Christian Becker.State-of-the art exact and heuristic solution procedures for simple assembly line balancing[J].European Journal of Operational Research.2006(168):669—693
[43]杜月普,杨月新.装配生产线的平衡问题研究[J].机械设计与制造,2003(2):104～106
[44]卫东等.给定序列的混合品种装配生产线平衡算法[J].机械工程学报,40(40):135.138
[45] Joaquin Bautista,Jordi Pereira.Ant algorithm for a time and space constrained assembly line balancing problem[J].European Journal of Operational Research.2007,177:2016—2032
[46]宋华明.基于遗传算法的装配线负荷平衡[J].机械设计与制造,2002(4):28-30
[47]曹振新.混流装配线负荷平衡与投产排序的优化研究[J].信息与控制,2004,33(6):660～664
[48]向玉琴,基于仿真的生产线系统优化设计及分析[D],上海交通大学硕士学位论文, 2000
[49]冯允成等离散系统仿真[M].北京:机械上业出版社,1998.1～21
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