基于能力优化的离散企业生产计划系统设计与实现
摘要
制造业是国民经济的支柱产业,为我国国民经济的可持续发展提供了物质基础,是我国提高经济实力和综合国力的根本。随着信息技术的发展,企业资源计划(Enterprise Resource Planning,简称ERP)软件在我国的制造企业中得到了越来越广泛的应用。ERP软件的使用大大提高制造企业的管理水平,降低成本,提高效益。作为ERP核心部分的生产计划与控制系统,要将其解决的重点放在生产计划的合理性上,研究如何适应众多的生产类型,制定出满足企业复杂多变的制造环境的合理可行的生产计划。
在离散制造企业,能力约束多、内部生产管理复杂,如何编制出合理可行的生产计划是生产计划控制的主要研究问题。在此对基于能力优化的生产计划体系等方面进行全面系统的研究,内容主要包括以下几方面:分析不同类型企业的能力需求特点,提出离散制造企业的能力管理模型;分析合理可行的计划所具有的各个优化目标,这其中包括满足性、均衡性、关键能力来利用率最大等。建立基于能力优化的生产计划模型,构建生产计划编制的评价体系。在生产计划编制模块中,增添能力评价和计划调整部分,最终形成由计划编制到能力计算到评价到调整计划这样的循环迭代过程,由此得到一个正确、合理、优化的生产计划。再根据不同生产类型企业的特点及其能力优化目标,提出相应的优化措施和调整方案。
基于以上模型和算法,按照软件工程的思想设计出离散制造企业生产计划系统。并在Java2企业版(Java2 Enterprise Edition,简称J2EE)平台上,使用模型-视图-控制(Model-View-Controller,简称MVC)开发模式实现了该系统。并通过对系统在哈尔滨空调股份有限公司的应用情况的介绍,对文中的理论研究进行了验证。
Discrete manufacture enterprises play a very important role in Chinese country economy. With the development of information technique, the software of ERP has been applied in more and more manufacture enterprises. By using ERP systems, the enterprise improves the management level, reduce the cost, and increase benefits. As the core of ERP system, production planning system must face the difficult issues how to make a feasible and stable production planning, which adapts the numerous production types and the complex demands.
This article presents the method of making a feasible and stable production planning on the basis of analyzing the discrete manufacture enterprise's production environment types and production planning’s characteristic. The core problem of this article is“How to make a perfect plan”. Capacity management model of discrete manufacture enterprises is respected in this paper and it analyses the various optimization object to reliable plans. The object contains satisfaction, smoothness, key capacity using most and so on. Based on Production Scheduling model with Capacity optimization, three modules are used to deal with this problem. They are planning module, estimate module and adjusting module. The plan will be well by making the cycle of planning, estimate, adjusting. Aimed to the various the discrete manufacture enterprise's production environment types and production planning’s characteristic, this article suggests optimization measures and technique.
The discrete manufacture enterprise production planning system is designed according to the thought of the software engineering and the above algorithms. And the system is implemented on the J2EE software platform and the model of MVC. Finally, validate the results of this dissertation by introducing the application situation in Harbin air-condition Co. Ltd. of the system.
在离散制造企业,能力约束多、内部生产管理复杂,如何编制出合理可行的生产计划是生产计划控制的主要研究问题。在此对基于能力优化的生产计划体系等方面进行全面系统的研究,内容主要包括以下几方面:分析不同类型企业的能力需求特点,提出离散制造企业的能力管理模型;分析合理可行的计划所具有的各个优化目标,这其中包括满足性、均衡性、关键能力来利用率最大等。建立基于能力优化的生产计划模型,构建生产计划编制的评价体系。在生产计划编制模块中,增添能力评价和计划调整部分,最终形成由计划编制到能力计算到评价到调整计划这样的循环迭代过程,由此得到一个正确、合理、优化的生产计划。再根据不同生产类型企业的特点及其能力优化目标,提出相应的优化措施和调整方案。
基于以上模型和算法,按照软件工程的思想设计出离散制造企业生产计划系统。并在Java2企业版(Java2 Enterprise Edition,简称J2EE)平台上,使用模型-视图-控制(Model-View-Controller,简称MVC)开发模式实现了该系统。并通过对系统在哈尔滨空调股份有限公司的应用情况的介绍,对文中的理论研究进行了验证。
Discrete manufacture enterprises play a very important role in Chinese country economy. With the development of information technique, the software of ERP has been applied in more and more manufacture enterprises. By using ERP systems, the enterprise improves the management level, reduce the cost, and increase benefits. As the core of ERP system, production planning system must face the difficult issues how to make a feasible and stable production planning, which adapts the numerous production types and the complex demands.
This article presents the method of making a feasible and stable production planning on the basis of analyzing the discrete manufacture enterprise's production environment types and production planning’s characteristic. The core problem of this article is“How to make a perfect plan”. Capacity management model of discrete manufacture enterprises is respected in this paper and it analyses the various optimization object to reliable plans. The object contains satisfaction, smoothness, key capacity using most and so on. Based on Production Scheduling model with Capacity optimization, three modules are used to deal with this problem. They are planning module, estimate module and adjusting module. The plan will be well by making the cycle of planning, estimate, adjusting. Aimed to the various the discrete manufacture enterprise's production environment types and production planning’s characteristic, this article suggests optimization measures and technique.
The discrete manufacture enterprise production planning system is designed according to the thought of the software engineering and the above algorithms. And the system is implemented on the J2EE software platform and the model of MVC. Finally, validate the results of this dissertation by introducing the application situation in Harbin air-condition Co. Ltd. of the system.
引文
1 Huin.S.F. Managing Deployment of ERP Systems in SMEs Using Multi-agents. International Journal of Project Management. 2004,22(6):511~517
2 杨智茗, 张洪伟, 赵立. ERP生产规划系统的探索和实现. 计算机工程与设计. 2003, 24(2):46
3 陈鹏, 张洪伟. 企业资源计划系统(ERP)探讨. 计算机应用研究. 2001,(1):118
4 陈启申. MRPII制造资源计划基础. 企业管理出版社. 2000:56~78
5 温咏棠. MRPII制造资源计划系统. 机械工业出版社. 1998:22~24
6 叶宏谟. 企业资源规划-制造业管理篇. 电子工业出版社. 2000:17~108
7 Benton W.C., Hojung Shin. Manufacturing Planning and Control: The Evolution of MRP and JIT Integration. European Journal of Operational Research. 1998,110(3):411~440
8 FREDERICKA.et al. A Recent Survey of Production Scheduling. IEEE Transactions on Systems, Man and Cybernetics. 1988,18(6):841~851
9 The PMI Standards Committee. Guide to the Project Management Body of Knowledge (PMBOK). Project Management Institute. 1995
10 李波, 杨灿军, 陈鹰. 基于面向对象技术的网络计划系统. 计算机集成制造系统. 2001,7(12):19~23
11 吴云从, 潘郁. 网络生产作业计划系统的开发和应用. 系统工程理论与实践. 1993,(2):46~49
12 OGDSONTJ, WANG Dingwei. Optimal Hybrid Push/pull Control Strategies for a Paralleled Multistage System. Int. Jour. of Production Research. 1991, 29(6):1279~1287
13 李小平. 单件生产企业的多级多层计划优化方法. 哈尔滨工业大学博士论文. 2002:23~33
14 李勇, 唐莹, 周明, 李相平. 基于ERP单件小批量订货型制造企业的管理模式. 重庆大学学报. 2003, 26(12):126~128
15 Sydney C.K.Chu. A Mathematical Programming Approach Towards Optimized Master Production Scheduling. International Journal of Production Economics. 1995,(38):269~279
16 任铃 , 王宁生 . CIMS 环境主生产计划的优化方法 . 航空制造工程 .1996,(7):111~114
17 D.Byrne, M.A.Bakir. Production Planning Using a Hybrid Simulation-analytical Approach. International Journal of Production Economics. 1999,(59):305~311
18 Bokang Kim, Sooyoung Kim. Extended Model for a Hybrid Production Planning Approach. International Journal of Production Economics. 2001,(73):165~173
19 Wang R C, Fang H H. Aggregate Production Planning with Multiple Objectives in Fuzzy Environment. European Journal of Operational Research. 2001,133(3):521~536
20 周峰. 一种基于OPT的MPS编制方法. 科技与管理. 2002,(2):33~35
21 周峰. 单一瓶颈环节条件下MPS的编制方法. 武汉冶金科技大学学报. 1998,21(2):241~244
22 Ou Tang, Robert W. Grubbstro. Planning and Replanning the Master Production Schedule Under Demand Uncertainty. Int.J.Production Economics 78. 2002:323~334
23 Jinxing Xie, Xiande Zhao, T.S. Lee. Freezing the Master Production Schedule Under Single Resource Constraint and Demand Uncertainty. Int.J.Production Economics 83. 2003:65~84
24 杨 红 红 , 吴 智 铭 . 遗 传 算 法 在 Job-Shop 调 度 中 的 应 用 . 系 统 工 程 . 2000,18(5):49~54
25 童刚, 李光泉, 刘宝坤. 用遗传算法解决在并行机上带有不同交货期窗口的Job-Shop调度问题. 系统工程. 2000,18(3):37~41
26 贾伟凤, 廖晓昕, 王明哲, 沈轶. 不确定环境多目标主生产计划制定方法. 系统工程. 2002,20(5):50~54
27 Kamarkar U.S.. Lot Sizes,Lead Times and In-process Inventories. Management science. 1987,33(3):409~418
28 Hyun-Joon Kim, Yasser A, Hosni. Manufacturing Lot-sizing Under MRPII Environment: an Improved Analytical Model & a Heuristic Procedure. Computers ind. Engng.1998, l.35(3-4):423~426
29 Nicholas A.J. Hastings, Peter Marshall, Robert J. Wills. Schedule Based MRP.: an Integrated Approach to Production Scheduling and Material Requirements Planning. J. Opl. Res. Soc.. 1982,(33):1021~1029
30 Miguel Constantino. A Polyhedral Approach to a Production Planning Problem. Annals of Operations Research 96. 2000:75~95
31 Samir Lamouri, Andre Thomas. The Two level Master Production Schedule and Planning Bills in a Just In Time MRP context. Int. J. Production Economics 64. 2000:409~415
32 胡仕成, 徐晓飞, 战德臣. 一种面向成本优化的生产计划调度算法. 计算机集成制造系统. 2003,9(9):735~739
33 徐福缘 , 犯晋鹰 . 一个小批量多品种的生产计划模型 . 工业工程 . 2000,3(4):44~47
34 杨智茗, 张洪伟, 赵立. ERP生产规划系统的探索和实现. 计算机工程与设计. 2003, 24(2):46~49
35 Wiendahl H P. Fundamentals and Experiences with Load-Oriented Manufacturing Control. APICS, Conference Proceedings. 1990
36 熊红云. MRPII系统提前期的估计及柔性化. 成组技术与生产现代化. 2000,(2):27~29
37 蓝 伯 雄 . 企 业 资 源 优 化 与 优 化 模 型 . 计 算 机 集 成 制 造 系 统 . 2004,10(3):241~251
38 吕伟文, 金旭星, 盛奎川. ERP环境下制造系统能力平衡模型的研究. 机械制造. 2005,43(495):72~75
39 J.C. Wortman.M.J., EUWE.M.TAAL, V.C.S. WIERS. A Review Of Capacity Planning Techniques Within Standard Software Packages. Production Planning&Control. 1996,7(2):117~128
40 BAKKE.N.A., HELLBERG.R.. The Challenges of Capacity Planning. International Journal of Production Economics. 1993:30~311,243~264
41 WEMMERLOV.U.. Capacity Management Techniquesfor Manufacturing Companies with MRPSystems. Fallschurch,Va:APICS. 1984
42 A KIMMS. Stability Measures for Rolling Schedules with Applications to Capacity Expansion Planning, Master Production Scheduling, and Lot Sizing. Omega, Int.J. Mgmt Sci. 1998,26(3):355~366
43 郑志民. 离散型制造企业生产系统生产能力的仿真和应用研究. 天津大学机械工程学院硕士论文. 2004:9~19
44 张海. 软件工程导论. 清华大学出版社. 1992:32~45
45 何成万 , 余秋惠 . 一个新的 Java 网络编程 MVC 模型 . 计算机工程 . 2001,27(8):124~127
2 杨智茗, 张洪伟, 赵立. ERP生产规划系统的探索和实现. 计算机工程与设计. 2003, 24(2):46
3 陈鹏, 张洪伟. 企业资源计划系统(ERP)探讨. 计算机应用研究. 2001,(1):118
4 陈启申. MRPII制造资源计划基础. 企业管理出版社. 2000:56~78
5 温咏棠. MRPII制造资源计划系统. 机械工业出版社. 1998:22~24
6 叶宏谟. 企业资源规划-制造业管理篇. 电子工业出版社. 2000:17~108
7 Benton W.C., Hojung Shin. Manufacturing Planning and Control: The Evolution of MRP and JIT Integration. European Journal of Operational Research. 1998,110(3):411~440
8 FREDERICKA.et al. A Recent Survey of Production Scheduling. IEEE Transactions on Systems, Man and Cybernetics. 1988,18(6):841~851
9 The PMI Standards Committee. Guide to the Project Management Body of Knowledge (PMBOK). Project Management Institute. 1995
10 李波, 杨灿军, 陈鹰. 基于面向对象技术的网络计划系统. 计算机集成制造系统. 2001,7(12):19~23
11 吴云从, 潘郁. 网络生产作业计划系统的开发和应用. 系统工程理论与实践. 1993,(2):46~49
12 OGDSONTJ, WANG Dingwei. Optimal Hybrid Push/pull Control Strategies for a Paralleled Multistage System. Int. Jour. of Production Research. 1991, 29(6):1279~1287
13 李小平. 单件生产企业的多级多层计划优化方法. 哈尔滨工业大学博士论文. 2002:23~33
14 李勇, 唐莹, 周明, 李相平. 基于ERP单件小批量订货型制造企业的管理模式. 重庆大学学报. 2003, 26(12):126~128
15 Sydney C.K.Chu. A Mathematical Programming Approach Towards Optimized Master Production Scheduling. International Journal of Production Economics. 1995,(38):269~279
16 任铃 , 王宁生 . CIMS 环境主生产计划的优化方法 . 航空制造工程 .1996,(7):111~114
17 D.Byrne, M.A.Bakir. Production Planning Using a Hybrid Simulation-analytical Approach. International Journal of Production Economics. 1999,(59):305~311
18 Bokang Kim, Sooyoung Kim. Extended Model for a Hybrid Production Planning Approach. International Journal of Production Economics. 2001,(73):165~173
19 Wang R C, Fang H H. Aggregate Production Planning with Multiple Objectives in Fuzzy Environment. European Journal of Operational Research. 2001,133(3):521~536
20 周峰. 一种基于OPT的MPS编制方法. 科技与管理. 2002,(2):33~35
21 周峰. 单一瓶颈环节条件下MPS的编制方法. 武汉冶金科技大学学报. 1998,21(2):241~244
22 Ou Tang, Robert W. Grubbstro. Planning and Replanning the Master Production Schedule Under Demand Uncertainty. Int.J.Production Economics 78. 2002:323~334
23 Jinxing Xie, Xiande Zhao, T.S. Lee. Freezing the Master Production Schedule Under Single Resource Constraint and Demand Uncertainty. Int.J.Production Economics 83. 2003:65~84
24 杨 红 红 , 吴 智 铭 . 遗 传 算 法 在 Job-Shop 调 度 中 的 应 用 . 系 统 工 程 . 2000,18(5):49~54
25 童刚, 李光泉, 刘宝坤. 用遗传算法解决在并行机上带有不同交货期窗口的Job-Shop调度问题. 系统工程. 2000,18(3):37~41
26 贾伟凤, 廖晓昕, 王明哲, 沈轶. 不确定环境多目标主生产计划制定方法. 系统工程. 2002,20(5):50~54
27 Kamarkar U.S.. Lot Sizes,Lead Times and In-process Inventories. Management science. 1987,33(3):409~418
28 Hyun-Joon Kim, Yasser A, Hosni. Manufacturing Lot-sizing Under MRPII Environment: an Improved Analytical Model & a Heuristic Procedure. Computers ind. Engng.1998, l.35(3-4):423~426
29 Nicholas A.J. Hastings, Peter Marshall, Robert J. Wills. Schedule Based MRP.: an Integrated Approach to Production Scheduling and Material Requirements Planning. J. Opl. Res. Soc.. 1982,(33):1021~1029
30 Miguel Constantino. A Polyhedral Approach to a Production Planning Problem. Annals of Operations Research 96. 2000:75~95
31 Samir Lamouri, Andre Thomas. The Two level Master Production Schedule and Planning Bills in a Just In Time MRP context. Int. J. Production Economics 64. 2000:409~415
32 胡仕成, 徐晓飞, 战德臣. 一种面向成本优化的生产计划调度算法. 计算机集成制造系统. 2003,9(9):735~739
33 徐福缘 , 犯晋鹰 . 一个小批量多品种的生产计划模型 . 工业工程 . 2000,3(4):44~47
34 杨智茗, 张洪伟, 赵立. ERP生产规划系统的探索和实现. 计算机工程与设计. 2003, 24(2):46~49
35 Wiendahl H P. Fundamentals and Experiences with Load-Oriented Manufacturing Control. APICS, Conference Proceedings. 1990
36 熊红云. MRPII系统提前期的估计及柔性化. 成组技术与生产现代化. 2000,(2):27~29
37 蓝 伯 雄 . 企 业 资 源 优 化 与 优 化 模 型 . 计 算 机 集 成 制 造 系 统 . 2004,10(3):241~251
38 吕伟文, 金旭星, 盛奎川. ERP环境下制造系统能力平衡模型的研究. 机械制造. 2005,43(495):72~75
39 J.C. Wortman.M.J., EUWE.M.TAAL, V.C.S. WIERS. A Review Of Capacity Planning Techniques Within Standard Software Packages. Production Planning&Control. 1996,7(2):117~128
40 BAKKE.N.A., HELLBERG.R.. The Challenges of Capacity Planning. International Journal of Production Economics. 1993:30~311,243~264
41 WEMMERLOV.U.. Capacity Management Techniquesfor Manufacturing Companies with MRPSystems. Fallschurch,Va:APICS. 1984
42 A KIMMS. Stability Measures for Rolling Schedules with Applications to Capacity Expansion Planning, Master Production Scheduling, and Lot Sizing. Omega, Int.J. Mgmt Sci. 1998,26(3):355~366
43 郑志民. 离散型制造企业生产系统生产能力的仿真和应用研究. 天津大学机械工程学院硕士论文. 2004:9~19
44 张海. 软件工程导论. 清华大学出版社. 1992:32~45
45 何成万 , 余秋惠 . 一个新的 Java 网络编程 MVC 模型 . 计算机工程 . 2001,27(8):124~127
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