H企业单件小批量订单排产的优化
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摘要
由于单件小批生产模式的生产标准化程度较低,同时用户订货提前期长,需要制定详细的生产计划来使企业更好地运营,因此如何提高单件小批生产运作类型的效率便成为生产运作管理最为关注的问题。文中H企业是典型的单件小批量生产企业,是订单驱动的生产模式,产品的类型与数量都是由客户的需求而定,面对的客户主要是国内外的大型电厂和船舶企业,所以很多订单对交货期有着很严格的要求,因此制定合理的生产计划就变得尤为重要。本文就是结合H企业的实际生产运营状况,运用TOC理论对企业产能进行分析,找出瓶颈工序,同时综合考虑企业交付能力、生产紧迫度、加工时间等多方面因素运用运筹学的相关方法,对企业的生产制定出详细的年生产计划,使设备运行效率提升9.3%,相应单位生产支出降低12%,平均生产周期由150d减少到120d,极大改善企业的现有状况,提高企业的运营成本。
Due to the low standard of single small batch production mode and the long lead time of user's order,it is necessary to develop detailed production plan to make the factory operate better.Therefore how to improve the efficiency of small batch production and operation types has become the most concern of the production and operation management.In this paper,H factory is a typical single small batch production factory,which has an order driven production mode.The type and quality of products are determined by the customer's needs.The clients are mainly domestic and overseas large power plants and ship enterprises,which has very strict requirements for the delivery time of orders.So it is particularly important to develop a reasonable production plan.Based on the actual production and operation of H factory,using TOC theory to analyze the production capacity,the bottleneck process has been found out.At the same time,considering the delivery capacity,production urgency,processing time the other factors,operational research methods is used to develop detailed annual production plan.It can increase efficiency by 9.3%,decrease unit production expense by 12% and reduce the average production cycle from 150 D to 120 D.It can greatly improve the current situation and raise operating costs of factory.
Due to the low standard of single small batch production mode and the long lead time of user's order,it is necessary to develop detailed production plan to make the factory operate better.Therefore how to improve the efficiency of small batch production and operation types has become the most concern of the production and operation management.In this paper,H factory is a typical single small batch production factory,which has an order driven production mode.The type and quality of products are determined by the customer's needs.The clients are mainly domestic and overseas large power plants and ship enterprises,which has very strict requirements for the delivery time of orders.So it is particularly important to develop a reasonable production plan.Based on the actual production and operation of H factory,using TOC theory to analyze the production capacity,the bottleneck process has been found out.At the same time,considering the delivery capacity,production urgency,processing time the other factors,operational research methods is used to develop detailed annual production plan.It can increase efficiency by 9.3%,decrease unit production expense by 12% and reduce the average production cycle from 150 D to 120 D.It can greatly improve the current situation and raise operating costs of factory.
引文
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[15]李浩,沈祖志,邓明荣.订货型企业基于约束理论的订单排产优化研究[J].中国机械工程.2004,15(10):865-869.
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[18]Zijm W H M.Towards intelligent manufacturing planning and control systems[J].OR-Spectrum,2000,22(3):313-345.
[19]杨晓英,郭青玉.离散型制造企业的生产能力平衡模型和算法研究[J].矿山机械,2012,40(6):102-106.
[20]Turner W C,Mize J H,Case K E.Introduction to industrial and systems engineering[M].北京:清华大学出版社,2002.
[2]赵启兰.生产运作管理[M].北京:北京交通大学出版社,2008.
[3]姜思杰,徐晓飞,战德臣,等.大型单件小批生产的计划与控制模式.计算机集成制造系统-CIMS[J],2001,7(2):1-5.
[4]Huang S H,Dismukes J P,Shi J,et al.Manufacturing system modeling for productivity improvement[J].Journal of Manufacturing Systems,2002,21(4):249-254.
[5]唐亚民.PL公司生产计划与控制系统改进研究[D].兰州:兰州大学,2012.
[6]熊禾根,吴志远,李建军.单件订货型生产中基于任务的生产能力研究[J].数学的实践与认识,2006,36(7):238-243.
[7]张红,郭飞鹏.面向敏捷询单处理的订单优先级排序方法[J].计算机工程与设计,2012,33(3):963-967.
[8]Glasserman P.Allocating production capacity among multiple products[J].Operations Research,1996,44(5):724-734.
[9]Stevenson W J.Operations management.International Edition.9th Edition[M].Mc Graw-Hill/Irwin.New York,2007.
[10]李彩丽.整车企业订单接受与排程研究[D].长沙:湖南大学,2013.
[11]董楠.基于制造型企业的生产能力评估方法研究[D].西安:西安电子科技大学,2009.
[12]刘强.离散型生产线生产能力评估系统研究[D].西安:西安电子科技大学,2010.
[13]面向汽轮机关键件的生产作业计划与调度研究[D].哈尔滨:哈尔滨工业大学,2009
[14]Gupta M,Synder D.Comparing TOC with MRP and JIT:a literature review[J].International Journal of Production Research,2009,47(13):3705-3739.
[15]李浩,沈祖志,邓明荣.订货型企业基于约束理论的订单排产优化研究[J].中国机械工程.2004,15(10):865-869.
[16]Nahmias S.Production and operations analysis[M].Mc Graw-Hill Co.Inc,2001.
[17]刘玉.基于约束理论的作业计划系统研究与实现[J].计算机工程与设计,2011,32(4):1152-1156.
[18]Zijm W H M.Towards intelligent manufacturing planning and control systems[J].OR-Spectrum,2000,22(3):313-345.
[19]杨晓英,郭青玉.离散型制造企业的生产能力平衡模型和算法研究[J].矿山机械,2012,40(6):102-106.
[20]Turner W C,Mize J H,Case K E.Introduction to industrial and systems engineering[M].北京:清华大学出版社,2002.