带返工的定点装配车间生产计划与调度集成优化
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摘要
针对定点装配车间不合格品返工导致生产计划及调度不可行的情况,提出一种基于返工延后处理的定点装配车间生产计划与调度集成优化方法.首先制定返工延后处理的粗生产计划;下达计划生产后,将每周期产生的不合格品放入缓冲区,在下周期初时重新调整生产计划并求解新计划下的最优调度,判断其是否满足装配班组负载率要求,不断交替迭代生产计划与调度直至达到计划与调度的均衡和优化.最后通过算例验证了所提出方法的可行性和有效性.
Considering that the rework of nonconforming product leads to the unfeasible production planning and scheduling in the fixed-position assembly workshop, an integrated optimization method for the production planning and scheduling based on delaying rework is proposed. Firstly, rough-cut production planning based on delaying rework is made. After this plan was delivered and performed, the nonconforming products of every cycle are put into the buffer.Correspondingly, at the beginning of the next cycle, the production plan is adjusted and its corresponding schedule is optimized. Both of them are identified whether to satisfy the requirement of load rate of assembly teams. Alternate iteration of the production plan and schedule is proceeded until the optimization and balance are achieved simultaneously.Finally, the examples are given to illustrate the feasibitily and effectiveness.
Considering that the rework of nonconforming product leads to the unfeasible production planning and scheduling in the fixed-position assembly workshop, an integrated optimization method for the production planning and scheduling based on delaying rework is proposed. Firstly, rough-cut production planning based on delaying rework is made. After this plan was delivered and performed, the nonconforming products of every cycle are put into the buffer.Correspondingly, at the beginning of the next cycle, the production plan is adjusted and its corresponding schedule is optimized. Both of them are identified whether to satisfy the requirement of load rate of assembly teams. Alternate iteration of the production plan and schedule is proceeded until the optimization and balance are achieved simultaneously.Finally, the examples are given to illustrate the feasibitily and effectiveness.
引文
[1]Qin W,Huang G Q.A two-level genetic algorithm for scheduling in assembly islands with fixed-position layouts[J].J of Systems Science and Systems Engineering,2010,19(2):150-160.
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[3]严洪森,夏琦峰,朱旻如,等.汽车装配车间生产计划与调度的同时优化方法[J].自动化学报,2002,28(6):911-918.(Yan H S,Xia Q F,Zhu M R,et al.Approaches to simultaneous production planning and scheduling in automobile assembly workshops[J].Acta Automatica Sinica,2002,28(6):911-918.)
[4]Du H,Lou P H,Ye W H.Application of hybrid particle swarm optimization in resource constrained multi-project scheduling[J].J of the Chinese Society of Mechanical Engineers,2014,35(5):371-379.
[5]谢志强,李志敏,郝淑珍,等.工序间存在零等待约束的复杂产品调度研究[J].自动化学报,2009,35(7):983-989.(Xie Z Q,Li Z M,Hao S Z,et al.Study on complex product scheduling problem with no-wait constraint between operations[J].Acta Automatica Sinica,2009,35(7):983-989.)
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[10]郭艳东,王庆,黄敏.就绪时间受限的负荷单机环境下返工工件重调度方法[J].自动化学报,2013,39(12):2100-2110.(Guo Y D,Wang Q,Huang M.Rescheduling with release time to minimize sum of waiting time considering waiting constraint of original loads[J].Acta Automatica Sinica,2013,39(12):2100-2110.)
[11]万峰,刘检华,宁汝新,等.面向复杂产品装配过程的可视化生产调度技术[J].计算机集成制造系统,2013,19(4):755-765.(Wan F,Liu J H,Ning R X,et al.Visual production scheduling technology for the complex product assembly process[J].Computer Integrated Manufacturing Systems,2013,19(4):755-765.)
[12]胡盛强,张毕西,张湘伟,等.基于合格品率及返工有效率的计划投产量决策[J].数学的实践与认识,2014,44(8):1-9.(Hu S Q,Zhang B X,Zhang X W,et al.Decision-making of planning input quantity based on qualified rate and effective rework rate[J].Mathematics in Practice and Theory,2014,44(8):1-9.)
[13]张国辉,高亮,刘文君.基于Memetic算法的车间动态调度策略研究[J].中国机械工程,2008,19(15):1827-1831.(Zhang G H,Gao L,Liu W J.Dynamic scheduling optimization strategy based on memetic algorithm[J].China Mechanical Engineering,2008,19(15):1827-1831.)
[14]吴满成,韩文民,孙晓梅,等.舾装作业中考虑周期驱动的虚拟单元多阶段动态调度研究[J].上海管理科学,2015,37(3):65-69.(Wu M C,Han W M,Sun X M,et al.Research on the multi-period virtual cellular dynamic scheduling with cycle-driven in outfitting[J].Shanghai Management Science,2015,37(3):65-69.)
[15]严洪森,张晓东,董昊.以正好满足产品需求为约束条件的车间最优生产计划[J].系统工程学报,2001,16(1):24-29.(Yan H S,Zhang X D,Dong H.Optimal production planning for workshops with demand constraints[J].J of Systems Engineering,2001,16(1):24-29.)
[16]Moscato P.An introduction to population approaches for optimization and hierarchical objective functions:A discussion on the role of Tabu search[J].Annals of Operations Research,1993,41(1/4):85-121.
[17]Tavakkoli M R,Safaei N,Sassani F.A memetic algorithm for the flexible flow line scheduling problem with processor blocking[J].Computer Operation Research,2009,36:402-414.
[18]Cai B,Wang S L,Hu H B.Genetic algorithm with local search for job shop scheduling problem[J].Advances in Information Sciences and Service Sciences,2011,3(9):42-49.
[2]Akyol D E,Bayhan M.A review on evolution of production scheduling with neural networks[J].Computers&Industrial Engineering,2007,53(1):95-122.
[3]严洪森,夏琦峰,朱旻如,等.汽车装配车间生产计划与调度的同时优化方法[J].自动化学报,2002,28(6):911-918.(Yan H S,Xia Q F,Zhu M R,et al.Approaches to simultaneous production planning and scheduling in automobile assembly workshops[J].Acta Automatica Sinica,2002,28(6):911-918.)
[4]Du H,Lou P H,Ye W H.Application of hybrid particle swarm optimization in resource constrained multi-project scheduling[J].J of the Chinese Society of Mechanical Engineers,2014,35(5):371-379.
[5]谢志强,李志敏,郝淑珍,等.工序间存在零等待约束的复杂产品调度研究[J].自动化学报,2009,35(7):983-989.(Xie Z Q,Li Z M,Hao S Z,et al.Study on complex product scheduling problem with no-wait constraint between operations[J].Acta Automatica Sinica,2009,35(7):983-989.)
[6]刘明周,张玺,刘从虎,等.不确定环境下再制造加工车间生产调度优化方法[J].机械工程学报,2014,50(10):206-212.(Liu M Z,Zhang X,Liu C H,et al.Optimization method of remanufacturing reprocessing shop scheduling under uncertain conditions[J].J of Mechanical Engineering,2014,50(10):206-212.)
[7]王冰,羊晓飞,李巧云.基于坏场景集的抗风险鲁棒调度模型[J].自动化学报,2012,38(2):270-278.(Wang B,Yang X F,Li Q Y.Bad-scenario set based risk-resisting robust scheduling model[J].Acta Automatica Sinica,2012,38(2):270-278.)
[8]王明春,凌光,刘鑫,等.考虑外包的并行调度随机期望值模型[J].系统工程学报,2011,26(1):91-97.(Wang M C,Ling G,Liu X,et al.Stochastic expected value model about parallel schedule considering outsourcing[J].J of Systems Engineering,2011,26(1):91-97.)
[9]Gupta A,Maranas C D,Nald C M Mc Donald.Mid-term supply chain planning under demand uncertainty:customer demand satisfaction and inventory management[J].Computers&Chemical Engineering,2000,24(12):2613-2621.
[10]郭艳东,王庆,黄敏.就绪时间受限的负荷单机环境下返工工件重调度方法[J].自动化学报,2013,39(12):2100-2110.(Guo Y D,Wang Q,Huang M.Rescheduling with release time to minimize sum of waiting time considering waiting constraint of original loads[J].Acta Automatica Sinica,2013,39(12):2100-2110.)
[11]万峰,刘检华,宁汝新,等.面向复杂产品装配过程的可视化生产调度技术[J].计算机集成制造系统,2013,19(4):755-765.(Wan F,Liu J H,Ning R X,et al.Visual production scheduling technology for the complex product assembly process[J].Computer Integrated Manufacturing Systems,2013,19(4):755-765.)
[12]胡盛强,张毕西,张湘伟,等.基于合格品率及返工有效率的计划投产量决策[J].数学的实践与认识,2014,44(8):1-9.(Hu S Q,Zhang B X,Zhang X W,et al.Decision-making of planning input quantity based on qualified rate and effective rework rate[J].Mathematics in Practice and Theory,2014,44(8):1-9.)
[13]张国辉,高亮,刘文君.基于Memetic算法的车间动态调度策略研究[J].中国机械工程,2008,19(15):1827-1831.(Zhang G H,Gao L,Liu W J.Dynamic scheduling optimization strategy based on memetic algorithm[J].China Mechanical Engineering,2008,19(15):1827-1831.)
[14]吴满成,韩文民,孙晓梅,等.舾装作业中考虑周期驱动的虚拟单元多阶段动态调度研究[J].上海管理科学,2015,37(3):65-69.(Wu M C,Han W M,Sun X M,et al.Research on the multi-period virtual cellular dynamic scheduling with cycle-driven in outfitting[J].Shanghai Management Science,2015,37(3):65-69.)
[15]严洪森,张晓东,董昊.以正好满足产品需求为约束条件的车间最优生产计划[J].系统工程学报,2001,16(1):24-29.(Yan H S,Zhang X D,Dong H.Optimal production planning for workshops with demand constraints[J].J of Systems Engineering,2001,16(1):24-29.)
[16]Moscato P.An introduction to population approaches for optimization and hierarchical objective functions:A discussion on the role of Tabu search[J].Annals of Operations Research,1993,41(1/4):85-121.
[17]Tavakkoli M R,Safaei N,Sassani F.A memetic algorithm for the flexible flow line scheduling problem with processor blocking[J].Computer Operation Research,2009,36:402-414.
[18]Cai B,Wang S L,Hu H B.Genetic algorithm with local search for job shop scheduling problem[J].Advances in Information Sciences and Service Sciences,2011,3(9):42-49.