产销一体化环境下钢铁企业冷轧生产计划与调度研究
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摘要
论文在钢铁企业实现产销一体化管理的环境下,以“宝钢五冷轧碳钢系列机组生产方式研究”项目为背景和依托,研究了冷轧生产计划与调度问题。文章总结了钢铁企业产销一体化的理论和冷轧系统生产管理研究现状与主要成果。介绍了该项目的研究成果——基于物流平衡的日生产计划方法,以“末端在制品库存拉动、各工序自律优化的多阶段逆向递推”思想来解决动态的多品种多阶段多目标多约束问题。
论文主要研究冷轧生产环境下的生产调度问题,对车间调度问题优化算法进行整理,结合冷轧系统的生产特点,以经典的置换流水车间(Flow shop)调度优化问题为理论支撑,建立了“带有中间库的流水车间批量(间隙性)生产调度优化模型”,并利用Matlab语言编写遗传算法程序寻求可行解,最后进行系统实例仿真,论证该算法的可行性和有效性,探索模型应用的可拓展性。
论文提出的模型可推广到钢铁、化工、水电站调度等半连续批量生产的流程工业生产调度优化问题,具有较强的实践意义和普遍实用性。
The paper researches planning and scheduling problem of cold-rolling production line which based on Baosteel's cold-rolled carbon steel manufacturing project in conditions of integrated management of producing and selling. This paper firstly summarizes main theories about computer integrated manufacturing system in cold-rolled production, then introduces the project's research result-daily planning method based on logistics balance aiming to smooth logistics, deliver goods in time and reduce cost. It solves dynamic problems with multi-kinds, multi-stage, multi-target, multi-constraint by means of "driven by downstream inventories each working procedure self-optimizes the production plans".
The paper is focused on production scheduling problems and establishes a new model for lot sizing production of flow shop problems with finite intermediate storage in cold-rolled system environment and use genetic algorithm to find appropriate solutions. Simulation results show the effectiveness of the model and the feasibility of the algorithm.
The model and algorithm proposed to solve production scheduling problems in this paper can be extended to semi-continuous mass production industries such as iron and steel, chemicals and hydropower industries. It is of great practical significance and widely applicability
论文主要研究冷轧生产环境下的生产调度问题,对车间调度问题优化算法进行整理,结合冷轧系统的生产特点,以经典的置换流水车间(Flow shop)调度优化问题为理论支撑,建立了“带有中间库的流水车间批量(间隙性)生产调度优化模型”,并利用Matlab语言编写遗传算法程序寻求可行解,最后进行系统实例仿真,论证该算法的可行性和有效性,探索模型应用的可拓展性。
论文提出的模型可推广到钢铁、化工、水电站调度等半连续批量生产的流程工业生产调度优化问题,具有较强的实践意义和普遍实用性。
The paper researches planning and scheduling problem of cold-rolling production line which based on Baosteel's cold-rolled carbon steel manufacturing project in conditions of integrated management of producing and selling. This paper firstly summarizes main theories about computer integrated manufacturing system in cold-rolled production, then introduces the project's research result-daily planning method based on logistics balance aiming to smooth logistics, deliver goods in time and reduce cost. It solves dynamic problems with multi-kinds, multi-stage, multi-target, multi-constraint by means of "driven by downstream inventories each working procedure self-optimizes the production plans".
The paper is focused on production scheduling problems and establishes a new model for lot sizing production of flow shop problems with finite intermediate storage in cold-rolled system environment and use genetic algorithm to find appropriate solutions. Simulation results show the effectiveness of the model and the feasibility of the algorithm.
The model and algorithm proposed to solve production scheduling problems in this paper can be extended to semi-continuous mass production industries such as iron and steel, chemicals and hydropower industries. It is of great practical significance and widely applicability
引文
1.柴天佑.基于ERP／MES／PCS三级结构的金矿企业现代集成制造系统.中国控制会议.杭州.
2. Davis L. Handbook of Genetic Algorithm[M]. New York:Van Nostrand Reinhold.1991.
3. Lee H S, Murthy S, Haider S W et al. Primary production scheduling at steel making industries. IBM Journal Research Development[J],1996,40(2): 231-252.
4. Ortiz A, Lario F, Ros L. Enterprise integration business processes integrated management:a proposal for a methodology to develop enterprise integration programs. Computers in Industry[J],1999,40:155-171.
5.雷德明,严新平,多目标智能优化算法及其应用[M].科学出版社.2003.
6.牛海军,混合流程生产系统优化调度方法研究[D].西安：西北工业大学.2003.
7.唐立新.CIMS下生产批量计划理论及其应用[M].科学出版社,1999
8.刘晓强,顾佳晨,孙彦广等,钢铁企业中的计划调度系统.冶金自动化[J],2004.1(28)：p.22-29.
9. 王宁,宝钢冷轧薄板厂生产计划排产系统的开发与应用[D].2005,大连：大连理工大学.
10.连立峰,左兵群,冷轧薄板生产车间作业及调度系统的研究与实现.冶金自动化[J],2006.30(5)：p.6-10.
11.施锦萍,生产管理在国际大型钢铁企业的发展.上海交通大学学报[J],2007.41：p.31-32.
12.雷英杰,张善文,李续武,周创明,MATLAB遗传算法工具箱及应用[M].2005,西安电子科技大学出版社
13. Wan Wei Shui, Tang Lixin.1998, An experimental development of rolling scheduling, IFACINCOM'98[J], France, June,24-26
14. Tang L X, Liu J Y'Rong A Y'et al. A review of planning and scheduling systems and methods for integrated steel production. European Journal of Operational Research[J],2001,133(1):1-20.
15.李铁克,施灿涛,冷轧生产批量计划与调度问题模型及算法,管理学报[J],2008.1(5)：p.64-69
16.郑忠,朱道飞,高小强,混合流程作业计划编制的时间并行倒推算法.计算机集成制造系统[J].2008,4(14)：p.749-756
17. Redwine C N & Wismer D A. Mixed Integer Programming Model for Scheduling Orders in a Steel Mill[J]. Journal of Optimization Theory and Applications,1974,14(9):305-318.
18.滕学,杨德礼,王众托.钢管厂热轧机组产品结构模型、合同分配模型及其优化分析[J].系统工程与理论与实践,1985,5(2)：40-48.
19.李耀华,宁树实,王伟等.基于准时制的轧钢厂生产计划模型及算法[J].控制工程,2004,11(4)：37-40.
20.王文鹏,杨再步,李铁克.冷轧生产线的批量计划与调度方法[J].企业信息化技术,2006,(5)：11-15.
21.彭威,刘爱国.冷轧企业负荷平衡原料计划模式和方法[J].计算机集成制造系统,2004,10(6)：63-67.
22.彭威,陈李军.冷轧生产线机组作业计划过程中的投料混合比算法[J].计算机集成制造系统,2005,11(4)：133-137.
23.张涛.基于MTO管理体系的钢厂合同计划和热轧生产调度的方法研究[D].沈阳： 东北大学,2000.
24.连立峰,左兵群.冷轧薄板生产车间作业计划及调度系统的研究与实现[J].冶金自动化,2006,30(5)：6-10.
25.李耀华.热轧生产计划与板坯库优化管理模型及算法研究[D].大连：大连理工大学,2006.
26.贾秀霞.基于物流平衡的冷轧系统作业计划方法研究[D].上海：复旦大学,2008
27.徐震浩,顾庆生,解决中间存储时间受限的间歇式调度问题的算法,系统工程理论与实践[J].2006,1：111-119
28.鞠全勇,智能制造系统生产计划与车间调度的研究[D].南京：南京航空航天大学,2007
29. Garey M, Johnson D, Sethi R. The complexity of flow shop and job Mathematics of Operations Research[J],1976,1:117-129.
30. Blazewicz J, Ecker K H, Schmidt G, et al. Scheduling in Computer Systems[M]. Second Revised Edition. Berlin:Springer-Verlag,1996.
31. Stephen C Graves. A Review of Production Scheduling [J]. Production Scheduling,1981,29(4):646-675.
32.玄光男 程润伟.遗传算法与工程设计[M].北京：科学出版社,2000.
33.王凌.车间调度及其遗传算法[M].北京：清华大学出版社,2003.
34.罗耀辉.车间作业计划调度系统的研究与开发[D].西安：西北工业大学2002, (3):16-17.
35. Panwalkar S. A survey of scheduling rules[J]. Operation Research, 1977,25(1):45-61.
36. Chen H X, Cheng B C and proth J M. A more efficient Lagrangian relaxation approach to job shop scheduling problems[J]. Proceeds of IEEE International Conference on Roboticso and Automation, Japan,1995,469-501.
37. Hisao I, Shinta M, Hideo T. Modified simulated annealing algorithms for the flow shop sequencing[J]. Euro J of Operation Research,1995,81: 388-398.
38.朱剑英.现代制造系统模式、建模方法及关键技术的新发展[J].机械工程学报,2000,36(8)：1-5.
39. Wein L M, Chevalier P B. A broader view of the job shop scheduling problem[J]. Management Science,1992,38(7):1018-1033.
40. Rodammer F A. White K P. A recent survey of production scheduling[J]. IEEE Trans on Systems Man and Cybernetics,1988,18(6):841-851.
41.何霆,刘飞,马玉林等.车间生产调度问题研究[J].机械工程学报,2002,36(5)：97-102.
42.. He Ting, Liu Fei, Ma Yulin etal. Study on shop-floor scheduling [J], 2002,36(5):97-102.
43.熊锐,吴澄.车间生产调度问题的技术现状与发展趋势[J].清华大学学报(自然科学版).1998,38(10)：55-60.
44. Xiong rui, Wu Cheng. Current status and developing trend of job shop scheduling research. Journal of Tsinghua University (Sci & Tech)[J]. 1998,38(10):55-60.
45.孙志峻.智能制造系统车间生产优化调度[D].南京：南京航空航天大学图书馆,2002.
46.方剑.进化算法及其在Job Shop调度中的应用[D].上海：上海交通大学图书馆,1996.
47.代勇.先进制造车间计划调度控制系统关键技术研究[D].哈尔滨：哈尔滨工业大学图书馆,2003.
48.张志英.CAPP与PPS集成理论和方法研究[D].北京：北京理工大学图书馆,2003.
49. Garey M, Johnson D, Sethi R. The complexity of flow shop and job shop scheduling[J]. Mathematics of Operations Research,1976,1:117-129.
50.张涛,王梦光,杨建夏.不确定计划数的轧制批量计划的模型和算法.系统工程学报,2000,15(1)：54—60.
51.常俊林,张春慨,邵惠鹤.求解一类并行多机调度问题的混合启发式算法.计算机仿真,2004,21(3)：121-123.
52.路飞,田国会.用多种群并行自适应遗传算法求解多机多阶段F1ow shop提前／拖期调度问题.电工技术学报,2005,20(4)：58-61.
53.李世俊,徐寅,姜尚青等.对中国钢铁工业发展的思考.轧钢,2004,21(6)：1-5.
54.覃一宁.冷轧薄板生产计划与调度系统的研究与应用[D].大连：大连理工大学,2007.
55. Moon S, Hrymak A N. Scheduling of the batch annealing process-deterministic case. Computers and Chemical Engineering,1999,23 (9): 1193-1208.
56. Liu Q, Wang W, Zhan H etal. Optimal scheduling method for abell-type batch annealing shop and its application. Control Engineering Practice, 2005,13(10):1315—1325.
57. Wang D D, Tieu Al(, Boer F G et al. Toward a heuristic optimum design of rolling schedules for tandem cold rolling mills. Engineering Application of Artificial Intelligence,2002,13(4):397-406.
58.覃一宁,王伟,王建军等.流程工业生产计划与调度系统的对象建模方法.计算机集成制造系统,2006,12(1)：4449.
59.于艾青.基于智能优化算法的并行机调度和flow shop调度问题研究[D],上海：华东理工大学.2007
2. Davis L. Handbook of Genetic Algorithm[M]. New York:Van Nostrand Reinhold.1991.
3. Lee H S, Murthy S, Haider S W et al. Primary production scheduling at steel making industries. IBM Journal Research Development[J],1996,40(2): 231-252.
4. Ortiz A, Lario F, Ros L. Enterprise integration business processes integrated management:a proposal for a methodology to develop enterprise integration programs. Computers in Industry[J],1999,40:155-171.
5.雷德明,严新平,多目标智能优化算法及其应用[M].科学出版社.2003.
6.牛海军,混合流程生产系统优化调度方法研究[D].西安：西北工业大学.2003.
7.唐立新.CIMS下生产批量计划理论及其应用[M].科学出版社,1999
8.刘晓强,顾佳晨,孙彦广等,钢铁企业中的计划调度系统.冶金自动化[J],2004.1(28)：p.22-29.
9. 王宁,宝钢冷轧薄板厂生产计划排产系统的开发与应用[D].2005,大连：大连理工大学.
10.连立峰,左兵群,冷轧薄板生产车间作业及调度系统的研究与实现.冶金自动化[J],2006.30(5)：p.6-10.
11.施锦萍,生产管理在国际大型钢铁企业的发展.上海交通大学学报[J],2007.41：p.31-32.
12.雷英杰,张善文,李续武,周创明,MATLAB遗传算法工具箱及应用[M].2005,西安电子科技大学出版社
13. Wan Wei Shui, Tang Lixin.1998, An experimental development of rolling scheduling, IFACINCOM'98[J], France, June,24-26
14. Tang L X, Liu J Y'Rong A Y'et al. A review of planning and scheduling systems and methods for integrated steel production. European Journal of Operational Research[J],2001,133(1):1-20.
15.李铁克,施灿涛,冷轧生产批量计划与调度问题模型及算法,管理学报[J],2008.1(5)：p.64-69
16.郑忠,朱道飞,高小强,混合流程作业计划编制的时间并行倒推算法.计算机集成制造系统[J].2008,4(14)：p.749-756
17. Redwine C N & Wismer D A. Mixed Integer Programming Model for Scheduling Orders in a Steel Mill[J]. Journal of Optimization Theory and Applications,1974,14(9):305-318.
18.滕学,杨德礼,王众托.钢管厂热轧机组产品结构模型、合同分配模型及其优化分析[J].系统工程与理论与实践,1985,5(2)：40-48.
19.李耀华,宁树实,王伟等.基于准时制的轧钢厂生产计划模型及算法[J].控制工程,2004,11(4)：37-40.
20.王文鹏,杨再步,李铁克.冷轧生产线的批量计划与调度方法[J].企业信息化技术,2006,(5)：11-15.
21.彭威,刘爱国.冷轧企业负荷平衡原料计划模式和方法[J].计算机集成制造系统,2004,10(6)：63-67.
22.彭威,陈李军.冷轧生产线机组作业计划过程中的投料混合比算法[J].计算机集成制造系统,2005,11(4)：133-137.
23.张涛.基于MTO管理体系的钢厂合同计划和热轧生产调度的方法研究[D].沈阳： 东北大学,2000.
24.连立峰,左兵群.冷轧薄板生产车间作业计划及调度系统的研究与实现[J].冶金自动化,2006,30(5)：6-10.
25.李耀华.热轧生产计划与板坯库优化管理模型及算法研究[D].大连：大连理工大学,2006.
26.贾秀霞.基于物流平衡的冷轧系统作业计划方法研究[D].上海：复旦大学,2008
27.徐震浩,顾庆生,解决中间存储时间受限的间歇式调度问题的算法,系统工程理论与实践[J].2006,1：111-119
28.鞠全勇,智能制造系统生产计划与车间调度的研究[D].南京：南京航空航天大学,2007
29. Garey M, Johnson D, Sethi R. The complexity of flow shop and job Mathematics of Operations Research[J],1976,1:117-129.
30. Blazewicz J, Ecker K H, Schmidt G, et al. Scheduling in Computer Systems[M]. Second Revised Edition. Berlin:Springer-Verlag,1996.
31. Stephen C Graves. A Review of Production Scheduling [J]. Production Scheduling,1981,29(4):646-675.
32.玄光男 程润伟.遗传算法与工程设计[M].北京：科学出版社,2000.
33.王凌.车间调度及其遗传算法[M].北京：清华大学出版社,2003.
34.罗耀辉.车间作业计划调度系统的研究与开发[D].西安：西北工业大学2002, (3):16-17.
35. Panwalkar S. A survey of scheduling rules[J]. Operation Research, 1977,25(1):45-61.
36. Chen H X, Cheng B C and proth J M. A more efficient Lagrangian relaxation approach to job shop scheduling problems[J]. Proceeds of IEEE International Conference on Roboticso and Automation, Japan,1995,469-501.
37. Hisao I, Shinta M, Hideo T. Modified simulated annealing algorithms for the flow shop sequencing[J]. Euro J of Operation Research,1995,81: 388-398.
38.朱剑英.现代制造系统模式、建模方法及关键技术的新发展[J].机械工程学报,2000,36(8)：1-5.
39. Wein L M, Chevalier P B. A broader view of the job shop scheduling problem[J]. Management Science,1992,38(7):1018-1033.
40. Rodammer F A. White K P. A recent survey of production scheduling[J]. IEEE Trans on Systems Man and Cybernetics,1988,18(6):841-851.
41.何霆,刘飞,马玉林等.车间生产调度问题研究[J].机械工程学报,2002,36(5)：97-102.
42.. He Ting, Liu Fei, Ma Yulin etal. Study on shop-floor scheduling [J], 2002,36(5):97-102.
43.熊锐,吴澄.车间生产调度问题的技术现状与发展趋势[J].清华大学学报(自然科学版).1998,38(10)：55-60.
44. Xiong rui, Wu Cheng. Current status and developing trend of job shop scheduling research. Journal of Tsinghua University (Sci & Tech)[J]. 1998,38(10):55-60.
45.孙志峻.智能制造系统车间生产优化调度[D].南京：南京航空航天大学图书馆,2002.
46.方剑.进化算法及其在Job Shop调度中的应用[D].上海：上海交通大学图书馆,1996.
47.代勇.先进制造车间计划调度控制系统关键技术研究[D].哈尔滨：哈尔滨工业大学图书馆,2003.
48.张志英.CAPP与PPS集成理论和方法研究[D].北京：北京理工大学图书馆,2003.
49. Garey M, Johnson D, Sethi R. The complexity of flow shop and job shop scheduling[J]. Mathematics of Operations Research,1976,1:117-129.
50.张涛,王梦光,杨建夏.不确定计划数的轧制批量计划的模型和算法.系统工程学报,2000,15(1)：54—60.
51.常俊林,张春慨,邵惠鹤.求解一类并行多机调度问题的混合启发式算法.计算机仿真,2004,21(3)：121-123.
52.路飞,田国会.用多种群并行自适应遗传算法求解多机多阶段F1ow shop提前／拖期调度问题.电工技术学报,2005,20(4)：58-61.
53.李世俊,徐寅,姜尚青等.对中国钢铁工业发展的思考.轧钢,2004,21(6)：1-5.
54.覃一宁.冷轧薄板生产计划与调度系统的研究与应用[D].大连：大连理工大学,2007.
55. Moon S, Hrymak A N. Scheduling of the batch annealing process-deterministic case. Computers and Chemical Engineering,1999,23 (9): 1193-1208.
56. Liu Q, Wang W, Zhan H etal. Optimal scheduling method for abell-type batch annealing shop and its application. Control Engineering Practice, 2005,13(10):1315—1325.
57. Wang D D, Tieu Al(, Boer F G et al. Toward a heuristic optimum design of rolling schedules for tandem cold rolling mills. Engineering Application of Artificial Intelligence,2002,13(4):397-406.
58.覃一宁,王伟,王建军等.流程工业生产计划与调度系统的对象建模方法.计算机集成制造系统,2006,12(1)：4449.
59.于艾青.基于智能优化算法的并行机调度和flow shop调度问题研究[D],上海：华东理工大学.2007