基于精益生产的制造/再制造混合系统生产决策模型研究
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摘要
再制造以其巨大的环保效益和经济效益吸引了越来越多的制造商在制造新产品的同时,开展对旧产品的再制造加工,制造/再制造混合系统(Manufacturing/Remanufacturing Hybrid System, MRHS)由此形成。然而,由于再制造过程中存在诸多不确定性,MRHS生产过程难以管理和控制、生产决策难以制定。精益生产集成先进的生产管理工具和生产控制方式,将其应用于MRHS不确定的生产环境里,在此基础上研究MRHS生产策略与决策具有重要的研究意义。
本文以MRHS为研究对象,考虑到消费者对再制造品的接受程度存在差别,再制造品和制造品的需求往往具有差异,表现出不同的需求源。研究两种产品需求非同源背景下的生产决策问题,相比以往文献对同需求源背景下生产决策问题的研究,更具有实际意义。本文的主要研究内容如下：
第一章,综述MRHS生产问题研究现状,分析研究中存在的问题及不足,在此基础上阐述本文的研究内容及意义。
第二章,概述MRHS流程及特点并分析其不确定性；对典型生产策略、MRHS生产决策及精益生产进行理论基础分析。
第三章,分析影响MRHS生产决策制定的因素,并提出在制定生产决策时需满足的特殊要求。在此基础上,阐述精益生产管理方法在降低MRHS不确定性上发挥的积极作用；通过比较分析典型生产策略在MRHS中应用的优缺点,提出再制造品和制造品具有需求差异但允许替换销售背景下结合推动式生产的MRHS精益生产策略。
第四章,基于所提出的MRHS精益生产策略,对再制造品和制造品具有同需求源下的MRHS生产决策模型进行扩展,建立再制造品和制造品需求非同源、允许产品替换销售的MRHS生产决策的数学模型,利用数学方法证明并求解。
第五章,将建立的生产决策模型应用于某产品的MRHS多周期的生产决策中,利用Matlab进行编程及数值运算,结果与再制造品和制造品同需求源下的生产决策模型的求解结果进行比较分析。
第六章,研究总结及研究方向展望。
In recent years, the huge benefits on economic and environment that remanufacturing can bring attract more and more manufacturers to recycle old items and begin to remanufacture while manufacturing new productions, manufacturing/remanufacturing hybrid system (MRHS) is formed. As remanufacturing process has many uncertainties, however, MRHS is hard to control as well as production decisions are difficult to make. Lean production, as the advanced production management and control tools, shows great superiorities in the adoption of traditional manufacturing system. How to extend the advantages to the uncertain environment of MRHS and make research on production control and decision-making are of grate significance.
This paper studies on the MRHS. Considering that not all the customers can accept the remanufactured productions as they accept the manufactured ones, the demand of remanufactured productions are different from the demand of manufactured productions. Compared to the same demand source, researching on production decision-making in different demand sources is of practical significance.
The main contents as following:
Chapter1, the research on production decision-making of MRHS is shown, problems need to be solved and points need to be improved are discussed also; on the basis of which, the main contents and significance of this paper are presented.
Chapter2, the process and characteristics of MRHS are briefly presented and the uncertainties are analyzed in the following; besides, theories about production strategy and production decision-making are basically introduced, lean production as well.
Chapter3, the factors that affecting production decision-making are discussed and the special requirements need to be considered before making production decisions are presented; the positive roles that lean production tools play on MRHS are shown, lean production strategy of MRHS based on production substitution are presented as well.
Chapter4, based on the presented production strategy, the original production decision-making model of MRHS without production substitution is extended, the model with production substitution based on lean production is developed; the optimal production decisions are solved in mathematical methods.
Chapter5, the developed model is applied in multi-period production decision-making of MRHS and the results are gotten by using Matlab, which will be compared with the results of original model.
Chapter6, overview and outlook of the research are presented.
本文以MRHS为研究对象,考虑到消费者对再制造品的接受程度存在差别,再制造品和制造品的需求往往具有差异,表现出不同的需求源。研究两种产品需求非同源背景下的生产决策问题,相比以往文献对同需求源背景下生产决策问题的研究,更具有实际意义。本文的主要研究内容如下：
第一章,综述MRHS生产问题研究现状,分析研究中存在的问题及不足,在此基础上阐述本文的研究内容及意义。
第二章,概述MRHS流程及特点并分析其不确定性；对典型生产策略、MRHS生产决策及精益生产进行理论基础分析。
第三章,分析影响MRHS生产决策制定的因素,并提出在制定生产决策时需满足的特殊要求。在此基础上,阐述精益生产管理方法在降低MRHS不确定性上发挥的积极作用；通过比较分析典型生产策略在MRHS中应用的优缺点,提出再制造品和制造品具有需求差异但允许替换销售背景下结合推动式生产的MRHS精益生产策略。
第四章,基于所提出的MRHS精益生产策略,对再制造品和制造品具有同需求源下的MRHS生产决策模型进行扩展,建立再制造品和制造品需求非同源、允许产品替换销售的MRHS生产决策的数学模型,利用数学方法证明并求解。
第五章,将建立的生产决策模型应用于某产品的MRHS多周期的生产决策中,利用Matlab进行编程及数值运算,结果与再制造品和制造品同需求源下的生产决策模型的求解结果进行比较分析。
第六章,研究总结及研究方向展望。
In recent years, the huge benefits on economic and environment that remanufacturing can bring attract more and more manufacturers to recycle old items and begin to remanufacture while manufacturing new productions, manufacturing/remanufacturing hybrid system (MRHS) is formed. As remanufacturing process has many uncertainties, however, MRHS is hard to control as well as production decisions are difficult to make. Lean production, as the advanced production management and control tools, shows great superiorities in the adoption of traditional manufacturing system. How to extend the advantages to the uncertain environment of MRHS and make research on production control and decision-making are of grate significance.
This paper studies on the MRHS. Considering that not all the customers can accept the remanufactured productions as they accept the manufactured ones, the demand of remanufactured productions are different from the demand of manufactured productions. Compared to the same demand source, researching on production decision-making in different demand sources is of practical significance.
The main contents as following:
Chapter1, the research on production decision-making of MRHS is shown, problems need to be solved and points need to be improved are discussed also; on the basis of which, the main contents and significance of this paper are presented.
Chapter2, the process and characteristics of MRHS are briefly presented and the uncertainties are analyzed in the following; besides, theories about production strategy and production decision-making are basically introduced, lean production as well.
Chapter3, the factors that affecting production decision-making are discussed and the special requirements need to be considered before making production decisions are presented; the positive roles that lean production tools play on MRHS are shown, lean production strategy of MRHS based on production substitution are presented as well.
Chapter4, based on the presented production strategy, the original production decision-making model of MRHS without production substitution is extended, the model with production substitution based on lean production is developed; the optimal production decisions are solved in mathematical methods.
Chapter5, the developed model is applied in multi-period production decision-making of MRHS and the results are gotten by using Matlab, which will be compared with the results of original model.
Chapter6, overview and outlook of the research are presented.
引文
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[2]GP.Kiesmuller. Optimal control of a one product recovery system with leadtimes[J]. Int.J.Production Economics,2003(81-82):333-340
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[4]Yongjian Li, Jian Chen,Xiaoqiang Cai.Uncapacitated production planning with multiple product types, returned product remanufacturing, and demand substitution[J]. OR Spectrum, 2006(28):98-122
[5]Karl Inderfurth. Optimal policies in hybrid manufacturing/remanufacturing systems with product substitution[J]. Int.J.Production Economics,2004(90):325-343
[6]Z.Pelin Bayindir,Nesim Erkip,Refik Gullu. Assessing the benefits of remanufacturing option under one-way substitution and capacity constraint [J]. Computers&Operations Research, 2007(34):487-514
[7]Ou Tang, Robert W.Grubbstrom,Simone Zanoni. Planned lead time determination in a make-to-order remanufacturing system [J]. Int.J.Production Economics,2007 (108):426-435
[8]Ruud Teunter,Konstantinos Kaparis,Ou Tang. Multi-product economic lot scheduling problem with separate production lines for manufacturing and remanufacturing [J]. European Journal of Operational Research,2008(191):1241-1253
[9]M.S.Barketau,T.C.E.Cheng,M.Y.Kovalyov. Batch scheduling of deteriorating reworkables[J]. European Journal of Operational Research,2008(189):1317-1326
[10]Onur Kaya. Incentive and production decisions for remanufacturing operations[J]. European Journal of Operational Research,2010(201):442-453
[11]Kibum Kim,Iksoo Song,Juyong Kim,Bongju Jeong. Supply planning model for remanufacturing system in reverse logistics environment [J]. Computers&Industrial Engineering, 2006(51):279-287
[12]Samar K.Mukhopadhyay,Huafan Ma. Joint procurement and production decisions in remanufacturing under quality and demand uncertainty[J]. Int.J.Production Economics,2009(120):5-17
[13]Jianzhi Li,Miguel Gonzalez,Yun Zhu. A hybrid simulation optimization method for production planning of dedicated remanufacturing [J]. Int.J.Production Economics,2009(117):286-301
[14]Sergio Rubio, Albert Corominas. Optimal manufacturing-remanufacturing policies in a lean production environment [J]. Computers&Industrial Engineering,2008(55):234-242
[15]赵晓敏,黄培清,骆建文.基于改进策略的混合型制造／再制造系统分析[J].中国管理科学,2007,4(15)：34-41
[16]姚国,吴茂全,洪宗友,黄敏.基于CONWIP控制的分流再制造生产系统分析[A].2009系统仿真技术及其应用学术会议论文集,2009
[17]姚国,黄敏.需求不确定的再制造生产系统分析[J].通化师范学院学报,2009,30(4)：10-12
[18]冯雪,单丽辉,王喜富,管小俊.基于供应链管理的再制造模式研究[J].2009,10(28)：121-122
[19]黄书慧.考虑再制造的多级生产计划控制研究[D].合肥：合肥工业大学,2009
[20]代颖,马祖军.制造/再制造混合系统的最优生产批量模型[J].西南交通大学学报,2006,41(1)：116-121
[21]包莉丽OEMs闭环供应链生产决策与物料计划研究[D].南京：南京航空航天大学,2007
[22]胡海菊,李勇建.考虑再制造和产品需求可替代的短生命周期产品动态批量生产计划问题[J].系统工程理论与实践,2007,12：76-84
[23]周垂日,梁樑,苟清龙,许传永,查勇.考虑产品可替换的再制造产品选择决策[J].中国管理科学,2008,2(16)：57-61
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