面向单件生产模式的调度系统研究
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摘要
由于个性化需求的发展,多品种、小批量已逐渐成为主流生产方式。随着这种生产方式的转变,企业在工作效率和应变能力等方面承受着更大的压力。因此,研究一套科学有效的调度方法和相应的计算机调度系统对提高企业的工作效率和应变能力具有非常重要的作用。
锅炉压力容器生产企业的生产模式是面向工程的生产,属于单件生产。本文根据锅炉压力容器生产企业的特点,建立了单件小批量生产调度的数学模型,探索出了单件生产车间的调度算法,对单件生产的调度系统进行了系统建模,研究开发出了一套车间生产调度的原型系统,并对该系统与MES及其它系统的集成技术进行了研究。
在理论方面,总结了现今调度问题的各种建模、求解方法与策略。从调度可行性出发,在保证交货期的前提下提出了基于优先规则的排产算法,针对作业控制层的要求,给出了相应的调度策略,以甘特图、报表等形式跟踪加工执行的状况,形成生产过程的闭环控制。这些都为解决车间一级的作业调度问题提供了有效的解决方案。
详细研究了面向单件生产模式的车间生产调度问题,并对调度理论作了一个深入细致的研究,通过在调度过程中的资源约束条件,对比较复杂的车间调度问题的进行优化,利用遗传算法、结合规则式的方法对车间生产调度任务进行了分配。阐述了基于单件小批量模式的车间生产调度系统的设计思想,利用具体建模工具对该系统进行分析和建模,详细介绍了系统的功能模块与关键技术,开发了较为实用的生产调度原型系统。该系统已在企业运行,取得了良好的收益,提高了企业的生产效益,降低了生产成本。
As the demand for the development of personalized, Multi-species, small quantities have gradually become the main mode of production. With this change in production methods, the enterprise undertakes pressure in efficiency and adaptability. Therefore, it is very important to develop a set of effective scheduling system in order to improve the efficiency and ability to solve problem.
The production model of vessel and pressure enterprise is oriented to engneering(OTE), Belonging to a single production. In this paper, according to the characteristic of vessel and pressure enterprise, set up the mathematical model of job shop scheduling. To explore the scheduling algorithm of job shop, and set up the system model of job shop system, developed a scheduling system, and researched the integration of job shop system with MES and other systems.
In theory, three aspects on Job-shop scheduling-modeling, scheduling methods and strategies are summed. Then by considering the feasibility of scheduling, the backward scheduling algorithm based on priority dispatcher rules is put forward to ensure the delivery time. And according to the request of production control layer, this paper proposes the scheduling strategies and tracks processing execution with the form of Gantt chart, report and so on, which forms the closed-loop control in production. These can solve effectively the problem of Job-shop production scheduling.
And researching the scheduling of job shop problem based on the small batch, then, made a deep research of Scheduling theory. Through the restrict condition of resource in scheduling, to optimize complex problem in the scheduling, and distribute the task scheduling in job shop through method of the genetic algorithms and Heuristic rule. Then, this paper discussed the design scheme of production scheduling system in the small batch workshop. The system is analyzed and designed by modeling tools. The function modules and the realizing technologies are introduced in detail. A prototype system is developed. The system has been used in the enterprise, and have achieved good effect, greatly improved the effectiveness of the enterprise, reducing production costs.
锅炉压力容器生产企业的生产模式是面向工程的生产,属于单件生产。本文根据锅炉压力容器生产企业的特点,建立了单件小批量生产调度的数学模型,探索出了单件生产车间的调度算法,对单件生产的调度系统进行了系统建模,研究开发出了一套车间生产调度的原型系统,并对该系统与MES及其它系统的集成技术进行了研究。
在理论方面,总结了现今调度问题的各种建模、求解方法与策略。从调度可行性出发,在保证交货期的前提下提出了基于优先规则的排产算法,针对作业控制层的要求,给出了相应的调度策略,以甘特图、报表等形式跟踪加工执行的状况,形成生产过程的闭环控制。这些都为解决车间一级的作业调度问题提供了有效的解决方案。
详细研究了面向单件生产模式的车间生产调度问题,并对调度理论作了一个深入细致的研究,通过在调度过程中的资源约束条件,对比较复杂的车间调度问题的进行优化,利用遗传算法、结合规则式的方法对车间生产调度任务进行了分配。阐述了基于单件小批量模式的车间生产调度系统的设计思想,利用具体建模工具对该系统进行分析和建模,详细介绍了系统的功能模块与关键技术,开发了较为实用的生产调度原型系统。该系统已在企业运行,取得了良好的收益,提高了企业的生产效益,降低了生产成本。
As the demand for the development of personalized, Multi-species, small quantities have gradually become the main mode of production. With this change in production methods, the enterprise undertakes pressure in efficiency and adaptability. Therefore, it is very important to develop a set of effective scheduling system in order to improve the efficiency and ability to solve problem.
The production model of vessel and pressure enterprise is oriented to engneering(OTE), Belonging to a single production. In this paper, according to the characteristic of vessel and pressure enterprise, set up the mathematical model of job shop scheduling. To explore the scheduling algorithm of job shop, and set up the system model of job shop system, developed a scheduling system, and researched the integration of job shop system with MES and other systems.
In theory, three aspects on Job-shop scheduling-modeling, scheduling methods and strategies are summed. Then by considering the feasibility of scheduling, the backward scheduling algorithm based on priority dispatcher rules is put forward to ensure the delivery time. And according to the request of production control layer, this paper proposes the scheduling strategies and tracks processing execution with the form of Gantt chart, report and so on, which forms the closed-loop control in production. These can solve effectively the problem of Job-shop production scheduling.
And researching the scheduling of job shop problem based on the small batch, then, made a deep research of Scheduling theory. Through the restrict condition of resource in scheduling, to optimize complex problem in the scheduling, and distribute the task scheduling in job shop through method of the genetic algorithms and Heuristic rule. Then, this paper discussed the design scheme of production scheduling system in the small batch workshop. The system is analyzed and designed by modeling tools. The function modules and the realizing technologies are introduced in detail. A prototype system is developed. The system has been used in the enterprise, and have achieved good effect, greatly improved the effectiveness of the enterprise, reducing production costs.
引文
[1]潘家招.现代生产管理学[M].北京:清华大学出版社,1994
[2]齐二石,朱秀文,柯桢.生产与运作管理教程[M].北京:清华大学出版社,2006
[3]赵晓波,周兆英.丰田生产系统特性分析[J].中国机械工程,1997,8(1):62-66
[4]邹海锋.面向多品种小批量生产的MES中作业计划的研究[D].广东工业大学,2005,5
[5]姬永清.多品种单件小批生产模式下生产计划与调度问题研究[D].南京航空航天大学,2005,3
[6]安进.车间生产批量优化调度研究[D].南京航空航天大学,2005,12
[7]黄学文.制造执行系统(MES)的研究和应用[D].大连理工大学,2003,5
[8]牛兴华等.一种独立制造岛作业计划的编制方法[D].天津理工学院学报 1999,15(2):18-23
[9]范路桥,常会友,朱旭东.作业调度问题研究[J].现代计算机,2004(187):21-25
[10]周志诚.运筹学教程[M].上海:立信会计图书用品社,1988,7
[11]Jeffcoat,David E,Robert L,Bulfin.Simulated annealing for resource- constrained scheduling[J].European Journal of Operational research,1993,70:43-51
[12]Momazeri M,Van Wassehove L.N.Analysis of scheduling rules of an FMS[J].International Journal Product Research,1990,28(4):785-790
[13]李士勇.蚁群算法及其应用[M].哈尔滨工业大学出版社,2004,9
[14]Glover F.Paths for Integer Programming and Links to Artificial Intelligence[J].Compute Operations,1986,13(5):533-549
[15]Mishra,S.,A hybrid least square-fuzzy bacteria foraging strategy for harmonic estimation[J],IEEE Trans.Evol.Comput.,Vol.9,No.1,61-73,Feb.2005
[16]周明 孙树栋.遗传算法原理及应用[M].北京:国防工业出版社,2005,3
[17]路正南 张怀胜.运筹学基础教程[M].中国科技大学出版社,2004,8
[18]Goldberg D E.Genetic Algorithms in Search,Optimization and Machine Learning[D].Addison-Wesley,1989
[19]曾佑琴.面向中小配套型企业制造执行系统的调度算法研究[D].重庆大学,2005,5
[20]Sun D,Batta R.LinL.Effective Job Shop Scheduling Algorithm through Active Chain Manipulation[D].Computers Ops.Res.1995,22(2):159-172
[21]Ann,B.-H.Hyun.Single facility multi-class job scheduling,Computer and Operations Research[D]vol.17,1989:265-272
[22]Psaraftis,H.N.A dynamic programming approach for sequencing groups of identical jobs[D].Operations Research,1980:1347-1359
[23]玄光男 程润伟.遗传算法与工程优化[M].北京:清华大学出版社,2004,1
[24]Michale Wicz,Z.,Genetic Algorithm + Data Structure = Evolutionary Programs[D].3rd edition,Springer-Verlag,New York.1996
[25]王海英.有交货期的非标准Job-shop调度问题算法研究[D].哈尔滨理工业大学,2001
[26]康宁,王凤儒,刘丕娥等.有交货期的单件车间调度问题的逆序算法[D].系统工程理论与实践,1999,19(12):25-30
[27]龚伟.制造执行系统中生产作业计划与调度技术研究[D].哈尔滨工业大学,2006,6
[28]艾兴海,杨建军.基于制造执行系统的调度统-数据模型[J].中国制造业信息化,2005,34(6):82-84
[29]钟远晖..NET平台下企业生产管理软件系统的研究和开发[D].东南大学,2004,3
[30]吴培栋.实际生产系统中考虑任务相关性的作业计划规则调度算法研究与实现[D].武汉科技大学,2005,6
[31]Yamada,T.and R.Nakano.A genetic algorithm applicable to large-scale job-shop problem[D].Elsevier Science Publishers,1992:281-290
[32]Kenneth N.McKay,Vincent C.S.Wiers.Planning,scheduling and dispatching tasks in production control[J].Cogn Tech Work,2003,5:82-93
[33]许文砚.基于单件小批生产模式的车间调度方法研究和系统开发[D].南京航空航天大学,2005,3
[34]初红艳,费仁元.基于UML的可重组制造系统的调度系统建模[J].制造技术与机床,2005,(8):107-110
[35]苏贵洋,黄穗,何丽,倪春雨等.ASRNET网络编程从基础到实践[M].北京:电子工业出版社,2007.6:
[36]Marlene Theriault.Oracle9i DBA基础教程[M].北京:机械出版社,2003:29-391
[37]殷泰晖,张强,杨豹等.C#编程从基础到实践[M].北京:电子工业出版社,2006,5
[38]饶运清.MES-面向制造车间的实时信息系统[J].信息技术,2002(2):61-62
[39]MESA International.Controls Definition & MES to Controls Data Flow Possibilities[R].MESA International White Paper Number 3,1995:1-8
[40]MESA International.MES Explained:A High Level Vision[R].MESA International White Paper Number 6,1997,7:1-8
[41]王万雷.制造执行系统(MES)若干关键技术研究[D].大连理工大学,2005,10
[42]吕文彦.基于规则的可重入生产系统调度问题研究[D].大连理工大学,2005,9
[43]程控,革扬.MRPII/ERP原理与应用[M].北京:清华大学出版社,2006,3
[44]胡鑫.MES与ERP系统集成接口的研究与设计[D].湖南大学,2006,11
[45]A.Liu,L.Bass,M.Klein.Analyzing enterprise remoting systems using quality attribute design primitives technical note.CMU/SEI-2001-TN-025,Carnegie Mellon University,2001:361-366
[46]Blom,G.,Probability and Statistics:Theory and Applications[D].Discrete Applied mathematics,1996
[47]王书锋,邹益仁.车间作业调度(JSSP)技术问题简明综述[J].系统工程理论与实践,2003.1(1):49-50
[48]吴培栋.实际生产系统中考虑任务相关性的作业计划规则调度算法研究与实现[D].武汉科技大学,2005,6
[49]周华,刘民,吴澄.基于遗传算法和代理的集成调度系统框架[J].计算机集成制造系统,2005,10(10):1414-1418
[50]于海滨,朱云龙.可集成的制造执行系统.计算机集成制造系统[J].2000,6(6):1-6
[51]MESA International.MES functionalities & MRP to MES date flow Possibilities[R].MESA International White Paper Number 2,1997
[2]齐二石,朱秀文,柯桢.生产与运作管理教程[M].北京:清华大学出版社,2006
[3]赵晓波,周兆英.丰田生产系统特性分析[J].中国机械工程,1997,8(1):62-66
[4]邹海锋.面向多品种小批量生产的MES中作业计划的研究[D].广东工业大学,2005,5
[5]姬永清.多品种单件小批生产模式下生产计划与调度问题研究[D].南京航空航天大学,2005,3
[6]安进.车间生产批量优化调度研究[D].南京航空航天大学,2005,12
[7]黄学文.制造执行系统(MES)的研究和应用[D].大连理工大学,2003,5
[8]牛兴华等.一种独立制造岛作业计划的编制方法[D].天津理工学院学报 1999,15(2):18-23
[9]范路桥,常会友,朱旭东.作业调度问题研究[J].现代计算机,2004(187):21-25
[10]周志诚.运筹学教程[M].上海:立信会计图书用品社,1988,7
[11]Jeffcoat,David E,Robert L,Bulfin.Simulated annealing for resource- constrained scheduling[J].European Journal of Operational research,1993,70:43-51
[12]Momazeri M,Van Wassehove L.N.Analysis of scheduling rules of an FMS[J].International Journal Product Research,1990,28(4):785-790
[13]李士勇.蚁群算法及其应用[M].哈尔滨工业大学出版社,2004,9
[14]Glover F.Paths for Integer Programming and Links to Artificial Intelligence[J].Compute Operations,1986,13(5):533-549
[15]Mishra,S.,A hybrid least square-fuzzy bacteria foraging strategy for harmonic estimation[J],IEEE Trans.Evol.Comput.,Vol.9,No.1,61-73,Feb.2005
[16]周明 孙树栋.遗传算法原理及应用[M].北京:国防工业出版社,2005,3
[17]路正南 张怀胜.运筹学基础教程[M].中国科技大学出版社,2004,8
[18]Goldberg D E.Genetic Algorithms in Search,Optimization and Machine Learning[D].Addison-Wesley,1989
[19]曾佑琴.面向中小配套型企业制造执行系统的调度算法研究[D].重庆大学,2005,5
[20]Sun D,Batta R.LinL.Effective Job Shop Scheduling Algorithm through Active Chain Manipulation[D].Computers Ops.Res.1995,22(2):159-172
[21]Ann,B.-H.Hyun.Single facility multi-class job scheduling,Computer and Operations Research[D]vol.17,1989:265-272
[22]Psaraftis,H.N.A dynamic programming approach for sequencing groups of identical jobs[D].Operations Research,1980:1347-1359
[23]玄光男 程润伟.遗传算法与工程优化[M].北京:清华大学出版社,2004,1
[24]Michale Wicz,Z.,Genetic Algorithm + Data Structure = Evolutionary Programs[D].3rd edition,Springer-Verlag,New York.1996
[25]王海英.有交货期的非标准Job-shop调度问题算法研究[D].哈尔滨理工业大学,2001
[26]康宁,王凤儒,刘丕娥等.有交货期的单件车间调度问题的逆序算法[D].系统工程理论与实践,1999,19(12):25-30
[27]龚伟.制造执行系统中生产作业计划与调度技术研究[D].哈尔滨工业大学,2006,6
[28]艾兴海,杨建军.基于制造执行系统的调度统-数据模型[J].中国制造业信息化,2005,34(6):82-84
[29]钟远晖..NET平台下企业生产管理软件系统的研究和开发[D].东南大学,2004,3
[30]吴培栋.实际生产系统中考虑任务相关性的作业计划规则调度算法研究与实现[D].武汉科技大学,2005,6
[31]Yamada,T.and R.Nakano.A genetic algorithm applicable to large-scale job-shop problem[D].Elsevier Science Publishers,1992:281-290
[32]Kenneth N.McKay,Vincent C.S.Wiers.Planning,scheduling and dispatching tasks in production control[J].Cogn Tech Work,2003,5:82-93
[33]许文砚.基于单件小批生产模式的车间调度方法研究和系统开发[D].南京航空航天大学,2005,3
[34]初红艳,费仁元.基于UML的可重组制造系统的调度系统建模[J].制造技术与机床,2005,(8):107-110
[35]苏贵洋,黄穗,何丽,倪春雨等.ASRNET网络编程从基础到实践[M].北京:电子工业出版社,2007.6:
[36]Marlene Theriault.Oracle9i DBA基础教程[M].北京:机械出版社,2003:29-391
[37]殷泰晖,张强,杨豹等.C#编程从基础到实践[M].北京:电子工业出版社,2006,5
[38]饶运清.MES-面向制造车间的实时信息系统[J].信息技术,2002(2):61-62
[39]MESA International.Controls Definition & MES to Controls Data Flow Possibilities[R].MESA International White Paper Number 3,1995:1-8
[40]MESA International.MES Explained:A High Level Vision[R].MESA International White Paper Number 6,1997,7:1-8
[41]王万雷.制造执行系统(MES)若干关键技术研究[D].大连理工大学,2005,10
[42]吕文彦.基于规则的可重入生产系统调度问题研究[D].大连理工大学,2005,9
[43]程控,革扬.MRPII/ERP原理与应用[M].北京:清华大学出版社,2006,3
[44]胡鑫.MES与ERP系统集成接口的研究与设计[D].湖南大学,2006,11
[45]A.Liu,L.Bass,M.Klein.Analyzing enterprise remoting systems using quality attribute design primitives technical note.CMU/SEI-2001-TN-025,Carnegie Mellon University,2001:361-366
[46]Blom,G.,Probability and Statistics:Theory and Applications[D].Discrete Applied mathematics,1996
[47]王书锋,邹益仁.车间作业调度(JSSP)技术问题简明综述[J].系统工程理论与实践,2003.1(1):49-50
[48]吴培栋.实际生产系统中考虑任务相关性的作业计划规则调度算法研究与实现[D].武汉科技大学,2005,6
[49]周华,刘民,吴澄.基于遗传算法和代理的集成调度系统框架[J].计算机集成制造系统,2005,10(10):1414-1418
[50]于海滨,朱云龙.可集成的制造执行系统.计算机集成制造系统[J].2000,6(6):1-6
[51]MESA International.MES functionalities & MRP to MES date flow Possibilities[R].MESA International White Paper Number 2,1997