大规模定制关键问题建模与应用研究
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摘要
随着人们生活水平的提高和消费理念的转变，家具的客户需求呈现多样化和个性化的趋势，这种转变引起制造企业的竞争环境发生了巨大的变化，表现在产品生命周期缩短、多品种小批量生产比例增大和市场的动态多变。为了适应竞争环境，企业必然选择定制生产模式。定制生产模式根据客户的具体要求有针对性地进行生产，充分满足客户的个性化需求，但是，与大批量生产模式相比，定制生产模式降低了生产效率，影响企业的效益，进而又将阻碍定制生产模式的推广应用。因此，探求提高定制生产模式的生产效率的方法和途径是一个具有理论意义和应用价值的课题。
本文相关研究针对技术水平较低的中小型制造业，通过将企业员工，与机器组成动态的柔性生产线，进行统一的生产调度管理和改造，实现了大规模定制生产，对其它中小型企业的大规模定制也有重要的参考价值和借鉴作用。
板式家具大规模定制的研究现在主要集中在家具快速设计和板材套裁优化两个方面。至于生产过程的优化，即板式家具大规模定制的生产调度优化还未见有专门的论述。
在家具快速设计方面：已有多个设计软件，但这些软件主要注重产品外观的显示和模块化设计。用虚拟现实来展现设计师的设计，由消费者判断设计是否符合自己的需求。用模块化提高设计速度。应用中发现两个问题：
一是用户需求的捕捉主要靠设计师和用户沟通来实现，虚拟现实的效果和实际效果存在较大错别，往往客户签字认可了的设计，生产完成在客户家安装后，客户并不喜欢，这样，定制家具设计就变成了一个遗憾的设计。如何正确捕捉客户需求，就成为定制家具设计的重要研究课题。
二是产品设计和工艺设计分离，在设计师完成产品设计后，还要花时间进行工艺设计，加长了定制家具制造时间，同时易于出错。如何实现产品设计、工艺设计的并行一体化，也是定制家具设计和生产中的重要研究课题。
在板材套裁优化方面，本身就是一个NP难问题。板材在定制家具成本中占45%以上的比例，进一步提高套裁优化效果是一个长期的研究改进课题。同时目前的相关研究还没有达到直接实现数控加工控制。
板式家具大规模定制的生产调度优化需要有适应大规模定制的信息平台，大规模定制是一种信息化制造的生产方式，订单个性化信息的及时处理，以及定制产品在生产企业内部和企业间的跟踪控制能力和信息共享程度，是决定大规模定制生产能否实施的关键因素。但是现在定制家具企业看到的只是能带来订单的网站平台，能做数据统计的仓库管理平台，而缺乏一个综合信息平台。如何建立定制家具企业的综合信息平台，简易地显示各类统计数据，是定制家具企业急需解决的重要课题。
针对定制家具大规模定制研究中上述重要课题，本文主要做了如下工作：研究基于功能粒度模型的快速设计系统的建模方法和真实感虚拟现实的实现技术；研究基于并行工程和知识设计数据库，生成产品全生命周期的各类所需数据；针对大批量定制生产方式的批生产调度问题，研究实时生产数据智能分批建模，粒子群多目标优化算法的应用与改进，以及优化过程的计算机实时可视化问题；研究比普通矩形布局问题难度更高的“一刀切”的板材排料优化算法，研究对非数控裁板机和数控裁板机的柔性制造系统改造；研究如何直观地、集中地显示出订单与时间相关的各类统计信息，研究其可视化表达方法，使生产管理人员能直观地了解跟踪的各类生产信息，进行动态调整。
论文主要创新点如下：
(1)采用功能粒度分析和模糊推理方法建立动态的功能单元模块数据库，实现客户需求的快速捕捉和设计数据库的聚类搜索。结合单元功能模块、特征建模、空间数据模型与知识化表达的建模结构，实现基于CAD/CAPP/CAM并行工程的板式家具快速设计系统。
(2)针对柔性生产线的多目标优化批调度问题，提出了平行机继列分批调度模式。设计了自适应元胞自动机变异粒子群多目标优化算法，其创新点在于使用元胞自动机进行变异搜索，提高了寻优能力。在采用此算法做单目标优化效果测试时，优于现有文献的结果（采用标准30平行机调度数据进行比较测试，30%的概率找到了最优解）。并利用瓶颈分解法,有效降低了多目标优化问题的维数，进行了各种组合参数设置的比较研究，找出了较优的基于黄金分割的权值设置参数，避免应用中参数设置的随意性，达到实用。
(3)研究了大规模多品种小批量的矩形件排样优化问题，针对其“一刀切”的特殊生产工艺要求，通过对待切板自动生成两个不同的编号：横切编号和纵切编号的方法，采用面积、长度、宽度启发的多种群蚁群算法，避免了单因素启发的不合理布局，做到了“生成即可行”，经比与单因素蚁群启发相比较，多种群蚁群算法寻优能力强，主要表现为：最大利用率最高；多次寻优的最大利用率变化区间小。研究并实现了板式家具的柔性制造。
(4)提出了动态时间二维界面方法，使用矩阵布局界面，实现了基于时间属性动态显示订单各种统计信息，直接表达对应生产工序的多维离散数据的统计信息科学可视化。解决了单一传统界面显示数据量少、订单状态显示不充分的缺陷，实现大规模定制的订单全生命周期的动态跟踪和动态调整的能力。
This study aimed at small and medium manufacturing enterprises, by employees andmachines to composed of dynamic, flexible production line, unified batch productionscheduling and Flexible Manufacturing transformation, for other small and mediumenterprises’s MC is also an important reference value and reference.
Furniture mass customization of existing research focused on furniture's rapid design,board cutting layout optimization. But for the furniture production process optimization,that furniture mass customization production scheduling optimize, there is no relateddiscussion and research. there are some furniture rapid design software, but the mainfocus of these software is products display appearance and modular design. using virtualreality to show the designer's design, let the consumer to determine whether the design fitstheir needs. modular design to increased speed. Applications found two problems:
First, designers and users, mainly through communication, to capture userrequirements, virtual reality display and there is a big difference between the actual results,often the customer signed off the design, after installation, customers do not like look, sothat custom furniture design becomes a regrettable design. How to properly capturecustomer’s needs, has become an important research topic of custom furniture design.
Second, product design and process design is separation, the designer after thecompletion of product design, but also take time to process design, custom furniture longertime and error-prone. how product design, process design parallel, integration, it is animportant research topic of custom furniture design and production.
Board cutting layout optimization is a NP-hard problem. In the cost of custom PanelFurniture for more than45%is boards cost, further improve the optimization effect is asubject of long-term research improvements, and the current research has not yet reacheddirectly implement CNC control.
Furniture mass customization production scheduling optimize needed can adapt to information platform of mass customization, Mass customization is aninformation-oriented manufacturing production, orders information processing in a timelymanner, and in the production of customized products within the enterprise and betweenenterprises tracking control and information sharing, is to determine the success of masscustomization implementation's key factors.
For study in these important issues of Furniture mass customization, this papercomplete the following work: rapid design system modeling theory based on functionalgranularity’s model and implementation of realistic virtual reality technology; based onengineering and knowledge database, the paper studies the generation of various types ofrequired data on the product’s life cycle. research mass customization batch productionscheduling problems, specifically, studies issues on real-time data modeling,multi-objective particle swarm optimization algorithm, and computer optimization problemof real-time visualization; Also studied is the “Guilloting Cutting” optimization layout,which is more difficult than the regular rectangular layout, and flexible manufacturingsystem reformation for the both CNC and non-CNC cutting machines; The research on thedirect and concentrated display of information related to time as well as the methods ofvisualization can benefit managing personnel in their knowledge of the production process.
The article has various following creative points:
Firstly, using functional granularity analysis and fuzzy reasoning to build a dynamicfunctional modules's database, to achieve the rapid capture customer needs and searchdesign database. in reaction to the inability of dynamic modeling concurrent engineering,and rapid design in furniture design software, the combination of functional modular,feature modeling and spatial data models has achieved CAD/CAPP/CAM concurrentengineering and panel furniture's rapid design.
Secondly, by analyzing production processes, the article proposes parallel machineserial-batching scheduling, in reaction to the problems of flexible production lines'multi-objective optimization of batch scheduling. The design is an adaptive Cellular Automata Variation multi-objective particle swarm optimization algorithm, which, whenused for the single objective test, is better than the current records (For comparison,30%of the probability finds the optimal solution, using parallel machine scheduling withstandard30set of data). The innovation point is using cellular automata to improve theoptimization search ability. Also, using the bottleneck decomposition method, effectivelyreduces the multi-objective optimization problem's dimension. and carrying out variouscombinations of parameters' comparative study, the proposal finds out the optimum basedon the parameters from golden section theory, thus reducing randomness, achieving highlevel of practical.
Thirdly, in order to solve problems in mass customization furniture corporation'smany varieties of small quantities of cutting optimization layout, meeting the “GuillotineCutting” and its special production process requirements, the proposal generates twodifferent numbers to all boards automatically: horizontal cutting number and verticalcutting number, inspired by area, length and width, and multiple colony ant algorithm, toavoid unreasonable layout, thus achieving that "what is just generated can be executed".Compared with single factor colony ant algorithm through application by multiplecompanies, multi-swarm optimization capability is found to be superior mainly as thehighest maximum utilization, and the smallest changes in several range searching ofmaximum utilization. Studied and implemented panel furniture flexible manufacturing.
Finally, this paper proposes algorithm for Two-dimensional dynamic timepulling interface, using the grid layout, and implementing the scientific visualization ofmultidimensional discrete data and statistics information of time-based property or otherproperty (such as spatial attributes). This solves traditional information systems’ problemsof scattered resources, poor data sharing, insufficient interface data display, and inability ofdisplaying various statistical data visualization in a singular interface. The tracking fromorder, product design, manufacturing processes and the supply chain and coordination isrealized through various information subsystems, a structured, economical, practical, and intelligent network of visualization, and high integration of information resources.
This study aimed at small and medium manufacturing enterprises, by employees andmachines to composed of dynamic, flexible production line, unified batch productionscheduling and Flexible Manufacturing transformation, for other small and mediumenterprises’s MC is also an important reference value and reference.
本文相关研究针对技术水平较低的中小型制造业，通过将企业员工，与机器组成动态的柔性生产线，进行统一的生产调度管理和改造，实现了大规模定制生产，对其它中小型企业的大规模定制也有重要的参考价值和借鉴作用。
板式家具大规模定制的研究现在主要集中在家具快速设计和板材套裁优化两个方面。至于生产过程的优化，即板式家具大规模定制的生产调度优化还未见有专门的论述。
在家具快速设计方面：已有多个设计软件，但这些软件主要注重产品外观的显示和模块化设计。用虚拟现实来展现设计师的设计，由消费者判断设计是否符合自己的需求。用模块化提高设计速度。应用中发现两个问题：
一是用户需求的捕捉主要靠设计师和用户沟通来实现，虚拟现实的效果和实际效果存在较大错别，往往客户签字认可了的设计，生产完成在客户家安装后，客户并不喜欢，这样，定制家具设计就变成了一个遗憾的设计。如何正确捕捉客户需求，就成为定制家具设计的重要研究课题。
二是产品设计和工艺设计分离，在设计师完成产品设计后，还要花时间进行工艺设计，加长了定制家具制造时间，同时易于出错。如何实现产品设计、工艺设计的并行一体化，也是定制家具设计和生产中的重要研究课题。
在板材套裁优化方面，本身就是一个NP难问题。板材在定制家具成本中占45%以上的比例，进一步提高套裁优化效果是一个长期的研究改进课题。同时目前的相关研究还没有达到直接实现数控加工控制。
板式家具大规模定制的生产调度优化需要有适应大规模定制的信息平台，大规模定制是一种信息化制造的生产方式，订单个性化信息的及时处理，以及定制产品在生产企业内部和企业间的跟踪控制能力和信息共享程度，是决定大规模定制生产能否实施的关键因素。但是现在定制家具企业看到的只是能带来订单的网站平台，能做数据统计的仓库管理平台，而缺乏一个综合信息平台。如何建立定制家具企业的综合信息平台，简易地显示各类统计数据，是定制家具企业急需解决的重要课题。
针对定制家具大规模定制研究中上述重要课题，本文主要做了如下工作：研究基于功能粒度模型的快速设计系统的建模方法和真实感虚拟现实的实现技术；研究基于并行工程和知识设计数据库，生成产品全生命周期的各类所需数据；针对大批量定制生产方式的批生产调度问题，研究实时生产数据智能分批建模，粒子群多目标优化算法的应用与改进，以及优化过程的计算机实时可视化问题；研究比普通矩形布局问题难度更高的“一刀切”的板材排料优化算法，研究对非数控裁板机和数控裁板机的柔性制造系统改造；研究如何直观地、集中地显示出订单与时间相关的各类统计信息，研究其可视化表达方法，使生产管理人员能直观地了解跟踪的各类生产信息，进行动态调整。
论文主要创新点如下：
(1)采用功能粒度分析和模糊推理方法建立动态的功能单元模块数据库，实现客户需求的快速捕捉和设计数据库的聚类搜索。结合单元功能模块、特征建模、空间数据模型与知识化表达的建模结构，实现基于CAD/CAPP/CAM并行工程的板式家具快速设计系统。
(2)针对柔性生产线的多目标优化批调度问题，提出了平行机继列分批调度模式。设计了自适应元胞自动机变异粒子群多目标优化算法，其创新点在于使用元胞自动机进行变异搜索，提高了寻优能力。在采用此算法做单目标优化效果测试时，优于现有文献的结果（采用标准30平行机调度数据进行比较测试，30%的概率找到了最优解）。并利用瓶颈分解法,有效降低了多目标优化问题的维数，进行了各种组合参数设置的比较研究，找出了较优的基于黄金分割的权值设置参数，避免应用中参数设置的随意性，达到实用。
(3)研究了大规模多品种小批量的矩形件排样优化问题，针对其“一刀切”的特殊生产工艺要求，通过对待切板自动生成两个不同的编号：横切编号和纵切编号的方法，采用面积、长度、宽度启发的多种群蚁群算法，避免了单因素启发的不合理布局，做到了“生成即可行”，经比与单因素蚁群启发相比较，多种群蚁群算法寻优能力强，主要表现为：最大利用率最高；多次寻优的最大利用率变化区间小。研究并实现了板式家具的柔性制造。
(4)提出了动态时间二维界面方法，使用矩阵布局界面，实现了基于时间属性动态显示订单各种统计信息，直接表达对应生产工序的多维离散数据的统计信息科学可视化。解决了单一传统界面显示数据量少、订单状态显示不充分的缺陷，实现大规模定制的订单全生命周期的动态跟踪和动态调整的能力。
This study aimed at small and medium manufacturing enterprises, by employees andmachines to composed of dynamic, flexible production line, unified batch productionscheduling and Flexible Manufacturing transformation, for other small and mediumenterprises’s MC is also an important reference value and reference.
Furniture mass customization of existing research focused on furniture's rapid design,board cutting layout optimization. But for the furniture production process optimization,that furniture mass customization production scheduling optimize, there is no relateddiscussion and research. there are some furniture rapid design software, but the mainfocus of these software is products display appearance and modular design. using virtualreality to show the designer's design, let the consumer to determine whether the design fitstheir needs. modular design to increased speed. Applications found two problems:
First, designers and users, mainly through communication, to capture userrequirements, virtual reality display and there is a big difference between the actual results,often the customer signed off the design, after installation, customers do not like look, sothat custom furniture design becomes a regrettable design. How to properly capturecustomer’s needs, has become an important research topic of custom furniture design.
Second, product design and process design is separation, the designer after thecompletion of product design, but also take time to process design, custom furniture longertime and error-prone. how product design, process design parallel, integration, it is animportant research topic of custom furniture design and production.
Board cutting layout optimization is a NP-hard problem. In the cost of custom PanelFurniture for more than45%is boards cost, further improve the optimization effect is asubject of long-term research improvements, and the current research has not yet reacheddirectly implement CNC control.
Furniture mass customization production scheduling optimize needed can adapt to information platform of mass customization, Mass customization is aninformation-oriented manufacturing production, orders information processing in a timelymanner, and in the production of customized products within the enterprise and betweenenterprises tracking control and information sharing, is to determine the success of masscustomization implementation's key factors.
For study in these important issues of Furniture mass customization, this papercomplete the following work: rapid design system modeling theory based on functionalgranularity’s model and implementation of realistic virtual reality technology; based onengineering and knowledge database, the paper studies the generation of various types ofrequired data on the product’s life cycle. research mass customization batch productionscheduling problems, specifically, studies issues on real-time data modeling,multi-objective particle swarm optimization algorithm, and computer optimization problemof real-time visualization; Also studied is the “Guilloting Cutting” optimization layout,which is more difficult than the regular rectangular layout, and flexible manufacturingsystem reformation for the both CNC and non-CNC cutting machines; The research on thedirect and concentrated display of information related to time as well as the methods ofvisualization can benefit managing personnel in their knowledge of the production process.
The article has various following creative points:
Firstly, using functional granularity analysis and fuzzy reasoning to build a dynamicfunctional modules's database, to achieve the rapid capture customer needs and searchdesign database. in reaction to the inability of dynamic modeling concurrent engineering,and rapid design in furniture design software, the combination of functional modular,feature modeling and spatial data models has achieved CAD/CAPP/CAM concurrentengineering and panel furniture's rapid design.
Secondly, by analyzing production processes, the article proposes parallel machineserial-batching scheduling, in reaction to the problems of flexible production lines'multi-objective optimization of batch scheduling. The design is an adaptive Cellular Automata Variation multi-objective particle swarm optimization algorithm, which, whenused for the single objective test, is better than the current records (For comparison,30%of the probability finds the optimal solution, using parallel machine scheduling withstandard30set of data). The innovation point is using cellular automata to improve theoptimization search ability. Also, using the bottleneck decomposition method, effectivelyreduces the multi-objective optimization problem's dimension. and carrying out variouscombinations of parameters' comparative study, the proposal finds out the optimum basedon the parameters from golden section theory, thus reducing randomness, achieving highlevel of practical.
Thirdly, in order to solve problems in mass customization furniture corporation'smany varieties of small quantities of cutting optimization layout, meeting the “GuillotineCutting” and its special production process requirements, the proposal generates twodifferent numbers to all boards automatically: horizontal cutting number and verticalcutting number, inspired by area, length and width, and multiple colony ant algorithm, toavoid unreasonable layout, thus achieving that "what is just generated can be executed".Compared with single factor colony ant algorithm through application by multiplecompanies, multi-swarm optimization capability is found to be superior mainly as thehighest maximum utilization, and the smallest changes in several range searching ofmaximum utilization. Studied and implemented panel furniture flexible manufacturing.
Finally, this paper proposes algorithm for Two-dimensional dynamic timepulling interface, using the grid layout, and implementing the scientific visualization ofmultidimensional discrete data and statistics information of time-based property or otherproperty (such as spatial attributes). This solves traditional information systems’ problemsof scattered resources, poor data sharing, insufficient interface data display, and inability ofdisplaying various statistical data visualization in a singular interface. The tracking fromorder, product design, manufacturing processes and the supply chain and coordination isrealized through various information subsystems, a structured, economical, practical, and intelligent network of visualization, and high integration of information resources.
This study aimed at small and medium manufacturing enterprises, by employees andmachines to composed of dynamic, flexible production line, unified batch productionscheduling and Flexible Manufacturing transformation, for other small and mediumenterprises’s MC is also an important reference value and reference.
引文
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