基于遗传算法的车间设备布局问题研究
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摘要
在全球制造业竞争日益激烈的今天，越来越多的工程设计人员意识到车间设备布局对整个制造系统的重要性。车间布局的优劣对于一个新建立的或改造的车间物流是否畅通、设备操作及维修是否方便和场地面积的使用率等都起着重要作用，是影响企业总体效益的重要因素之一。传统的车间设备布局主要依靠设计者的经验以及定性设计为主，缺乏科学定量的问题描述和相应的解决办法，不仅成本高，而且周期长。本论文以某机械加工车间为主要研究对象，对车间设备布局优化模型设计及其算法进行相关研究，主要做了以下工作：
(1)对国内外关于车间设备布局问题的相关研究进行了详细的分析和综述，阐述了车间设备布局的基本理论。
(2)对某制造企业机械加工车间设备布局及生产物流情况进行了详细的分析，并将其调整为油压阀流水生产单元和离散制造单元。
(3)根据实际情况将车间设备布局抽象为单行布局和多行布局两种类型，并建立优化的车间设备线性布局数学模型。
(4)运用遗传算法求解车间设备布局模型，在单行布局的基础上，运用自动换行技术对多行设备布局进行二维优化。
(5)利用上述车间设备布局模型，结合某制造企业车间布局状况，用Java语言开发了车间设备布局管理系统。
车间设备布局实例表明，运用此模型遗传求解与人机交互布局的新方法大大优于传统的经验布局模式，从而验证了本文的研究成果具有一定的理论和现实意义，为其它相关中小车间的设备布局和优化起到了一定的借鉴作用。
Under the increasing global competition in the fields of manufacture, more and more engineering designer are aware of the importance of the facility layout of workshop in the manufacturing system. The layout design is one of significant factors in many aspects, for instance, it affect the smooth of workshop material flow, the manipulation and servicing of the facilities, the using ratio of workshop area, and it is one of the important factors which affect the production performance of the enterprise. Traditionally, facility layout depends mainly on the experience of the designer and it's qualitative on very big degree, lacking scientific and quantitative description and the measures to it, the cost is high and the cycle is long. This thesis is taking a machining workshop as the object, researching on the optimal model and arithmetic of facility layout, some researches have been made as follows:
(1) Make detailed analysis and survey of the facility layout problem, expatiate the basal theory of facility layout.
(2) Make detailed analysis on facility layout and production logistics of one machine center workshop, adjust it into hydraulic valve cell and discrete manufacture cell.
(3) Divides the facility layout problem into two types, single line layout and lows layout, the optimized models are constructed respectively.
(4) Resolve the facility layout model by genetic algorithms, based on single line layout, realize the rows layout of facility with the instruction of automatic newline technology and optimize layout in different dimensions.
(5) According to the circs of one workshop, a workshop facility layout management system is developed based on the above workshop facility layout model using Java.
The actual facility layout application indicates that the new hybrid solution is much better than traditional methods, it proves that the research has theoretic and practice significance, also the method provides the optimization and layout of the related manufacture workshop with a highly effective and efficient way.
(1)对国内外关于车间设备布局问题的相关研究进行了详细的分析和综述，阐述了车间设备布局的基本理论。
(2)对某制造企业机械加工车间设备布局及生产物流情况进行了详细的分析，并将其调整为油压阀流水生产单元和离散制造单元。
(3)根据实际情况将车间设备布局抽象为单行布局和多行布局两种类型，并建立优化的车间设备线性布局数学模型。
(4)运用遗传算法求解车间设备布局模型，在单行布局的基础上，运用自动换行技术对多行设备布局进行二维优化。
(5)利用上述车间设备布局模型，结合某制造企业车间布局状况，用Java语言开发了车间设备布局管理系统。
车间设备布局实例表明，运用此模型遗传求解与人机交互布局的新方法大大优于传统的经验布局模式，从而验证了本文的研究成果具有一定的理论和现实意义，为其它相关中小车间的设备布局和优化起到了一定的借鉴作用。
Under the increasing global competition in the fields of manufacture, more and more engineering designer are aware of the importance of the facility layout of workshop in the manufacturing system. The layout design is one of significant factors in many aspects, for instance, it affect the smooth of workshop material flow, the manipulation and servicing of the facilities, the using ratio of workshop area, and it is one of the important factors which affect the production performance of the enterprise. Traditionally, facility layout depends mainly on the experience of the designer and it's qualitative on very big degree, lacking scientific and quantitative description and the measures to it, the cost is high and the cycle is long. This thesis is taking a machining workshop as the object, researching on the optimal model and arithmetic of facility layout, some researches have been made as follows:
(1) Make detailed analysis and survey of the facility layout problem, expatiate the basal theory of facility layout.
(2) Make detailed analysis on facility layout and production logistics of one machine center workshop, adjust it into hydraulic valve cell and discrete manufacture cell.
(3) Divides the facility layout problem into two types, single line layout and lows layout, the optimized models are constructed respectively.
(4) Resolve the facility layout model by genetic algorithms, based on single line layout, realize the rows layout of facility with the instruction of automatic newline technology and optimize layout in different dimensions.
(5) According to the circs of one workshop, a workshop facility layout management system is developed based on the above workshop facility layout model using Java.
The actual facility layout application indicates that the new hybrid solution is much better than traditional methods, it proves that the research has theoretic and practice significance, also the method provides the optimization and layout of the related manufacture workshop with a highly effective and efficient way.
引文
[1] 张树武．工业工程导论．中国标准出版社，1995：16-28
[2] Marcello Braglia, Simone Zanon and Lucio Zavanella. Layout design in dynamic environments: strategies and quantitative indices [J]. TNT. J.PROD.RES., 2003, 41 (5):995-1016.
[3] Chwif L, Pereira Barretto M R, Moscato L A. A solution to the facility layout problem using simulated annealing. Computers in Industry, 1998, 36, 125-132.
[4] 刘丽文．生产与运作管理．北京：清华大学出版，1998：25-36
[5] Louis C, Yaya S K. Computational aspects of the facility layout design problem.Nonlinear Analysis, 2001, 7, 5599-5610.
[6] Muther R. Practical Plant Layout. McGraw-Hill, New York, NY, 1995.
[7] Muther R. Systematic Layout Planning. Cahners Books, Boston, MA, 1973.
[8] 理查德·缪瑟．系统布置设计．机械工业出版社，1988：2-9
[9] Dowsland Kathryn A, Dowsland William B, Packing Problems. European joumal of Operational Research, 1992, 56(1):2-14
[10] Scheithauer G, Terno J. Modeling of packing problems. Optimization 1993, 28:63-84.
[11] Kouvelis P, Wen C Y, Fitzsimmons J. Simulated annealing for machine layout problems in the presence of zoning constraints. European Journal of Operational Research, 1992, 57(2): 203-223.
[12] 詹叔浩，黄文奇．一类几何布局问题的计算机辅助设计．应用数学学报．1993，6(1)：34-46
[13] 龚全胜，李世其．基于遗传算法的制造系统设备布局设计．计算机工程与应用．2004．26：202-205
[14] 罗宜美，林强等．基于当量物流量的设备系统平面布置设计研究．机械设计．2000，11：46-48
[15] 王定益，王丽亚．一种单元制生产方式设备布局问题的研究方法．工业工程与管理．2006，1：10-13
[16] 刘晖．多生产线车间设备布局问题研究．上海交通大学硕士学位论文．2002：4-5
[17] Marcello Braglia, Simone Zanon and Lucio Zavanella. Layout design in dynamic enviromnents: strategies and quantitative indices[J].INT. J PROD. RES., 2003, 41(5):995-1016
[18] R.G.Askin F.W.Ciarallo. An empirical evaluation of holonic and fractal layouts[J]. INT. PROD.RES, 1999, 37(5):961-978
[19] 吴晓丹，王云峰，朱昭贤等．单元制造系统理论与方法研究综述[丁]．河北工业大学学报．1999，128(3)：1-5
[20] Caccetta L. Kusumah Y S, Computational Aspects of the Facility Layout Design Problem[J], Nonlinear Analysis, 2001 (47):5599-5610
[21] 王颖．工厂设计中制造加工车间工艺设计分析．工厂建设与设计．1996，2：18-20
[22] 董海，梁迪．设施规划与物流分析．北京：机械工业出版社，2005：32-37
[23] 兰洪杰，施先亮，赵启兰．供应链与企业物流管理．北京：清华大学出版社，北京交通大学出版社，2004：182-185
[24] 张礼镇．工业工程．科学出版社，1995：36-49
[25] 查建中，唐晓君，陆一平．布局及布置设计问题求解自动化的理论与方法综述．计算机辅助设计与图形学学报[J]．2002，8：705-711
[26] 曹振新，朱云龙，宋崎．制造系统的设备布局方法．辽宁工程技术大学学报．2005，24(3)：413-416
[27] Dowsland K A. An exact algorithm for the pallet loading problem. European Journal of Operational Research, 1987, 31:78-84
[28] Leung J. A new graph-theoretic heuristic for facility layout. Management Science,1992, 38(4): 594-605
[29] 饶运清，邓建春，李培根．面向对象的FMS机床布局设计．机械设计与制造工程．1999，5：17-21
[30] 戴佐．智能布局系统设计理论与方法的研究．天津大学博士学位论文．1995：15-18
[31] Z Dai, J Z Cha. A Hybrid algorithm of heuristic and neural network for packing problems. Proceedings of Conference on Design Automation, Minneapolis, 1994:117-124
[32] Bischoff E E, Marriott M D. A comparative evaluation of heuristics for container loading [J]. European Journal of Operational Research, 1990, 44:267-276
[33] Garey MR, Johnson DS. Computer and Intractability: A Guide to the Theory of NP-Completeness [M]. New York: Freeman, 1979, 24:438-446
[34] Kusiak A, Heragu S S. The Facility Layout Problem. European Journal of Operational Research, 1987:229-251
[35] Sahni S, Gonzalez T. NP complete approximation problem. Journal of Association for Computer Machniary, 1976, 23(3): 555-565
[36] Ossama K, Muhittin O. Reformulating Quadratic Assignment Problems for Efficient Optimization. IIE Transaction, 1993, 25:97-107
[37] Tompkings J A. Facilities Planning, 2nd edn. New York: John Wiley, 1996: 335-365
[38] Koulamas, Christos P. Design of tool magazine and operational areas for a multi-tool machine. European Journal of Operational Research, 1992, 63(2) : 223-232
[39] Heragu S, Kusiak A. Machine layout problem in flexible manufacturing system. Operations Research, 1988, 36(2): 258-268
[40] 王小平，曹立明．遗传算法——理论、应用与软件实现．西安交通大学出版社，2002：36-50
[41] 余琦玮．基于遗传算法的作业车间调度问题研究．浙江大学硕士学位论文，2004：20-27
[42] Goldberg, D. and R. Lingle, Alleles, Loci and the traveling salesman problem, in Grefenstette [186], pp: 154-159
[43] 玄光男，程润伟．遗传算法与工程设计[M]．科学出版社，2000：211-213
[44] 郑莉，王行言，马素霞．Java语言程序设计．清华大学出版社，2006：2-3
[45] 马海军，景丽．Java实用教程．清华大学出版社，2005：2-10
[2] Marcello Braglia, Simone Zanon and Lucio Zavanella. Layout design in dynamic environments: strategies and quantitative indices [J]. TNT. J.PROD.RES., 2003, 41 (5):995-1016.
[3] Chwif L, Pereira Barretto M R, Moscato L A. A solution to the facility layout problem using simulated annealing. Computers in Industry, 1998, 36, 125-132.
[4] 刘丽文．生产与运作管理．北京：清华大学出版，1998：25-36
[5] Louis C, Yaya S K. Computational aspects of the facility layout design problem.Nonlinear Analysis, 2001, 7, 5599-5610.
[6] Muther R. Practical Plant Layout. McGraw-Hill, New York, NY, 1995.
[7] Muther R. Systematic Layout Planning. Cahners Books, Boston, MA, 1973.
[8] 理查德·缪瑟．系统布置设计．机械工业出版社，1988：2-9
[9] Dowsland Kathryn A, Dowsland William B, Packing Problems. European joumal of Operational Research, 1992, 56(1):2-14
[10] Scheithauer G, Terno J. Modeling of packing problems. Optimization 1993, 28:63-84.
[11] Kouvelis P, Wen C Y, Fitzsimmons J. Simulated annealing for machine layout problems in the presence of zoning constraints. European Journal of Operational Research, 1992, 57(2): 203-223.
[12] 詹叔浩，黄文奇．一类几何布局问题的计算机辅助设计．应用数学学报．1993，6(1)：34-46
[13] 龚全胜，李世其．基于遗传算法的制造系统设备布局设计．计算机工程与应用．2004．26：202-205
[14] 罗宜美，林强等．基于当量物流量的设备系统平面布置设计研究．机械设计．2000，11：46-48
[15] 王定益，王丽亚．一种单元制生产方式设备布局问题的研究方法．工业工程与管理．2006，1：10-13
[16] 刘晖．多生产线车间设备布局问题研究．上海交通大学硕士学位论文．2002：4-5
[17] Marcello Braglia, Simone Zanon and Lucio Zavanella. Layout design in dynamic enviromnents: strategies and quantitative indices[J].INT. J PROD. RES., 2003, 41(5):995-1016
[18] R.G.Askin F.W.Ciarallo. An empirical evaluation of holonic and fractal layouts[J]. INT. PROD.RES, 1999, 37(5):961-978
[19] 吴晓丹，王云峰，朱昭贤等．单元制造系统理论与方法研究综述[丁]．河北工业大学学报．1999，128(3)：1-5
[20] Caccetta L. Kusumah Y S, Computational Aspects of the Facility Layout Design Problem[J], Nonlinear Analysis, 2001 (47):5599-5610
[21] 王颖．工厂设计中制造加工车间工艺设计分析．工厂建设与设计．1996，2：18-20
[22] 董海，梁迪．设施规划与物流分析．北京：机械工业出版社，2005：32-37
[23] 兰洪杰，施先亮，赵启兰．供应链与企业物流管理．北京：清华大学出版社，北京交通大学出版社，2004：182-185
[24] 张礼镇．工业工程．科学出版社，1995：36-49
[25] 查建中，唐晓君，陆一平．布局及布置设计问题求解自动化的理论与方法综述．计算机辅助设计与图形学学报[J]．2002，8：705-711
[26] 曹振新，朱云龙，宋崎．制造系统的设备布局方法．辽宁工程技术大学学报．2005，24(3)：413-416
[27] Dowsland K A. An exact algorithm for the pallet loading problem. European Journal of Operational Research, 1987, 31:78-84
[28] Leung J. A new graph-theoretic heuristic for facility layout. Management Science,1992, 38(4): 594-605
[29] 饶运清，邓建春，李培根．面向对象的FMS机床布局设计．机械设计与制造工程．1999，5：17-21
[30] 戴佐．智能布局系统设计理论与方法的研究．天津大学博士学位论文．1995：15-18
[31] Z Dai, J Z Cha. A Hybrid algorithm of heuristic and neural network for packing problems. Proceedings of Conference on Design Automation, Minneapolis, 1994:117-124
[32] Bischoff E E, Marriott M D. A comparative evaluation of heuristics for container loading [J]. European Journal of Operational Research, 1990, 44:267-276
[33] Garey MR, Johnson DS. Computer and Intractability: A Guide to the Theory of NP-Completeness [M]. New York: Freeman, 1979, 24:438-446
[34] Kusiak A, Heragu S S. The Facility Layout Problem. European Journal of Operational Research, 1987:229-251
[35] Sahni S, Gonzalez T. NP complete approximation problem. Journal of Association for Computer Machniary, 1976, 23(3): 555-565
[36] Ossama K, Muhittin O. Reformulating Quadratic Assignment Problems for Efficient Optimization. IIE Transaction, 1993, 25:97-107
[37] Tompkings J A. Facilities Planning, 2nd edn. New York: John Wiley, 1996: 335-365
[38] Koulamas, Christos P. Design of tool magazine and operational areas for a multi-tool machine. European Journal of Operational Research, 1992, 63(2) : 223-232
[39] Heragu S, Kusiak A. Machine layout problem in flexible manufacturing system. Operations Research, 1988, 36(2): 258-268
[40] 王小平，曹立明．遗传算法——理论、应用与软件实现．西安交通大学出版社，2002：36-50
[41] 余琦玮．基于遗传算法的作业车间调度问题研究．浙江大学硕士学位论文，2004：20-27
[42] Goldberg, D. and R. Lingle, Alleles, Loci and the traveling salesman problem, in Grefenstette [186], pp: 154-159
[43] 玄光男，程润伟．遗传算法与工程设计[M]．科学出版社，2000：211-213
[44] 郑莉，王行言，马素霞．Java语言程序设计．清华大学出版社，2006：2-3
[45] 马海军，景丽．Java实用教程．清华大学出版社，2005：2-10