企业制造执行系统和关键性能指标评估技术研究
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摘要
本文针对制造业信息化进程中面临的难题,深入研究企业信息集成架构中担当重要纽带作用的制造执行系统的体系结构、功能模块和信息交互机制,基于对象过程方法论和IEC/ISO62264标准重构了制造执行系统的基础信息集成模型,规范了制造企业的层次结构,打通了实际生产过程和企业决策系统的数据上传和指令下达的通道。为了保证制造执行系统的稳定和高效运行,需要引入必要的评估机制。本文细化和扩展了制造执行系统的绩效分析功能模块,提出了一个基于关键性能指标的制造执行系统评估体系,将制造执行系统的评估分为“静态分析”和“动态分析”两个部分。静态分析以规范化的通用模板定义了每个关键性能指标,并建立了指标集合；动态分析包括关键性能指标的计算和基准的设定,是关键性能指标的应用机制。通过动静态结合的方式发掘制造执行系统优化运行的潜力,提高运行效率、稳定性和可持续性。本文的主要研究工作和创新点如下：
1)针对制造执行系统层次模型的不规范以及缺乏统一有效的建模理论现状,引入了IEC/ISO62264的设备层次模型,以及对象过程方法论来描述和构建制造执行系统涉及的层次模型。通过过程对象方法论与统一建模语言的对比,突出了对象过程方法论在复杂系统以及动态系统方面的建模优势。最后在一家炼油厂的实际应用验证了IEC/ISO62264模型的正确性和普适性,以及对象过程方法论建模的有效性。
2)提出了一个基于关键性能指标的制造执行系统评估体系,该体系细化和拓展了制造执行系统的绩效分析模块,将制造执行系统的评估分为“静态”和“动态”两个部分。静态部分涉及制造执行系统关键性能指标的提炼和定义,动态部分包括关键性能指标的计算和基准的设定。动静态结合的评估机制支撑了制造执行系统自我完善和改进,提升了制造执行系统的运行效率、稳定性和可持续性。
3)针对制造执行系统关键性能指标评估体系的静态分析部分,按照时间、数量和质量等三种类型详细分析了关键性能指标的基础要素和数据来源,并提出了一个通用的关键性能指标模型,规范描述关键性能指标的定义、公式和属性。根据制造企业的实际应用经验,列举了制造执行系统涉及的生产、质量、维护、库存、能源等运行活动关注的典型关键性能指标,并分析其异同性,形成了关键性能指标集合。最后通过对十多家制造企业的关键性能指标使用的调研,验证了指标集合的合理性和有效性,并完善了关键性能指标的提炼和定义。
4)详细分析了流程行业制造执行系统关键性能指标评估体系,剖析了关于制造设备的六个典型的关键性能指标,建立了制造设备的关键性能指标集合。针对制造执行系统关键性能指标评估体系的动态分析部分,提出了基于稳态优化理论的制造设备关键性能指标基准的设定方法,建立了通用的评估模型。最后以二元精馏塔为例分析了其生产率的计算过程以及基准的设定,同时验证了基于稳态优化确定关键性能指标基准方法的可行性。
5)详细分析了中石化生产执行系统SMES3.0的架构、组件和实现方式,验证了本文的制造执行系统体系和IEC/ISO62264制造设备层次模型的有效性和实用性。通过SMES3.0企业层次模型和IEC/ISO62264设备层次模型的对比,指明了规范化统一信息集成模型的优势。详细剖析了SMES3.0的综合展示模块,并将基于关键性能指标的评估方法应用在该模块之中,提高了综合展示模块的可视性和实用性,实现了石化企业跟踪、分析、优化、决策的一体化。
In order to deal with the problems in the application of manufacturing information systems, the framework architecture, functional modules and information exchange mechanism of Manufacturing Execution System (MES) which plays an important role in the field of enterprise information integration, are studied in this thesis. The basic information integration models of MES are reconstructed based on Object Process Methodology (OPM) and IEC/ISO62264standard. These models specify the hierarchy of manufacturing enterprises, and establish the data channel between actual production process and corporate decision-making system. An evaluation system based on Key Performance Indicator (KPI) is proposed for MES, which refines and extends the capability of performance analysis module in MES, and ensures the stability and efficiency of MES. This evaluation system is divided into two parts:static analysis and dynamic analysis. Static analysis defines the indicators according to a standardized template and provides a set of indicators; dynamic analysis includes calculation and benchmark determination of KPIs. By combining the static and dynamic aspects, the potential of MES is explored. Thus the efficiency and stability are improved. The major contributions of this thesis are described as follows:
1) For the lack of standardized hierarchical models and a unified and effective modeling theory for MES, the Equipment Hierarchy Model in IEC/ISO62264, as well as OPM are introduced to describe and build the models involved in MES. By comparing OPM and Unified Modeling Language, the advantages of OPM in modeling complex systems and dynamic systems are highlighted. The application in an oil refinery factory verifies the correctness and universality of these models and the effectiveness of OPM.
2) An evaluation system based on KPI is proposed, which refines and extends the capabilities of performance analysis modules in MES. This evaluation system is divided into two parts:static analysis and dynamic analysis. Static analysis defines the indicators and provides a set of indicators; dynamic analysis includes calculation and benchmark determination of KPIs. By combining the static and dynamic aspects, the efficiency, stability and sustainability of MES can be improved.
3) According to the static analysis part of the evaluation system for MES based on KPI, the fundamental elements and data sources of KPIs are analyzed, which can be divided into three types, such as time, quantity and quality. And a generic model is proposed to describe the definitions, formulas and attributes of KPIs. According to the experience in the application of the manufacturing enterprises, a set of typical KPIs is listed. A survey for the using of KPIs from more than ten manufacturing enterprises verifies the rationality and effectiveness of KPI sets, and improves the definitions of KPIs.
4) The evaluation architecture of KPIs for MES in process industry is analyzed, in which six typical KPIs are listed referred to manufacturing equipment, and a set of KPIs for manufacturing equipment is established. According to the dynamic analysis part of this evaluation architecture, a method based on steady-state optimization is proposed to determine the benchmark for KPIs of manufacturing equipment. Finally, the calculation and benchmark setting for the produced ratio of a distillation column are achieved as an application case.
5) The architecture, components, and implementation of SMES3.0are analyzed to verify the effectiveness of the models in IEC/ISO62264. By comparing the enterprise level model of SMES3.0and the equipment hierarchical model in IEC/ISO62264, the advantages of unified information integration models are pointed out. The integrated display module in SMES3.0is analyzed, and the KPI evaluation method is applied in this module, which improves the visibility and practicality.
1)针对制造执行系统层次模型的不规范以及缺乏统一有效的建模理论现状,引入了IEC/ISO62264的设备层次模型,以及对象过程方法论来描述和构建制造执行系统涉及的层次模型。通过过程对象方法论与统一建模语言的对比,突出了对象过程方法论在复杂系统以及动态系统方面的建模优势。最后在一家炼油厂的实际应用验证了IEC/ISO62264模型的正确性和普适性,以及对象过程方法论建模的有效性。
2)提出了一个基于关键性能指标的制造执行系统评估体系,该体系细化和拓展了制造执行系统的绩效分析模块,将制造执行系统的评估分为“静态”和“动态”两个部分。静态部分涉及制造执行系统关键性能指标的提炼和定义,动态部分包括关键性能指标的计算和基准的设定。动静态结合的评估机制支撑了制造执行系统自我完善和改进,提升了制造执行系统的运行效率、稳定性和可持续性。
3)针对制造执行系统关键性能指标评估体系的静态分析部分,按照时间、数量和质量等三种类型详细分析了关键性能指标的基础要素和数据来源,并提出了一个通用的关键性能指标模型,规范描述关键性能指标的定义、公式和属性。根据制造企业的实际应用经验,列举了制造执行系统涉及的生产、质量、维护、库存、能源等运行活动关注的典型关键性能指标,并分析其异同性,形成了关键性能指标集合。最后通过对十多家制造企业的关键性能指标使用的调研,验证了指标集合的合理性和有效性,并完善了关键性能指标的提炼和定义。
4)详细分析了流程行业制造执行系统关键性能指标评估体系,剖析了关于制造设备的六个典型的关键性能指标,建立了制造设备的关键性能指标集合。针对制造执行系统关键性能指标评估体系的动态分析部分,提出了基于稳态优化理论的制造设备关键性能指标基准的设定方法,建立了通用的评估模型。最后以二元精馏塔为例分析了其生产率的计算过程以及基准的设定,同时验证了基于稳态优化确定关键性能指标基准方法的可行性。
5)详细分析了中石化生产执行系统SMES3.0的架构、组件和实现方式,验证了本文的制造执行系统体系和IEC/ISO62264制造设备层次模型的有效性和实用性。通过SMES3.0企业层次模型和IEC/ISO62264设备层次模型的对比,指明了规范化统一信息集成模型的优势。详细剖析了SMES3.0的综合展示模块,并将基于关键性能指标的评估方法应用在该模块之中,提高了综合展示模块的可视性和实用性,实现了石化企业跟踪、分析、优化、决策的一体化。
In order to deal with the problems in the application of manufacturing information systems, the framework architecture, functional modules and information exchange mechanism of Manufacturing Execution System (MES) which plays an important role in the field of enterprise information integration, are studied in this thesis. The basic information integration models of MES are reconstructed based on Object Process Methodology (OPM) and IEC/ISO62264standard. These models specify the hierarchy of manufacturing enterprises, and establish the data channel between actual production process and corporate decision-making system. An evaluation system based on Key Performance Indicator (KPI) is proposed for MES, which refines and extends the capability of performance analysis module in MES, and ensures the stability and efficiency of MES. This evaluation system is divided into two parts:static analysis and dynamic analysis. Static analysis defines the indicators according to a standardized template and provides a set of indicators; dynamic analysis includes calculation and benchmark determination of KPIs. By combining the static and dynamic aspects, the potential of MES is explored. Thus the efficiency and stability are improved. The major contributions of this thesis are described as follows:
1) For the lack of standardized hierarchical models and a unified and effective modeling theory for MES, the Equipment Hierarchy Model in IEC/ISO62264, as well as OPM are introduced to describe and build the models involved in MES. By comparing OPM and Unified Modeling Language, the advantages of OPM in modeling complex systems and dynamic systems are highlighted. The application in an oil refinery factory verifies the correctness and universality of these models and the effectiveness of OPM.
2) An evaluation system based on KPI is proposed, which refines and extends the capabilities of performance analysis modules in MES. This evaluation system is divided into two parts:static analysis and dynamic analysis. Static analysis defines the indicators and provides a set of indicators; dynamic analysis includes calculation and benchmark determination of KPIs. By combining the static and dynamic aspects, the efficiency, stability and sustainability of MES can be improved.
3) According to the static analysis part of the evaluation system for MES based on KPI, the fundamental elements and data sources of KPIs are analyzed, which can be divided into three types, such as time, quantity and quality. And a generic model is proposed to describe the definitions, formulas and attributes of KPIs. According to the experience in the application of the manufacturing enterprises, a set of typical KPIs is listed. A survey for the using of KPIs from more than ten manufacturing enterprises verifies the rationality and effectiveness of KPI sets, and improves the definitions of KPIs.
4) The evaluation architecture of KPIs for MES in process industry is analyzed, in which six typical KPIs are listed referred to manufacturing equipment, and a set of KPIs for manufacturing equipment is established. According to the dynamic analysis part of this evaluation architecture, a method based on steady-state optimization is proposed to determine the benchmark for KPIs of manufacturing equipment. Finally, the calculation and benchmark setting for the produced ratio of a distillation column are achieved as an application case.
5) The architecture, components, and implementation of SMES3.0are analyzed to verify the effectiveness of the models in IEC/ISO62264. By comparing the enterprise level model of SMES3.0and the equipment hierarchical model in IEC/ISO62264, the advantages of unified information integration models are pointed out. The integrated display module in SMES3.0is analyzed, and the KPI evaluation method is applied in this module, which improves the visibility and practicality.
引文
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