面向单件小批MES的车间作业调度问题研究
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摘要
制造执行系统(Manufacturing Execution System,MES)是面向车间生产的管理信息系统,也是实现快捷制造、节约企业成本的基础。随着经济形势的转变,单件小批生产已成为现有中小型企业的主要生产方式,如何将MES系统应用到单件小批生产中,已是最具吸引力的研究热点之一。车间作业调度问题是MES的核心模块,其实质是一种资源约束、时间约束和工序约束等组合优化问题,研究及应用车间作业调度问题对于我国制造业提高管理水平,生产效率,以及实施先进制造战略等均有重要的意义。但是由于实际车间作业调度的动态不确定性和复杂性,给实际的研究及应用带来了很大挑战。
首先,在研究分析传统MES体系结构的基础上,根据单件小批车间作业调度实际生产所面临的压力及困难,构建了单件小批制造执行系统的功能模型,对单件小批MES体系结构的功能模块进行了详细阐述。同时,从单件小批企业实际需求出发,研究了单件小批MES与企业资源计划、车间现场控制的信息集成。
然后,在分析传统的车间作业调度问题的基础上,结合单件小批调度的约束条件,针对GA算法会发生进化缓慢或者早熟现象,将SA算法引入到交叉和变异操作,提出了遗传模拟退火调度算法——GASA混合调度算法,并给出算法数学模型、算法模型、算法流程。GA的并行抽样性可以将算法时间优化性能提高,而SA的控制准则可以控制结合后算法的收敛性,避免出现早熟现象。利用经典调度问题FT06,验证了GASA算法的正确性,并与传统GA算法进行比较,验证了GASA算法的高效性。
最后,论文采用Java编程语言、JBuilder开发环境、B/S模式开发MES中的车间作业调度原型系统。在充分调研的基础上,构建了车间作业调度系统的数据库,并结合作业计划与调度的实际问题,对单件小批MES作业计划与调度优化方法进行了实例研究。
Manufacturing execution system MES is a workshop for the production of management information systems, but also to achieve efficient production, saving companies the cost basis. With the economic situation changes, single and small batch production of existing small and medium enterprises have become the main mode of production, how to MES system applied to the single and small batch production, is one of the most attractive research focus. MES job shop scheduling problem is the core module, and its essence is a kind of resource constraints, time constraints and process constraints such as combinatorial optimization problems, research and application of job shop scheduling problem for China's manufacturing sector improve management, productivity, and the implementation of advanced manufacturing strategies are important, therefore, job shop scheduling research has theoretical and practical significance. However, due to the dynamic job shop scheduling real uncertainty and complexity, to the actual research and applications is a big challenge.
In the study analyzed characteristics of single and small batch production and the MES architecture based on this small group of single function modules MES architecture elaborate. According to a single small-batch job shop scheduling Shiji production of the pressures and difficulties, from needs analysis to start research on the system use case model analysis, and on this basis, build a single-piece and small batch job shop scheduling system functional model , the corresponding module in detail. In this paper, the slow evolution of GA algorithm will occur, or premature, and the SA algorithm is introduced to the crossover and mutation, genetic simulated annealing algorithm is proposed - GASA algorithm, mathematical model is given algorithm, the algorithm model, the algorithm process. GA parallel sampling of the time optimization algorithm performance can be improved, and the control of SA binding guidelines to control the convergence of the algorithm to avoid prematurity. The classical scheduling problem FT06, GASA correctness of the algorithm is verified and compared with the traditional GA algorithm is verified GASA efficiency of the algorithm.
Finally, the paper uses Java programming language, JBuilder development environment, B/S mode MES in the development of a prototype job shop scheduling system. On the basis of thorough investigation to build a database of job shop scheduling system, and typically through practical shop scheduling problem solving, demonstrate the effectiveness of the system and the scheduling algorithm, the actual project has a strong reference value.
首先,在研究分析传统MES体系结构的基础上,根据单件小批车间作业调度实际生产所面临的压力及困难,构建了单件小批制造执行系统的功能模型,对单件小批MES体系结构的功能模块进行了详细阐述。同时,从单件小批企业实际需求出发,研究了单件小批MES与企业资源计划、车间现场控制的信息集成。
然后,在分析传统的车间作业调度问题的基础上,结合单件小批调度的约束条件,针对GA算法会发生进化缓慢或者早熟现象,将SA算法引入到交叉和变异操作,提出了遗传模拟退火调度算法——GASA混合调度算法,并给出算法数学模型、算法模型、算法流程。GA的并行抽样性可以将算法时间优化性能提高,而SA的控制准则可以控制结合后算法的收敛性,避免出现早熟现象。利用经典调度问题FT06,验证了GASA算法的正确性,并与传统GA算法进行比较,验证了GASA算法的高效性。
最后,论文采用Java编程语言、JBuilder开发环境、B/S模式开发MES中的车间作业调度原型系统。在充分调研的基础上,构建了车间作业调度系统的数据库,并结合作业计划与调度的实际问题,对单件小批MES作业计划与调度优化方法进行了实例研究。
Manufacturing execution system MES is a workshop for the production of management information systems, but also to achieve efficient production, saving companies the cost basis. With the economic situation changes, single and small batch production of existing small and medium enterprises have become the main mode of production, how to MES system applied to the single and small batch production, is one of the most attractive research focus. MES job shop scheduling problem is the core module, and its essence is a kind of resource constraints, time constraints and process constraints such as combinatorial optimization problems, research and application of job shop scheduling problem for China's manufacturing sector improve management, productivity, and the implementation of advanced manufacturing strategies are important, therefore, job shop scheduling research has theoretical and practical significance. However, due to the dynamic job shop scheduling real uncertainty and complexity, to the actual research and applications is a big challenge.
In the study analyzed characteristics of single and small batch production and the MES architecture based on this small group of single function modules MES architecture elaborate. According to a single small-batch job shop scheduling Shiji production of the pressures and difficulties, from needs analysis to start research on the system use case model analysis, and on this basis, build a single-piece and small batch job shop scheduling system functional model , the corresponding module in detail. In this paper, the slow evolution of GA algorithm will occur, or premature, and the SA algorithm is introduced to the crossover and mutation, genetic simulated annealing algorithm is proposed - GASA algorithm, mathematical model is given algorithm, the algorithm model, the algorithm process. GA parallel sampling of the time optimization algorithm performance can be improved, and the control of SA binding guidelines to control the convergence of the algorithm to avoid prematurity. The classical scheduling problem FT06, GASA correctness of the algorithm is verified and compared with the traditional GA algorithm is verified GASA efficiency of the algorithm.
Finally, the paper uses Java programming language, JBuilder development environment, B/S mode MES in the development of a prototype job shop scheduling system. On the basis of thorough investigation to build a database of job shop scheduling system, and typically through practical shop scheduling problem solving, demonstrate the effectiveness of the system and the scheduling algorithm, the actual project has a strong reference value.
引文
[1]严隽琪.基于网络的敏捷制造[J].中国机械工程,2000,1l (1-2):101-104.
[2] MICHAEL MCCLELLAN.Applying Manufacturing Execution Systems[M],CRC Press,1997:3-15.
[3]张良扬.单件小批生产模式下的计划系统与优化算法研究[D],南京:南京航空航天大学,2004:34-43.
[4] MESA INTERNATIONAL . The Benefits of MES : A Report from the Field[M].Pittsburgh,USA:MESA International White Paper Number 1,1997:25-45.
[5] MESA INTERNATIONAL.MES Functionalities & MRP to MES Data Flow Possibilities[M].Pittsburgh,USA:MESA International White Paper Number 2,1997:35-40.
[6] MESA INTERNATIONAL.Controls Definition & MES to Controls Data Flow Possibilities[M].Pittsburgh,USA:MESA International White Paper Number 3,1997:52-54.
[7] MESA INTERNATIONAL.MES Software Evaluation/Selection[M].Pittsburgh,USA:MES A International White Paper Number 4,1997:60-65.
[8] MESA INTERNATIONAL.Execution-Driven Manufacturing Management for Competitive Advantage[M].Pittsburgh,USA:MES A International White Paper Number 5,1997:45-75.
[9] MESA INTERNATIONAL.A High Level Vision[M].Pittsburgh,USA:MESA International White Paper Number 6,1997:57-72.
[10] ANSI/ISA-95.00.01.Enterprise Control System Integration Part 1:Models and Terminology[M].2000:75-85.
[11] ANSI/ISA-95.00.02.Enterprise Control System Integration Part 2:Data Structure and Attributes[M].2000:23-33.
[12] ANSI/ISA-95.00.03.Enterprise Control System Integration Part 3:Activity Models of Manufacturing Operations Management[M].2000:46-61.
[13] ANSI/ISA-95.00.04.Enterprise Control System Integration Part 4:Object Models of Manufacturing Operations Management[M].2000:57-75.
[14] WU YU,XU XIAODONG,LI CONGXIN.Modeling Research on ManufacturingExecution System Based on Large-scale System Cybernetics.Journal of Shanghai Jiaotong University(Science)[J],2008,13(6):744-747.
[15] HWANG YEONGDONG.The Practices of Integrating Manufacturing Execution System and Six Sigma Methodology[J].The International Journal of Advanced Manufacturing Technology,2006,31(11):761-768.
[16] HUANG CHINYIN.Distributed Manufacturing Execution Systems:A Workflow Perspective[J].Journal of Intelligent Manufacturing,2002,13(6):485-497.
[17] ARTURO MOLINA , ARMANDO RAMíREZ SANTAELLA . Achieving E-Manufacturing:Multihead Control and Web Technology for the Implementation of a Manufacturing Execution System[J].Journal of Intelligent Manufacturing,2006,17(6):715-724.
[18] DIEP D,MASSOTTE P.,MEIMOUNI A.A Distributed Manufacturing Execution System Implemented with Agent:the PABADIS Model[C].Proceedings.IEEE International Conference on Industrial Informatics,2003:301-306.
[19] QIU R,WYSK R,XU Q.Extended Structured Adaptive Supervisory Control Model of Shop Floor Controls for all E-Manufacturing System[J].Int.Pmd.Res,2003,4l(8):1605-1620.
[20] FLETCHER M,BRERMAN R.,NORRIE D.Modeling and reconfiguring intelligent holonic manufacturing systems with Internet-based mobile agents[J].Intelligent manufacturing,2003,(14):7-23.
[21] BARRY J,APARICIO M.,DUMIAK T.,HERMAN P.,etal.NIIIP-SMART:an investigation of distributed object approaches to support MES development and deployment in a virtual enterprise[C],Proceedings Second International Enterprise Distributed Object Computing,1998:366-377.
[22] JIMENEZ G,MOLINA A,CANCHE L.Manufacturing execution systems interoperability and web services technologies[C].Proceedings of the ASME Computers and Information in Engineering Division,2005:191-197.
[23] CHENG FANTIEN,CHANG CHIHFENG,WU SHANGLUN.Development of holonic manufacturing execution systems[J].Journal of Intelligent Manufacturing,2004,15(2):253-267.
[24] SAAD S.M.The reconfiguration issues in manufacturing systems[J].Journal of Materials Processing Technology,2003,138(1):277-283.
[25] CHOI B . K. , KIM B . H . MES architecture for FMS compatible toERP[J].International Journal of Computer Integrated Manufacturing,2002,15(3):274-284.
[26] SIEBERG W.J.A scheduling and resource optimising MES for the semiconductor and MEMS industry[C].14th Annual IEEE/SEMI Advanced Semiconductor Manufacturing Conference and Workshop(ASMC),2003:101-105.
[27] BENAISSA M. , BENABDELHAFID A. , ALIMI A . The integration of manufacturing execution system and product & enterprise resource planning in the logistic chain[C].1 st Industrial Simulation Conference,2003:317-320.
[28] ANON.Seamless integration between manufacturing execution system and SAP system[J].Paper Asia,2003,19(1):31-33.
[29] KULGA K.S,GILFANOV R.R.Integration of CAD/CAM/PDM/MES and ERP systems[J].Russian Engineering Research,2008,28(2):169-172.
[30] ZAGIDULLIN R.R.,FROLOV E.B.Control of manufacturing production by means of MES systems[J].Russian Engineering Research,2008,28(2):166-168.
[31]徐海军,景旭文,周宏根.面向柴油机企业的MES建模方法研究[J].现代制造工程,2008,(3):32-35.
[32]于海斌,朱云龙.可集成的制造执行系统[J].计算机集成制造系,2000,6(6):1-11.
[33]潘颖,张文孝.基于多AGENT的离散制造业制造执行系统框架研究[J].计算机应用研究,2009,12(1):244-248.
[34]吴立辉,张洁.电子装配行业的MES体系结构及技术实现[J].计算机工程,2009,35(5):12-16.
[35]程志伦,范玉青.钢铁企业基于组件的柔性制造执行系统设计[J].计算机集成制造系统,2007,13(3):490-496.
[36]罗国富,施法中.基于CORBA的可重构制造执行系统实现[J].高技术通讯,2004,67(11):47-50.
[37]周华,刘民,吴澄.基于代理的可重构制造执行系统研究[J].计算机集成制造系统,2005,11(6):776-780.
[38]王琦峰,阎春平,刘飞.基于知识集成的车间制造系统运行模式研究[J].计算机集成制造系,2009,15(4):698-704.
[39]王琦峰,刘飞,黄海龙.面向服务的离散车间可重构制造执行系统研究[J].计算机集成制造系,2008,14(4):737-744.
[40]丁伯慧,霍艳芳,齐二石.离散型制造业MES的深入研究[J].组合机床与自动化加工技术,2007,(5): 84-87.
[41]刘卫宁,黄文雷,孙棣华,等.基于射频识别的离散制造业制造执行系统设计与实现[J].计算机集成制造系统,2007,13(10):1885-1890.
[42]潘操,杨小英,施连敏,等.基于S95标准的流程工业制造执行系统的设计与实现[J].计算机与应用化学,2009,26(8):1025-1030.
[43]施灿涛,尹静,李铁克.钢铁企业ERP与MES集成方法研究及应用[J].冶金自动化,2008,32(2):54-58.
[44]张毅坤,邓晶晶,杨凯峰,等.基于组件的柔性制造执行系统软件集成测试研究[J].计算机集成制造系统.2007,13(10):1958-1963.
[45]许鹏,王焱.车间动态调度方法研究与应用[J].航空制造技术,2009,21:82-87.
[46] AMIT KUMAR GUPTA,APPER I S.Job shop scheduling techniques in semiconductor manufacturing[J].Int J Adv Manuf Technol,2006,27(6):13-34.
[47]李春德.MES中基于单亲遗传算法的调度技术研究[D].合肥:合肥工业大学,2009:43-57.
[48]张利平.改进蚁群算法在车间作业调度中的应用研究[J].三峡大学学报,2009,2:345-367.
[49]蒋丽雯.基于遗传算法的车间作业调度问题研究[D].上海:上海交通大学,2007,1:12-34.
[50]张长胜,孙吉贵,欧阳丹彤,等.求解车间作业调度问题的自适应混合粒子群算法[J].计算机学报,2009,32(11):2137-2145.
[51]佟萍.模拟退火算法在Web服务合成中的应用[J].计算机技术与发展,2006,16(3):220-222.
[52]白国振,适用于中小企业的生产调度系统[J].组合机床与自动化技术,2002,16(9):11-14.
[2] MICHAEL MCCLELLAN.Applying Manufacturing Execution Systems[M],CRC Press,1997:3-15.
[3]张良扬.单件小批生产模式下的计划系统与优化算法研究[D],南京:南京航空航天大学,2004:34-43.
[4] MESA INTERNATIONAL . The Benefits of MES : A Report from the Field[M].Pittsburgh,USA:MESA International White Paper Number 1,1997:25-45.
[5] MESA INTERNATIONAL.MES Functionalities & MRP to MES Data Flow Possibilities[M].Pittsburgh,USA:MESA International White Paper Number 2,1997:35-40.
[6] MESA INTERNATIONAL.Controls Definition & MES to Controls Data Flow Possibilities[M].Pittsburgh,USA:MESA International White Paper Number 3,1997:52-54.
[7] MESA INTERNATIONAL.MES Software Evaluation/Selection[M].Pittsburgh,USA:MES A International White Paper Number 4,1997:60-65.
[8] MESA INTERNATIONAL.Execution-Driven Manufacturing Management for Competitive Advantage[M].Pittsburgh,USA:MES A International White Paper Number 5,1997:45-75.
[9] MESA INTERNATIONAL.A High Level Vision[M].Pittsburgh,USA:MESA International White Paper Number 6,1997:57-72.
[10] ANSI/ISA-95.00.01.Enterprise Control System Integration Part 1:Models and Terminology[M].2000:75-85.
[11] ANSI/ISA-95.00.02.Enterprise Control System Integration Part 2:Data Structure and Attributes[M].2000:23-33.
[12] ANSI/ISA-95.00.03.Enterprise Control System Integration Part 3:Activity Models of Manufacturing Operations Management[M].2000:46-61.
[13] ANSI/ISA-95.00.04.Enterprise Control System Integration Part 4:Object Models of Manufacturing Operations Management[M].2000:57-75.
[14] WU YU,XU XIAODONG,LI CONGXIN.Modeling Research on ManufacturingExecution System Based on Large-scale System Cybernetics.Journal of Shanghai Jiaotong University(Science)[J],2008,13(6):744-747.
[15] HWANG YEONGDONG.The Practices of Integrating Manufacturing Execution System and Six Sigma Methodology[J].The International Journal of Advanced Manufacturing Technology,2006,31(11):761-768.
[16] HUANG CHINYIN.Distributed Manufacturing Execution Systems:A Workflow Perspective[J].Journal of Intelligent Manufacturing,2002,13(6):485-497.
[17] ARTURO MOLINA , ARMANDO RAMíREZ SANTAELLA . Achieving E-Manufacturing:Multihead Control and Web Technology for the Implementation of a Manufacturing Execution System[J].Journal of Intelligent Manufacturing,2006,17(6):715-724.
[18] DIEP D,MASSOTTE P.,MEIMOUNI A.A Distributed Manufacturing Execution System Implemented with Agent:the PABADIS Model[C].Proceedings.IEEE International Conference on Industrial Informatics,2003:301-306.
[19] QIU R,WYSK R,XU Q.Extended Structured Adaptive Supervisory Control Model of Shop Floor Controls for all E-Manufacturing System[J].Int.Pmd.Res,2003,4l(8):1605-1620.
[20] FLETCHER M,BRERMAN R.,NORRIE D.Modeling and reconfiguring intelligent holonic manufacturing systems with Internet-based mobile agents[J].Intelligent manufacturing,2003,(14):7-23.
[21] BARRY J,APARICIO M.,DUMIAK T.,HERMAN P.,etal.NIIIP-SMART:an investigation of distributed object approaches to support MES development and deployment in a virtual enterprise[C],Proceedings Second International Enterprise Distributed Object Computing,1998:366-377.
[22] JIMENEZ G,MOLINA A,CANCHE L.Manufacturing execution systems interoperability and web services technologies[C].Proceedings of the ASME Computers and Information in Engineering Division,2005:191-197.
[23] CHENG FANTIEN,CHANG CHIHFENG,WU SHANGLUN.Development of holonic manufacturing execution systems[J].Journal of Intelligent Manufacturing,2004,15(2):253-267.
[24] SAAD S.M.The reconfiguration issues in manufacturing systems[J].Journal of Materials Processing Technology,2003,138(1):277-283.
[25] CHOI B . K. , KIM B . H . MES architecture for FMS compatible toERP[J].International Journal of Computer Integrated Manufacturing,2002,15(3):274-284.
[26] SIEBERG W.J.A scheduling and resource optimising MES for the semiconductor and MEMS industry[C].14th Annual IEEE/SEMI Advanced Semiconductor Manufacturing Conference and Workshop(ASMC),2003:101-105.
[27] BENAISSA M. , BENABDELHAFID A. , ALIMI A . The integration of manufacturing execution system and product & enterprise resource planning in the logistic chain[C].1 st Industrial Simulation Conference,2003:317-320.
[28] ANON.Seamless integration between manufacturing execution system and SAP system[J].Paper Asia,2003,19(1):31-33.
[29] KULGA K.S,GILFANOV R.R.Integration of CAD/CAM/PDM/MES and ERP systems[J].Russian Engineering Research,2008,28(2):169-172.
[30] ZAGIDULLIN R.R.,FROLOV E.B.Control of manufacturing production by means of MES systems[J].Russian Engineering Research,2008,28(2):166-168.
[31]徐海军,景旭文,周宏根.面向柴油机企业的MES建模方法研究[J].现代制造工程,2008,(3):32-35.
[32]于海斌,朱云龙.可集成的制造执行系统[J].计算机集成制造系,2000,6(6):1-11.
[33]潘颖,张文孝.基于多AGENT的离散制造业制造执行系统框架研究[J].计算机应用研究,2009,12(1):244-248.
[34]吴立辉,张洁.电子装配行业的MES体系结构及技术实现[J].计算机工程,2009,35(5):12-16.
[35]程志伦,范玉青.钢铁企业基于组件的柔性制造执行系统设计[J].计算机集成制造系统,2007,13(3):490-496.
[36]罗国富,施法中.基于CORBA的可重构制造执行系统实现[J].高技术通讯,2004,67(11):47-50.
[37]周华,刘民,吴澄.基于代理的可重构制造执行系统研究[J].计算机集成制造系统,2005,11(6):776-780.
[38]王琦峰,阎春平,刘飞.基于知识集成的车间制造系统运行模式研究[J].计算机集成制造系,2009,15(4):698-704.
[39]王琦峰,刘飞,黄海龙.面向服务的离散车间可重构制造执行系统研究[J].计算机集成制造系,2008,14(4):737-744.
[40]丁伯慧,霍艳芳,齐二石.离散型制造业MES的深入研究[J].组合机床与自动化加工技术,2007,(5): 84-87.
[41]刘卫宁,黄文雷,孙棣华,等.基于射频识别的离散制造业制造执行系统设计与实现[J].计算机集成制造系统,2007,13(10):1885-1890.
[42]潘操,杨小英,施连敏,等.基于S95标准的流程工业制造执行系统的设计与实现[J].计算机与应用化学,2009,26(8):1025-1030.
[43]施灿涛,尹静,李铁克.钢铁企业ERP与MES集成方法研究及应用[J].冶金自动化,2008,32(2):54-58.
[44]张毅坤,邓晶晶,杨凯峰,等.基于组件的柔性制造执行系统软件集成测试研究[J].计算机集成制造系统.2007,13(10):1958-1963.
[45]许鹏,王焱.车间动态调度方法研究与应用[J].航空制造技术,2009,21:82-87.
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