基于资源约束的项目制造型装配生产计划管理方法与应用研究
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摘要
随着全球化市场的形成和产品生命周期的缩短,我国装备制造企业面对的是客户对产品越来越高的个性化要求和更加紧迫的产品交付时间所带来的竞争压力。新形势、新发展目标下的大型装备制造企业需要提升现有产品开发能力,增强自主创新能力,转变现有生产管理模式,向项目制造模式转变,合理利用资源,快速响应客户的个性化需求,提高服务质量,实现企业的新发展。
大型机械装备产品体积庞大,结构复杂,具有独特性、高设计性等特征,通常为根据订单设计(Engineering to Order,ETO)的单件小批生产,装配过程与配套零部件生产过程执行上的独立性与管理上的相关性要求有与之相适应的计划管理模式,以及适应复杂装配过程资源需求的能力描述模型和匹配方法。基于MRPII/ERP系统的生产计划与控制模式较好的实现了生产过程中独立需求与相关需求的转换,但是基于产品BOM的层层分解所形成的物料需求计划,在项目制造环境下难以实现项目驱动的物料追溯,不满足面向项目的制造管理要求。因此,大型单件小批生产方式以MRPII/ERP为核心的生产计划与控制方法需要进行完善和补充,以满足大型装备面向项目制造管理的要求。本文针对大型装备制造企业生产计划管理的共性需求,在广泛调研和深入分析的基础上,以项目为主线围绕“生产计划”与“资源匹配”两大主题展开研究,旨在实现面向项目的生产计划管理。
结合项目驱动的装备类产品设计制造模式的特点,提出了基于资源约束的项目制造生产计划体系框架,以及面向项目制造的分级生产计划业务模型(H3PM)。结合基于装配单元的项目主计划和项目MRP驱动的多级生产计划管理,有效实现最终产品装配与零部件加工过程在计划上的分离。在面向项目主计划的关键资源三维匹配模型基础上,采用非线性整数规划方法从资源满足程度出发对项目主计划时间进行优化。
结合大型单件小批装配生产过程资源需求的特点,提出项目制造模式下装配制造资源二维能力模型,实现装配制造资源工时能力和数量能力的统一描述,并针对单一装配制造资源和非单一装配制造资源,通过资源与资源组的混合组织管理方式,建立项目制造的资源组织、分配、协调管理的装配制造资源库。针对最终装配计划与装配制造资源的匹配问题,在多项目混合时标网络图基础上,基于时间分段的资源匹配矩阵和资源二维能力模型,分析资源能力匹配程度。利用排队原则和任务的缓冲时间对资源冲突进行消解,提高最终装配计划的可行性。
基于快速响应客户的产品开发平台,设计、开发了面向项目制造的生产计划管理软件功能系统,通过在某风电成套设备公司的实施应用,使其生产管理水平和业务过程的效率得到显著改善,验证了论文所提出理论和关键方法的正确性。
With the forming of the global market and the shortening of product life cycle, the equipment manufacturing industry in china is under more pressure of competition from the requirements of customers personalized higher and higher and the deliver time shorter and shorter. It is necessary that large equipment manufacturing enterprise must promote existing product development capacity, enhance independent innovation capacity, transform current production management mode into project-based manufacturing(PM), so that they can achieve new development in reasonable use of manufacturing resources, rapid response to personalized needs of customers, as well as improving products and service quality.
Large mechanized equipment products have the characteristics of large volume, complex structure and high customization, belonging to typical single-piece and small-batch production mode oriented to ETO. It is necessary to build compatible production planning mode for independence of planning executing and relevance of management between final assemble process and components production process, as well as description method and matching method for resource capacity. Production planning and control model based on MRPII/ERP system can better realize the transformation management between independent requirements and dependent requirements in the course of production. The material requirement planning is formed by layer upon layer decompose of product BOM so that it is difficult to trace materials process oriented to project under project-based management (PM) environment so that MRPII/ERP system dissatisfies manufacturing management requirements based on project. Therefore production planning and control methods derived from MRPII/ERP system need be improved and supplemented so to meet management demands for PM under the large-scale and single-piece production mode. For the common demands of production planning in equipment manufacturing enterprise, this paper studies two themes—the production planning and the resource matching oriented to project on the basis of broad research and deep analysis, aims to build PM management model.
This paper combines the characteristics of product design and manufacturing mode by project in equipment manufacturing enterprises, and proposes the production planning system framework of project-based manufacturing oriented to resource constraint as well as hierarchical production planning model of PM. Multistage production planning is formed according to project master planning based on assembly cell and material requirement planning by project that can separate effectively final assembly scheduling (FAS) from manufacturing of components, and through three-dimension matching model of key resources project master planning can be optimized by use of nonlinear integer programming model from level of satisfaction of resource requirement
This paper combines the characteristics of manufacturing resource requirement for assemble in large-scale and single-piece production process, and proposes two-dimensional capacity model of assembly manufacturing resource by PM which can reflect uniformly time capacity and quantity capacity of assembly manufacturing resources. A manufacturing resource pool for assemble is set up so as to organize, allocate and manage individualized and non-individualized resource according to the form of resource and resource group. In addition aiming at the problem of assembly manufacturing resource matching with final assembly planning under PM, the degree of resource capacity matching requirements is analyzed by means of manufacturing resource matching matrix and two-dimension capacity model under time-scale network diagram. And then resource conflict resolution is carried out by queue discipline and time-buffer of tasks, so as to increase the feasibility of final assembly scheduling.
Through the product development platform for quick response to customer production planning management software function system is designed and developed which has be implemented in a wind turbine manufacturing enterprise. The application of software platform can remarkably improve the level of production management and the efficiency of business process, at the same time proves the validity of theory and main methods of this paper.
大型机械装备产品体积庞大,结构复杂,具有独特性、高设计性等特征,通常为根据订单设计(Engineering to Order,ETO)的单件小批生产,装配过程与配套零部件生产过程执行上的独立性与管理上的相关性要求有与之相适应的计划管理模式,以及适应复杂装配过程资源需求的能力描述模型和匹配方法。基于MRPII/ERP系统的生产计划与控制模式较好的实现了生产过程中独立需求与相关需求的转换,但是基于产品BOM的层层分解所形成的物料需求计划,在项目制造环境下难以实现项目驱动的物料追溯,不满足面向项目的制造管理要求。因此,大型单件小批生产方式以MRPII/ERP为核心的生产计划与控制方法需要进行完善和补充,以满足大型装备面向项目制造管理的要求。本文针对大型装备制造企业生产计划管理的共性需求,在广泛调研和深入分析的基础上,以项目为主线围绕“生产计划”与“资源匹配”两大主题展开研究,旨在实现面向项目的生产计划管理。
结合项目驱动的装备类产品设计制造模式的特点,提出了基于资源约束的项目制造生产计划体系框架,以及面向项目制造的分级生产计划业务模型(H3PM)。结合基于装配单元的项目主计划和项目MRP驱动的多级生产计划管理,有效实现最终产品装配与零部件加工过程在计划上的分离。在面向项目主计划的关键资源三维匹配模型基础上,采用非线性整数规划方法从资源满足程度出发对项目主计划时间进行优化。
结合大型单件小批装配生产过程资源需求的特点,提出项目制造模式下装配制造资源二维能力模型,实现装配制造资源工时能力和数量能力的统一描述,并针对单一装配制造资源和非单一装配制造资源,通过资源与资源组的混合组织管理方式,建立项目制造的资源组织、分配、协调管理的装配制造资源库。针对最终装配计划与装配制造资源的匹配问题,在多项目混合时标网络图基础上,基于时间分段的资源匹配矩阵和资源二维能力模型,分析资源能力匹配程度。利用排队原则和任务的缓冲时间对资源冲突进行消解,提高最终装配计划的可行性。
基于快速响应客户的产品开发平台,设计、开发了面向项目制造的生产计划管理软件功能系统,通过在某风电成套设备公司的实施应用,使其生产管理水平和业务过程的效率得到显著改善,验证了论文所提出理论和关键方法的正确性。
With the forming of the global market and the shortening of product life cycle, the equipment manufacturing industry in china is under more pressure of competition from the requirements of customers personalized higher and higher and the deliver time shorter and shorter. It is necessary that large equipment manufacturing enterprise must promote existing product development capacity, enhance independent innovation capacity, transform current production management mode into project-based manufacturing(PM), so that they can achieve new development in reasonable use of manufacturing resources, rapid response to personalized needs of customers, as well as improving products and service quality.
Large mechanized equipment products have the characteristics of large volume, complex structure and high customization, belonging to typical single-piece and small-batch production mode oriented to ETO. It is necessary to build compatible production planning mode for independence of planning executing and relevance of management between final assemble process and components production process, as well as description method and matching method for resource capacity. Production planning and control model based on MRPII/ERP system can better realize the transformation management between independent requirements and dependent requirements in the course of production. The material requirement planning is formed by layer upon layer decompose of product BOM so that it is difficult to trace materials process oriented to project under project-based management (PM) environment so that MRPII/ERP system dissatisfies manufacturing management requirements based on project. Therefore production planning and control methods derived from MRPII/ERP system need be improved and supplemented so to meet management demands for PM under the large-scale and single-piece production mode. For the common demands of production planning in equipment manufacturing enterprise, this paper studies two themes—the production planning and the resource matching oriented to project on the basis of broad research and deep analysis, aims to build PM management model.
This paper combines the characteristics of product design and manufacturing mode by project in equipment manufacturing enterprises, and proposes the production planning system framework of project-based manufacturing oriented to resource constraint as well as hierarchical production planning model of PM. Multistage production planning is formed according to project master planning based on assembly cell and material requirement planning by project that can separate effectively final assembly scheduling (FAS) from manufacturing of components, and through three-dimension matching model of key resources project master planning can be optimized by use of nonlinear integer programming model from level of satisfaction of resource requirement
This paper combines the characteristics of manufacturing resource requirement for assemble in large-scale and single-piece production process, and proposes two-dimensional capacity model of assembly manufacturing resource by PM which can reflect uniformly time capacity and quantity capacity of assembly manufacturing resources. A manufacturing resource pool for assemble is set up so as to organize, allocate and manage individualized and non-individualized resource according to the form of resource and resource group. In addition aiming at the problem of assembly manufacturing resource matching with final assembly planning under PM, the degree of resource capacity matching requirements is analyzed by means of manufacturing resource matching matrix and two-dimension capacity model under time-scale network diagram. And then resource conflict resolution is carried out by queue discipline and time-buffer of tasks, so as to increase the feasibility of final assembly scheduling.
Through the product development platform for quick response to customer production planning management software function system is designed and developed which has be implemented in a wind turbine manufacturing enterprise. The application of software platform can remarkably improve the level of production management and the efficiency of business process, at the same time proves the validity of theory and main methods of this paper.
引文
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