离散型制造过程工时数据处理与优化调度方法研究
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摘要
经济危机的全球化、市场竞争的日益激烈,使企业管理者意识到基础研究工作的重要性,工时定额研究是企业进行科学化、标准化管理的必要手段之一,是提升企业核心竞争力的关键。在此背景下,本文分析比较现有工时消耗的分类方法,并对现有分类方法的不足之处做了改进。结合离散型制造企业自身的特点,给出一种基于精益生产理念的工时定额数字化测算方法,研究并开发了计算机辅助工时测算系统——工时定额管理系统。该系统首先采集机床功率信号,滤波后判断加工状态;其次根据加工状态得出切削时间,并整合成工时定额;最后存储数据支持数据挖掘并为产品成本核算、生产计划的制定、车间生产调度提供了可靠的依据和保证。
通过以上研究,基于得到的工时定额,结合哈尔滨汽轮机厂有限责任公司关键部件生产的多品种、小批量、生产周期长、加工难度大,高精尖设备少、生产协调困难等特点,以最短完工时间、最少工序成本、关键件最少拖期个数为优化目标,设计了基于多目标的倒序交叉的作业车间遗传算法对汽轮机关键件的生产制定车间生产调度计划,并详细叙述该算法的编码设计、初始化种群的生成及交叉、变异等算子设计。最后在本文的研究基础上,开发了工时定额管理系统及车间生产调度模块,以该企业三分厂的生产调度为例进行了应用验证。该系统实现了对工时的准确测算,具有结构简单、成本低、可实施性强的优点,面向离散型制造企业具有应用和推广价值。
With the gobalization of economic crisis and the increasing fierce market competition, managers are awaring of the importance of basic research. The research of man-hour quota is one of the necessary means of enterprises’scientific and standardized management, and also a key factor to enhance the core competitiveness of enterprises. In this background, the classification methods of man-hour consumption were analyzed and compared, and their shortcomings were improved. Combining with the characteristics of discrete manufacturing, a digital method of man-hour quota calculation based on the theory of lean production was proposed, and a man-hour quota management system which was a computer-aided measurement system was researched and developed. Firstly, machine power signals were acquired and the processing state was judged after filtering in this system. Secondly, the cutting processing time was gotten according to the processing status, which was integrated as man-hour quota. Finally, the data was stored for future use in data mining and also for providing a reliable basis and guarantee for the accounting of product costs, the plan of production and shop scheduling.
Through above study, multi-objective based genetic algorithm of reverse crossing for job-shop was designed on multi-objective optimization of production scheduling of turbines’key pieces according to the objectives of minimum completion time, least process cost, minimum number of key pieces’delay. The algorithm was base on man-hour quota and the production characteristics of Harbin turbine company limited that was many varieties, small batch, long production cycle, few advanced facilities, difficult processing and production coordination. And, the coding of the algorithm, initial population generation, crossing operator and mutation operator were described in detail. Finally, the man-hour quota management system and job-shop scheduling module were developed and verified in the third branch of the company. The accurate counting of man-hour is realized in this system which has the advantages of simple structure, low cost and practicality, and is suitable to be applied and popularized in discrete manufacturing enterprises.
通过以上研究,基于得到的工时定额,结合哈尔滨汽轮机厂有限责任公司关键部件生产的多品种、小批量、生产周期长、加工难度大,高精尖设备少、生产协调困难等特点,以最短完工时间、最少工序成本、关键件最少拖期个数为优化目标,设计了基于多目标的倒序交叉的作业车间遗传算法对汽轮机关键件的生产制定车间生产调度计划,并详细叙述该算法的编码设计、初始化种群的生成及交叉、变异等算子设计。最后在本文的研究基础上,开发了工时定额管理系统及车间生产调度模块,以该企业三分厂的生产调度为例进行了应用验证。该系统实现了对工时的准确测算,具有结构简单、成本低、可实施性强的优点,面向离散型制造企业具有应用和推广价值。
With the gobalization of economic crisis and the increasing fierce market competition, managers are awaring of the importance of basic research. The research of man-hour quota is one of the necessary means of enterprises’scientific and standardized management, and also a key factor to enhance the core competitiveness of enterprises. In this background, the classification methods of man-hour consumption were analyzed and compared, and their shortcomings were improved. Combining with the characteristics of discrete manufacturing, a digital method of man-hour quota calculation based on the theory of lean production was proposed, and a man-hour quota management system which was a computer-aided measurement system was researched and developed. Firstly, machine power signals were acquired and the processing state was judged after filtering in this system. Secondly, the cutting processing time was gotten according to the processing status, which was integrated as man-hour quota. Finally, the data was stored for future use in data mining and also for providing a reliable basis and guarantee for the accounting of product costs, the plan of production and shop scheduling.
Through above study, multi-objective based genetic algorithm of reverse crossing for job-shop was designed on multi-objective optimization of production scheduling of turbines’key pieces according to the objectives of minimum completion time, least process cost, minimum number of key pieces’delay. The algorithm was base on man-hour quota and the production characteristics of Harbin turbine company limited that was many varieties, small batch, long production cycle, few advanced facilities, difficult processing and production coordination. And, the coding of the algorithm, initial population generation, crossing operator and mutation operator were described in detail. Finally, the man-hour quota management system and job-shop scheduling module were developed and verified in the third branch of the company. The accurate counting of man-hour is realized in this system which has the advantages of simple structure, low cost and practicality, and is suitable to be applied and popularized in discrete manufacturing enterprises.
引文
1 Shaofeng Liu, R I M Young. An exploration of key information models and their relationships in global manufacturing decision support[J]. ImechE, 2007, 221: 711
2王东,生产线标准工时制定方法研究[D],西安电子科技大学硕士论文, 2009, 1-2
3 Yuan-Jye Tseng, Yu-Wen Kao, Feng-Yi Huang. A model for evaluating a design change and the distributed manufacturing operations in a collaborative manufacturing environment[J]. Computers in Industry, 2008, 59: 798
4党新民,苏迎斌,蓝旭日.制造业效率提升技法[M].北京:北京大学出版社, 2008: 105-106
5 Chisholm A W J. Nomenclature and definitions for manufacturing systems[C]. Annals of the CIRP, 1990, 39(2): 735-642
6郭超,周丹晨.遗传神经网络在工时定额计算中的应用[J].机械, 2009, 36(2): 15
7杨有兰.工时定额在工程中的作用[J].宁夏科技,2003, (6): 40
8张贵德.浅议机械加工劳动定额[J].一重技术, 2000, (1): 103-104
9董丰收.基于工艺标准化的工时定额标准工时研究[D].西北工业大学硕士研究生学位论文, 2006: 1-56
10孙浩.浅析劳动工时定额的作用及制定[J].林业机械与木工设备, 2009, 37(8): 57-58
11孙绍文.中小型单件制造企业CAPP系统中工时定额编制子系统的开发[D],华中农业大学硕士论文, 2008, 2-3
12祝巧巧,许映秋,周怡君.计算机辅助工时定额系统的研究与开发[J].机械制造与研究, 2008, 37(2): 25-28
13向北平,蔡茂蓉.机械加工工时定额管理系统的研究与开发[J].微计算机信息, 2007, 23(8): 22-23
14陆远, Shahid Ikramullah Butt.工时定额动态参数建模及可视化研究[J].系统仿真学报, 2008, 20: 330-333
15 Qiaoying Dong, Shulin Kan, Zhihui Huang, Ling Qin. Research on man-hour calculation and cooperative management system of multi-stage manufacturing system[J]. IEEE, 2008: 1-4
16 Fred E Meyers, James R Stewart. Motion and time study for lean manufacturing [M]. Upper Saddle River, N J: Prentice Hall, 2002: 34-78
17 Maeda, Sugano, Kondo. Development of a routing and standard-time estimationexpert system for work management in medium-and small-quantity batch production[J]. ASME, 1992, 1451-1456
18 Nakayama, Shun ichi. A study on setting standard time using work achievement quotient[J]. International Journal of Production, 2002, 40: 3945-3954
19 Shun Ichi Nakayama, Ken Ichiro Nakayama, Hiroshi Nakayama. A study on setting standard time using work achievement quotient[J]. International Journal of Production Research, 2002, 40(15): 3945-3953
20 Shell, Richard L, O.Geoffrey Okogbaa. The Effect of Mental Fatigue on Knowledge Worker Performance [J]. White Collar Productivity (Industrial Engineering and Management Press), Institute of Industrial Engineers, 1997, 14: 42-49
21 Hamdi A Bashir, Vince Thomson. Models of estimating design effort and time Design Studies[J]. Design Studies, 2001, (22): 141-155
22 Abbie Griffin. Modeling and Measuring Product Development Cycle Time Across Industries Journal of Engineering and technology management [J]. Journal of Engineering and Technology Management, 1997, (14): 1-24
23 Abbie Griffin. Product development cycle time for business-to-business products[J]. Industrial Marcketing Mangement. 2002, (31): 291-304
24 Jacome, M.F, V. Lapinskii. Risk assessment and planning of complex designs[J]. Design & Test of Computer. 1997, 14: 42-49
25孙红云.机床检测及精度修正浅析[J].机床与液压, 2009, 37(8): 165-166
26杨峰,王宏颖.数控机床检测元件故障诊断及维修实例[J].新技术新工艺, 2009, (1): 32-35
27刘志,蒋增强,葛茂根,扈静,张铭鑫.面向装配的现场数据采集和过程监控研究[J].机械工程师, 2009, (4): 52-54
28 Johan Riehardson, Martin Fabian. Automatic Generation of PLC Programs for Conirol of Flexible Manufacturing Cells[J]. IEEE, 2003: 337-344
29 B.Brophy, K.Kelly, G.Byrne. AI-based condition monitoring of the drilling process[J]. Journal of Materials Processing Technology, 2002: 305-310
30 MaxFelser, Thilo Sauter. Standardization of Industrial Ethernet-the Next Battefield[J]. IEEE, 2004: 413-421
31冯亚岗.基于改进遗传算法的混合车间调度问题研究[D].兰州理工大学硕士论文, 2009: 1
32 Weijun Xia, Zhiming Wu. An effective hybrid optimization approach for multi-objective flexible job-shop scheduling problems[J]. Computers & Industrial Engineering, 2005, (48): 409-410
33宋华明,马士华.考虑流水线平衡的混合装配线排序[J].中国机械工程,2006, 17(11): 1138-1147
34唐国兰,唐成华,吴云忠.车间生产计划动态调整应用研究[J].机电工程技术, 2004, 33(8): 92-94
35雷德明,吴智明.基于粒子群优化的多目标作业车间调度[J].上海交通大学学报, 2007, 41(11): 1796-1800
36吴启迪,汪镭.智能蚁群算法及应用[M].上海:上海科技教育出版社, 2004: 1-100
37 Hall, N.G.Potts, C.N.. Rescheduling for new orders[J]. Operations Research, 2004, 52(3): 440-453
38 Esquivel S, Ferrer O S, Gallard R. Enhanced evolution aryalgorithm for single and multi objective optimization in job-shop scheduling problem[J]. Knowledge-Based System, 2002, 15(1): 13-25
39 Ho N B, Tay J C. GENACE. An efficient cultural algorithm solving the flexible Job-Shop problem[C]. The Proceedings of 2004 Congress on Evolutionary Computation Piscataway. IEEE Press, 2004, 2: 1759-1766
40罗志清,王润孝,雷建,姜晓鹏,崔怡.机械制造辅助加工时间定额研究[J].机床与液压, 2004, (12): 62-64
41朱历新,刘诚恪.计算机工时定额标准工时络系统建模与实现[J].航天制造技术, 2004, (2): 44-47
42魏学祯,李新勇.合理制定工时定额促进生产率的提高[J].机械研究与应用, 2001, 1: 19-22
43 P Vichare, A Nassehi, S Newman. A unified manufacturing rsource model for representation of computerized numerically controlled machine tools[J]. ImechE, 2009, 223: 463
44 LIANG Y S, HECKER L R, LANGERS R G. Machining process monitoring and control:The State-of-the-art[J]. Journal of Manufacturing Science and Engineering, 2004, 126(3): 297-310
45 LI Ning, SHI Tielin. Estimation of the number of correlated sources with common frequencies based on power spectral density[J]. Chinese Journal of Mechanical Engineering, 2007, 20(4): 88-93
46 NIU Junchuan, ZHAO Guoquan. Research on active vibration control based on combined model for coupled system[J]. Chinese Journal of Mechanical Engineering, 2004, 17(4): 524-527
47王海丽,马春翔,邵华等.车削过程中刀具磨损和破损状态的自动识别[J].上海交通大学学报, 2006, 40(12): 2057-2062
48 AMER W, GROSVENOR R, PRICKETT P. Machine tool condition monitoring using sweeping filter techniques[C]. Proceedings of the Institution ofMechanical Engineers, Part I:Journal of Systems and Control Engineering, 2007, 221(1): 103-117
49王寒枫,林益耀.关于利用切削功率监控刀具状态的评述[J].机械制造, 1995, (4): 6
50赵慧.加速度传感器数字化关键技术研究[D],中北大学硕士论文, 2008: 28-31
51邵华,林益耀.刀具功率监控系统中功率信号的实时处理问题[J].机械设计与研究, 1994, (1): 19-20
52石锦风.基于智能优化算法的车间调度问题的研究[D].无锡:江南大学, 2008: 8-9
53 Ching-JongLiao, Hsiao-Chien Juan. An ant colony optimization for single-machine tardiness scheduling with sequence-dependent setups[J]. Computers & Operations Research, 2007, (34): 1899-1900
54 Tsung-Lieh Lin, Shi-Jinn Horng, Tzong-Wann Kao, Yuan-Hsin Chen, Ray-Shine Run. An efficient job-shop scheduling algorithm based on particle swarm optimization[J]. Expert Systems with Applications, 2010, (37): 2629-2630
55 Changsheng Zhang, Jigui Sun. An alternate two phases particle swarm optimization algorithm for flow shop scheduling problem[J]. Expert Systems with Applications, 2009, (36): 5162-5167
56王方良,吴启迪.生产调度智能算法及其应用[M].北京:科学出版社, 2007: 21-22
57 P B Bacchewar, S K Singhal, P M Pandey. Statistical modelling and optimization of surface roughness in the selective laser sintering process[J]. ImechE, 2007, 221: 35
58于竟.基于遗传算法的Job-Shop车间调度问题研究[D].南京:南京理工大学, 2008: 24
2王东,生产线标准工时制定方法研究[D],西安电子科技大学硕士论文, 2009, 1-2
3 Yuan-Jye Tseng, Yu-Wen Kao, Feng-Yi Huang. A model for evaluating a design change and the distributed manufacturing operations in a collaborative manufacturing environment[J]. Computers in Industry, 2008, 59: 798
4党新民,苏迎斌,蓝旭日.制造业效率提升技法[M].北京:北京大学出版社, 2008: 105-106
5 Chisholm A W J. Nomenclature and definitions for manufacturing systems[C]. Annals of the CIRP, 1990, 39(2): 735-642
6郭超,周丹晨.遗传神经网络在工时定额计算中的应用[J].机械, 2009, 36(2): 15
7杨有兰.工时定额在工程中的作用[J].宁夏科技,2003, (6): 40
8张贵德.浅议机械加工劳动定额[J].一重技术, 2000, (1): 103-104
9董丰收.基于工艺标准化的工时定额标准工时研究[D].西北工业大学硕士研究生学位论文, 2006: 1-56
10孙浩.浅析劳动工时定额的作用及制定[J].林业机械与木工设备, 2009, 37(8): 57-58
11孙绍文.中小型单件制造企业CAPP系统中工时定额编制子系统的开发[D],华中农业大学硕士论文, 2008, 2-3
12祝巧巧,许映秋,周怡君.计算机辅助工时定额系统的研究与开发[J].机械制造与研究, 2008, 37(2): 25-28
13向北平,蔡茂蓉.机械加工工时定额管理系统的研究与开发[J].微计算机信息, 2007, 23(8): 22-23
14陆远, Shahid Ikramullah Butt.工时定额动态参数建模及可视化研究[J].系统仿真学报, 2008, 20: 330-333
15 Qiaoying Dong, Shulin Kan, Zhihui Huang, Ling Qin. Research on man-hour calculation and cooperative management system of multi-stage manufacturing system[J]. IEEE, 2008: 1-4
16 Fred E Meyers, James R Stewart. Motion and time study for lean manufacturing [M]. Upper Saddle River, N J: Prentice Hall, 2002: 34-78
17 Maeda, Sugano, Kondo. Development of a routing and standard-time estimationexpert system for work management in medium-and small-quantity batch production[J]. ASME, 1992, 1451-1456
18 Nakayama, Shun ichi. A study on setting standard time using work achievement quotient[J]. International Journal of Production, 2002, 40: 3945-3954
19 Shun Ichi Nakayama, Ken Ichiro Nakayama, Hiroshi Nakayama. A study on setting standard time using work achievement quotient[J]. International Journal of Production Research, 2002, 40(15): 3945-3953
20 Shell, Richard L, O.Geoffrey Okogbaa. The Effect of Mental Fatigue on Knowledge Worker Performance [J]. White Collar Productivity (Industrial Engineering and Management Press), Institute of Industrial Engineers, 1997, 14: 42-49
21 Hamdi A Bashir, Vince Thomson. Models of estimating design effort and time Design Studies[J]. Design Studies, 2001, (22): 141-155
22 Abbie Griffin. Modeling and Measuring Product Development Cycle Time Across Industries Journal of Engineering and technology management [J]. Journal of Engineering and Technology Management, 1997, (14): 1-24
23 Abbie Griffin. Product development cycle time for business-to-business products[J]. Industrial Marcketing Mangement. 2002, (31): 291-304
24 Jacome, M.F, V. Lapinskii. Risk assessment and planning of complex designs[J]. Design & Test of Computer. 1997, 14: 42-49
25孙红云.机床检测及精度修正浅析[J].机床与液压, 2009, 37(8): 165-166
26杨峰,王宏颖.数控机床检测元件故障诊断及维修实例[J].新技术新工艺, 2009, (1): 32-35
27刘志,蒋增强,葛茂根,扈静,张铭鑫.面向装配的现场数据采集和过程监控研究[J].机械工程师, 2009, (4): 52-54
28 Johan Riehardson, Martin Fabian. Automatic Generation of PLC Programs for Conirol of Flexible Manufacturing Cells[J]. IEEE, 2003: 337-344
29 B.Brophy, K.Kelly, G.Byrne. AI-based condition monitoring of the drilling process[J]. Journal of Materials Processing Technology, 2002: 305-310
30 MaxFelser, Thilo Sauter. Standardization of Industrial Ethernet-the Next Battefield[J]. IEEE, 2004: 413-421
31冯亚岗.基于改进遗传算法的混合车间调度问题研究[D].兰州理工大学硕士论文, 2009: 1
32 Weijun Xia, Zhiming Wu. An effective hybrid optimization approach for multi-objective flexible job-shop scheduling problems[J]. Computers & Industrial Engineering, 2005, (48): 409-410
33宋华明,马士华.考虑流水线平衡的混合装配线排序[J].中国机械工程,2006, 17(11): 1138-1147
34唐国兰,唐成华,吴云忠.车间生产计划动态调整应用研究[J].机电工程技术, 2004, 33(8): 92-94
35雷德明,吴智明.基于粒子群优化的多目标作业车间调度[J].上海交通大学学报, 2007, 41(11): 1796-1800
36吴启迪,汪镭.智能蚁群算法及应用[M].上海:上海科技教育出版社, 2004: 1-100
37 Hall, N.G.Potts, C.N.. Rescheduling for new orders[J]. Operations Research, 2004, 52(3): 440-453
38 Esquivel S, Ferrer O S, Gallard R. Enhanced evolution aryalgorithm for single and multi objective optimization in job-shop scheduling problem[J]. Knowledge-Based System, 2002, 15(1): 13-25
39 Ho N B, Tay J C. GENACE. An efficient cultural algorithm solving the flexible Job-Shop problem[C]. The Proceedings of 2004 Congress on Evolutionary Computation Piscataway. IEEE Press, 2004, 2: 1759-1766
40罗志清,王润孝,雷建,姜晓鹏,崔怡.机械制造辅助加工时间定额研究[J].机床与液压, 2004, (12): 62-64
41朱历新,刘诚恪.计算机工时定额标准工时络系统建模与实现[J].航天制造技术, 2004, (2): 44-47
42魏学祯,李新勇.合理制定工时定额促进生产率的提高[J].机械研究与应用, 2001, 1: 19-22
43 P Vichare, A Nassehi, S Newman. A unified manufacturing rsource model for representation of computerized numerically controlled machine tools[J]. ImechE, 2009, 223: 463
44 LIANG Y S, HECKER L R, LANGERS R G. Machining process monitoring and control:The State-of-the-art[J]. Journal of Manufacturing Science and Engineering, 2004, 126(3): 297-310
45 LI Ning, SHI Tielin. Estimation of the number of correlated sources with common frequencies based on power spectral density[J]. Chinese Journal of Mechanical Engineering, 2007, 20(4): 88-93
46 NIU Junchuan, ZHAO Guoquan. Research on active vibration control based on combined model for coupled system[J]. Chinese Journal of Mechanical Engineering, 2004, 17(4): 524-527
47王海丽,马春翔,邵华等.车削过程中刀具磨损和破损状态的自动识别[J].上海交通大学学报, 2006, 40(12): 2057-2062
48 AMER W, GROSVENOR R, PRICKETT P. Machine tool condition monitoring using sweeping filter techniques[C]. Proceedings of the Institution ofMechanical Engineers, Part I:Journal of Systems and Control Engineering, 2007, 221(1): 103-117
49王寒枫,林益耀.关于利用切削功率监控刀具状态的评述[J].机械制造, 1995, (4): 6
50赵慧.加速度传感器数字化关键技术研究[D],中北大学硕士论文, 2008: 28-31
51邵华,林益耀.刀具功率监控系统中功率信号的实时处理问题[J].机械设计与研究, 1994, (1): 19-20
52石锦风.基于智能优化算法的车间调度问题的研究[D].无锡:江南大学, 2008: 8-9
53 Ching-JongLiao, Hsiao-Chien Juan. An ant colony optimization for single-machine tardiness scheduling with sequence-dependent setups[J]. Computers & Operations Research, 2007, (34): 1899-1900
54 Tsung-Lieh Lin, Shi-Jinn Horng, Tzong-Wann Kao, Yuan-Hsin Chen, Ray-Shine Run. An efficient job-shop scheduling algorithm based on particle swarm optimization[J]. Expert Systems with Applications, 2010, (37): 2629-2630
55 Changsheng Zhang, Jigui Sun. An alternate two phases particle swarm optimization algorithm for flow shop scheduling problem[J]. Expert Systems with Applications, 2009, (36): 5162-5167
56王方良,吴启迪.生产调度智能算法及其应用[M].北京:科学出版社, 2007: 21-22
57 P B Bacchewar, S K Singhal, P M Pandey. Statistical modelling and optimization of surface roughness in the selective laser sintering process[J]. ImechE, 2007, 221: 35
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