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.
引文
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