基于MES架构的轮胎成型与硫化工序优化排产系统研究
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摘要
轮胎制造行业是传统的劳动密集型制造行业,在轮胎行业推广、应用信息化技术对提升轮胎制造企业的生产效率和产品质量有极其重要的作用。
制造执行系统(Manufacturing Execution System,MES)作为计划管理层和底层控制层之间的桥梁,起着承上启下的关键作用,是解决二者之间信息断层的重要措施,是实现企业信息化集成的关键,对提升我国工业信息化建设水平有着重要而深远的意义。优化排产系统作为MES的核心组成部分,主要承担企业生产计划的调度和管理,以及底层生产信息和库存信息的统计管理方面的工作；该系统能有效地管理企业生产资源和生产信息,并作出最优的调度和管理策略。如何在轮胎生产企业中建立优化排产系统,提升企业的生产效益和管理水平,是当前轮胎工业信息化过程中正在探索的难题,也是本文研究的出发点和根本点。
本文首先立足于企业制造执行系统框架介绍了轮胎企业优化排产系统的功能和设计框架,结合轮胎企业生产现状和国内某大型轮胎生产企业的实际需求,设计了硫化和成型工序优化排产系统的功能、逻辑结构模型,并对其中的信息采集、数据库技术、生产调度、统计报表等方面的关键技术进行了研究设计。
其次,结合该大型轮胎生产企业生产实际,对轮胎生产行业成型和硫化工序进行建模分析,详细论述了基于订单划分组批策略下的生产模型,设计了优化排产系统的生产调度子系统。为解决人工经验编排成型和硫化任务的低效和精度不高等缺点,针对成型和硫化工序的特点,建立了相应的多目标优化模型,并采用遗传算法求解批次调度问题,通过一系列的仿真研究,证实可以有效地改善当前人工排产调度的效率低、精度差、个体依赖度高的弊端。
再次,采用Delphi2007和SQL Server2005为平台开发设计了成型和硫化工序优化排产系统,并且在国内某大型轮胎生产企业进行现场实施,有效地提高了企业的生产调度水平,提高了生产效率和轮胎产量,减少成型和硫化工序的脱节时间,获得厂家的好评。
现场应用表明,本文设计的轮胎企业成型和硫化优化排产系统能满足企业的实际生产需要,解决计划和执行之间的隔断,对于提升轮胎行业企业信息化水平有重要的意义。
The manufacture of tire & rubber products is a traditional labor-intensive industry. Thus, the utilizing and application of information technology would be very important to improve the quality and efficiency of tire productions.
As a connection between ERP and PCS, manufacturing execution system (MES) plays a key role in solving the information gap and achieving enterprise informatization constructions. MES is very important and significant in improving the informatization construction in our country. The subsystem, the planning optimization system, which serves as the key part of MES, is used to schedule and manage the production plan and responsible for the statistics of the production and storage information. This subsystem can handle the production resource and market information, and make a best decision of optimized scheduling. However, how to estimate such a planning optimization system to improve the production efficiency and economic benefit, is still a difficult topic in the current tire industry. Also, that's why we research and propose my methods in this work.
In this work, based on the requirement and the basic design framework of manufacturing execution systems, a functional and logical structural model was designed to meet the needs of the current situation of the whole tire production and a large manufactory in China. Our design included some key work in information collection, database, scheduling and statistical reporting etc.
Secondly, according to the production requirement of the mentioned manufactory, a model for the tire modeling and vulcanization processes was analyzed and established. In the proposed model, the group strategy based on order was discussed in detail. a production scheduling system was designed to optimize the production plan. What's more, to address the disadvantages such as the poor efficiency and inaccuracy in tire modeling and vulcanization process due to the traditional working schedule based on individual's experience, a multi-object optimized model with genetic algorithm was built. Through the experiments of simulation, the efficiency, accuracy and the dependence on individual are all improved.
Finally, a planning optimization system for tire modeling and vulcanization process is set up based on Delphi 2007 and SQL Server 2005, which is also adopted in the real industry. It is shown that our system can improve the production scheduling effect, the quality and quantity of the tire production, and deduce the time gap between tire modeling and vulcanization processes, compared to the former strategy based on personal experience.
As shown in practice, the designed optimization system can meet the actual requirement of the tire manufacturing, and bridge the gap between the plan and execution. In conclusion, this work plays a significant role to improve the enterprise informatization for the tire and rubber products.
制造执行系统(Manufacturing Execution System,MES)作为计划管理层和底层控制层之间的桥梁,起着承上启下的关键作用,是解决二者之间信息断层的重要措施,是实现企业信息化集成的关键,对提升我国工业信息化建设水平有着重要而深远的意义。优化排产系统作为MES的核心组成部分,主要承担企业生产计划的调度和管理,以及底层生产信息和库存信息的统计管理方面的工作；该系统能有效地管理企业生产资源和生产信息,并作出最优的调度和管理策略。如何在轮胎生产企业中建立优化排产系统,提升企业的生产效益和管理水平,是当前轮胎工业信息化过程中正在探索的难题,也是本文研究的出发点和根本点。
本文首先立足于企业制造执行系统框架介绍了轮胎企业优化排产系统的功能和设计框架,结合轮胎企业生产现状和国内某大型轮胎生产企业的实际需求,设计了硫化和成型工序优化排产系统的功能、逻辑结构模型,并对其中的信息采集、数据库技术、生产调度、统计报表等方面的关键技术进行了研究设计。
其次,结合该大型轮胎生产企业生产实际,对轮胎生产行业成型和硫化工序进行建模分析,详细论述了基于订单划分组批策略下的生产模型,设计了优化排产系统的生产调度子系统。为解决人工经验编排成型和硫化任务的低效和精度不高等缺点,针对成型和硫化工序的特点,建立了相应的多目标优化模型,并采用遗传算法求解批次调度问题,通过一系列的仿真研究,证实可以有效地改善当前人工排产调度的效率低、精度差、个体依赖度高的弊端。
再次,采用Delphi2007和SQL Server2005为平台开发设计了成型和硫化工序优化排产系统,并且在国内某大型轮胎生产企业进行现场实施,有效地提高了企业的生产调度水平,提高了生产效率和轮胎产量,减少成型和硫化工序的脱节时间,获得厂家的好评。
现场应用表明,本文设计的轮胎企业成型和硫化优化排产系统能满足企业的实际生产需要,解决计划和执行之间的隔断,对于提升轮胎行业企业信息化水平有重要的意义。
The manufacture of tire & rubber products is a traditional labor-intensive industry. Thus, the utilizing and application of information technology would be very important to improve the quality and efficiency of tire productions.
As a connection between ERP and PCS, manufacturing execution system (MES) plays a key role in solving the information gap and achieving enterprise informatization constructions. MES is very important and significant in improving the informatization construction in our country. The subsystem, the planning optimization system, which serves as the key part of MES, is used to schedule and manage the production plan and responsible for the statistics of the production and storage information. This subsystem can handle the production resource and market information, and make a best decision of optimized scheduling. However, how to estimate such a planning optimization system to improve the production efficiency and economic benefit, is still a difficult topic in the current tire industry. Also, that's why we research and propose my methods in this work.
In this work, based on the requirement and the basic design framework of manufacturing execution systems, a functional and logical structural model was designed to meet the needs of the current situation of the whole tire production and a large manufactory in China. Our design included some key work in information collection, database, scheduling and statistical reporting etc.
Secondly, according to the production requirement of the mentioned manufactory, a model for the tire modeling and vulcanization processes was analyzed and established. In the proposed model, the group strategy based on order was discussed in detail. a production scheduling system was designed to optimize the production plan. What's more, to address the disadvantages such as the poor efficiency and inaccuracy in tire modeling and vulcanization process due to the traditional working schedule based on individual's experience, a multi-object optimized model with genetic algorithm was built. Through the experiments of simulation, the efficiency, accuracy and the dependence on individual are all improved.
Finally, a planning optimization system for tire modeling and vulcanization process is set up based on Delphi 2007 and SQL Server 2005, which is also adopted in the real industry. It is shown that our system can improve the production scheduling effect, the quality and quantity of the tire production, and deduce the time gap between tire modeling and vulcanization processes, compared to the former strategy based on personal experience.
As shown in practice, the designed optimization system can meet the actual requirement of the tire manufacturing, and bridge the gap between the plan and execution. In conclusion, this work plays a significant role to improve the enterprise informatization for the tire and rubber products.
引文
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