以“中间产品”为导向的现代造船模式研究与应用
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摘要
由传统造船模式向现代造船模式转换是满足船舶市场需求、提高生产效率、缩短造船周期的重要手段,也是企业获取更高利润的方法和途径。现代造船模式通过中间产品组织生产的总装造船方式,优化生产组织结构,去掉一切无效的生产过程和环节,通过减少生产过程中的一切浪费来缩短生产周期,提高生产效率,降低生产成本,保证生产质量,从而获得好的产品利润。因此,本文在国内外造船一体化生产管理现状与发展的研究基础上,指出了传统造船生产管理方面存在的问题,同时,对以中间产品为导向的造船一体化生产问题进行深入研究。
首先,对现代造船模式一体化生产特征进行研究,归纳分析现代造船特征,包括空间组织、过程统筹、生产设计、计划管理等方面,对比分析壳、舾、涂一体化与设计、生产、管理一体化的关系。
其次,提出以中间产品为导向的造船一体化生产的管理框架,包括中间产品为导向的设计、生产、管理一体化的作用、内涵、程序和工作内容,提出一种以中间产品为导向的造船设计、生产、管理一体化研制程序,重点研究以中间产品为导向的壳、舾、涂一体化工作内容。
再次,分析了传统造船模式生产管理的不足,阐述了基于“中间产品”的生产管理模式下工程计划管理、工程任务分解及生产过程控制等,以某造船厂的中间产品为研究对象,在对不同功能和结构的中间产品进行分类的基础上,提出一种中间产品的扩展赋时库所Petri网模型,结合生产仿真软件eM-Plant的应用功能,对中间产品库存量仿真数据的监控和分析,对造船中间产品的瓶颈环节、利用率、排序调度的优化与否以及生产的连续性和稳定性进行分析。
最后将上述理论研究成果应用于重庆某造船厂,提出了以中间产品为导向的现代造船模式生产管理中应采取的一些措施,并列举了造船一体化生产过程中间产品调运仿真案例,并从经济效益、社会效益以及推广应用前景总结了应用实施效果。
The conservation of modern shipbuilding mode from traditional is an important way to content the requirement of ship trisection market, improve the production efficient and decline the life-time of shipbuilding. It is also a way and method to help the enterprise to obtain much more revenue. The modern shipbuilding mode optimize the production organization structure, cancel the non-effective process and all the wasting so as to make a good performance in efficiency, production cost, quality and revenue via the integrated shipbuilding mode based on intermediate products. So, based on the integrated shipbuilding production management research result around the world, the exiting problems of the traditional shipbuilding mode are analyzed, and the integrated shipbuilding mode based on intermediate product is studied in this paper.
Firstly, the feature of the integrated production in modern shipbuilding mode is analyzed, including the space organization, process configuration, production design and planning management, etc. The comparation analysis between the integrated bull, outfitting and painting and integrated design, production and management are studied in this paper.
Secondly, the total management frame of shipbuilding integrated production based on intermediate product is proposed in this paper. It included the affection, definition, processes and detail content of the integrated design, production and management which is intermediate product oriented. Certainly, the research process of integrated design, production and management based on intermediate products is studied, and the detailed content of the integrated bull, outfitting and painting based on intermediate products is the core content being studied.
Thirdly, after analyzing the faults of traditional shipbuilding mode, the project planning management, project tasks deviation and production process control of the production management model based on the intermediate product are described. Then, taking the certain intermediate products of one shipyard as the research object, a Timed Place Petri Net model is established based on the classification of intermediate products from different functions and structure. The intermediate products inventory simulation data surveying and analysis, the continually and stable of the production, the bottleneck recognition, equipments utility and the schedule optimization of shipbuilding intermediate products are studied and analyzed in this paper, combined with the application functions of eM-Plant simulation software.
Finally, all above theory studies are applied to one of the shipyards in Chongqing. Some production management proposals to the modern shipbuilding mode based on the intermediate product are given. The example of intermediate products dispatched simulation of shipbuilding integrated production process is studied. And the application implementation effect are concluded from economical benefit, social benefit and the expand application prospect in this paper.
首先,对现代造船模式一体化生产特征进行研究,归纳分析现代造船特征,包括空间组织、过程统筹、生产设计、计划管理等方面,对比分析壳、舾、涂一体化与设计、生产、管理一体化的关系。
其次,提出以中间产品为导向的造船一体化生产的管理框架,包括中间产品为导向的设计、生产、管理一体化的作用、内涵、程序和工作内容,提出一种以中间产品为导向的造船设计、生产、管理一体化研制程序,重点研究以中间产品为导向的壳、舾、涂一体化工作内容。
再次,分析了传统造船模式生产管理的不足,阐述了基于“中间产品”的生产管理模式下工程计划管理、工程任务分解及生产过程控制等,以某造船厂的中间产品为研究对象,在对不同功能和结构的中间产品进行分类的基础上,提出一种中间产品的扩展赋时库所Petri网模型,结合生产仿真软件eM-Plant的应用功能,对中间产品库存量仿真数据的监控和分析,对造船中间产品的瓶颈环节、利用率、排序调度的优化与否以及生产的连续性和稳定性进行分析。
最后将上述理论研究成果应用于重庆某造船厂,提出了以中间产品为导向的现代造船模式生产管理中应采取的一些措施,并列举了造船一体化生产过程中间产品调运仿真案例,并从经济效益、社会效益以及推广应用前景总结了应用实施效果。
The conservation of modern shipbuilding mode from traditional is an important way to content the requirement of ship trisection market, improve the production efficient and decline the life-time of shipbuilding. It is also a way and method to help the enterprise to obtain much more revenue. The modern shipbuilding mode optimize the production organization structure, cancel the non-effective process and all the wasting so as to make a good performance in efficiency, production cost, quality and revenue via the integrated shipbuilding mode based on intermediate products. So, based on the integrated shipbuilding production management research result around the world, the exiting problems of the traditional shipbuilding mode are analyzed, and the integrated shipbuilding mode based on intermediate product is studied in this paper.
Firstly, the feature of the integrated production in modern shipbuilding mode is analyzed, including the space organization, process configuration, production design and planning management, etc. The comparation analysis between the integrated bull, outfitting and painting and integrated design, production and management are studied in this paper.
Secondly, the total management frame of shipbuilding integrated production based on intermediate product is proposed in this paper. It included the affection, definition, processes and detail content of the integrated design, production and management which is intermediate product oriented. Certainly, the research process of integrated design, production and management based on intermediate products is studied, and the detailed content of the integrated bull, outfitting and painting based on intermediate products is the core content being studied.
Thirdly, after analyzing the faults of traditional shipbuilding mode, the project planning management, project tasks deviation and production process control of the production management model based on the intermediate product are described. Then, taking the certain intermediate products of one shipyard as the research object, a Timed Place Petri Net model is established based on the classification of intermediate products from different functions and structure. The intermediate products inventory simulation data surveying and analysis, the continually and stable of the production, the bottleneck recognition, equipments utility and the schedule optimization of shipbuilding intermediate products are studied and analyzed in this paper, combined with the application functions of eM-Plant simulation software.
Finally, all above theory studies are applied to one of the shipyards in Chongqing. Some production management proposals to the modern shipbuilding mode based on the intermediate product are given. The example of intermediate products dispatched simulation of shipbuilding integrated production process is studied. And the application implementation effect are concluded from economical benefit, social benefit and the expand application prospect in this paper.
引文
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[6]刘成岗.造船模式概述及展望[J].中国水运,2007,07(11):27-28.
[7]高介祜.加快建立现代造船模式的思考[J].上海造船,2008,(03):39-42.
[8]胡耀辉.浅析建立现代造船模式的核心基础[J].广船科技,2008,(04):27-30,51.
[9]刁淑华.我国现代造船模式的探讨[J].齐鲁渔业,2008,25(06):63-64.
[10]许巨林,库耘.引进先进模式做强我国造船业[J].中国水运,2004,(06):19-20.
[11]徐学光.探索船舶工业的持续发展[J].上海造船,1999,(01):13-17.
[12]杨国兵,李百洲.关于加快建立我国现代造船模式的对策建议[J].中国行政管理,2008,(3):65-67.
[13]董爱国,杨国安.标准化是建立现代造船模式的基础[J].舰船科学技术,2008,(2):3-4.
[14]张明华,黄胜.精益造船——日本造船模式研究[J].船舶工程,2005,27(02):62-66.
[15]高介祜,郁照荣.造船企业转模的回顾与当今任务[J].造船技术,2000,(05):1-2,10.
[16]黄迪.数字化造船:中国造船工业的必然选择[J].中国水运,2008,(10):44-45.
[17]高晖,陶永宏,管义锋.现代造船模式与船舶工业集群化发展的思考[J].江苏船舶,2006,23(02):39-42.
[18] Tu Jian-Wei, Qu Wei-Lian; Chen Jing. An experimental study on semi-active seismic response control of a large-span building on top of ship lift towers [J]. Journal of Vibration and Control, 2008,20(7) :1055-1074.
[19] Thomas Lamb. Japan’s shipbuilding yards enjoyed the lion’s share of orders at the end of 2000 [J]. International bulk journal. 2001(1):63-64.
[20] Nobohisa Iwase. The machine that changes Japan [J]. Steel times international.1999(23):35-39.
[21] A. Guldem Cerit.Market Orientation Measures of the U.S. and Turkish Shipbuilding Industries: A Comparative Study [J]. Journal of ship production.2002,18(1):19-32.
[22] John King. New directions in shipbuilding policy [J]. Marine Policy. 1999.23(3):191-205
[23] Ivankovic J (Ivankovic, Jakov), Ljubenkov B (Ljubenkov, Boris), Ziha K (Ziha, Kalman). Review of the World Merchant Shipbuilding[J]. BRODOGRADNJA. 2009,60(01):44-50.
[24]吴定龙,张光明,刘群喜.与现代造船模式相适应的船厂管理[J].江苏船舶, 1999,(05):21-25.
[25]王新华,汪静君,章祖岐.建立适应于现代总装化造船的生产体制[J].上海造船,2006,(2):26-29.
[26]柳良音,刘建峰,孙建志,高飞.现代造船模式下精度管理的新探索[J].造船技术, 2008,(06):5-7.
[27]陈炜,黄若波.造船区域舾装技术综述[J].造船技术,2009,(6):5-7.
[28]张海森.系统与造船区域生产管理[J].船舶工程,2005,27(02):67-69.
[29]周子桦.造船生产管理标准化研究[J].上海造船,2004,(02):34-37.
[30] Richard Lee Storch,Sang Gyu Lim. Improving flow to achieve lean manufacturing in shipbuilding [J]. Production Planning and Control. 1999(10):127-137.
[31] L.Bomber,B.G.Dale. Lean production: a study of application in a traditional manufacturing environment [J]. Production Planning and Contro1. 2000(11).
[32] Cho Kyu-Kab,Lee Soo-Hong. An Automatic Process-Planning System for Block Assembly in Shipbuilding [J]. CIRP Annals一Manufacturing Technology.1996,45(l):41-44.
[33] Fafandjel N (Fafandjel, Niksa), Rubesa R (Rubesa, Rajko), Matulja T (Matulja, Tin). Improvement of Industrial Production Process Design Using Systematic Layout Planning [J]. STROJARSTVO. 2009,51(3):177-186.
[34] Yue WH (Yue, Weihong)1, Wang CF (Wang, Chengfang)1, Zhang QY (Zhang, Qingying). Research on the Shipbuilding Logistics System under Modern Shipbuilding[C]. 2008 ISECS INTERNATIONAL COLLOQUIUM ON COMPUTING, COMMUNICATION, CONTROL, AND MANAGEMENT. 2008,3:222-225.
[35]侯小林,苏翔.现代造船模式下工程计划体系研究[J].现在商贸工业:2009,(20):19-20
[36]张海森.现代造船的两个一体化[J].中国造船,2006,47(04):89-95.
[37]张佳春,钟宏才,刘建峰.基于中间产品专业化生产的造船生产成本控制[J].造船技术,2006,(06):10-14.
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