订单式生产MOS生产控制优化研究
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摘要
2l世纪是充满竞争与机遇的时代。随着竞争的加剧,产品更新速度的加快,用户需求的不断变化,制造企业不得不采用多品种小批量的生产模式来生产。据有关资料统计,在我国工业企业中,中小型企业占95%以上,订单式生产(MTO Make-To-Order)人工作业系统(MOS Manual Operation System)是我国中小制造企业广泛采用的生产模式,本文提出一种适合MOS特定生产环境的运作模式—基于约束理论的生产控制模式,以实现在多品种小批量环境下的精益化生产。
全文围绕订单式生产MOS的两个特点展开：一,针对MOS多品种小批量的生产环境,提出基于约束理论的DBR生产控制模式。运用约束理论的技术与方法对其实施的细则如瓶颈的侦测、瓶颈的排产、缓冲大小的设置与管理,以及持续改善和实时监控等方面进行了深入研究。运用DBR的生产控制模式能够使企业的运作在计划层和状态层两个层次上实现闭环控制,可快速、有效地查找到系统中的约束,并且制定出利用和消除这些约束的整体优化方案,这极大地挖掘出了制造系统的潜在产能,提高系统产能的同时降低运营费用。二,针对MOS生产模式人员组织灵活多变的特点,提出作业人员的组织优化方法。中小制造企业系统本身存在的人员组织方面效率低下的问题,而对于MTO/MOS生产模式尤为明显,人员分配—在特定的时间,如何找到工作集合和人员集合之间的最佳匹配是一个核心的问题。本文提出一种针对在制品库存系数的人员自组织优化方法,用以改善生产系统的物流平衡,最终提高系统的有效产出。
在理论研究的基础上,本文借助系统仿真软件WITNESS以某文具用品生产企业的现实生产线和订单建立模型蓝本,通过主流生产模式—先来先服务模式和本文提出的基于约束理论的生产控制模式进行对比分析,结果显示基于约束理论的生产控制模式在MOS多品种小批量生产环境下具有明显的优越性。最后,在总结全文的基础上,针对如何进一步完善此生产控制模式进行了展望。
The 21st century is an era full of competition and opportunities. As the competition intensifies, product updates speed up, and the needs of customer constantly changed, Manufacturing enterprises have to use the mode of many varieties and small batch to produce. According to the statistics of relevant information, the industrial enterprises in our country, small and medium-size enterprise (smes) account for 95%, MTO/MOS is the production model used by most smes enterprises. Therefore, this paper explore a mode which adapt to the production environment for MOS-the production control system based on constraint theory, In order to achieve the lean production in the environment of many varieties and small batch.
The paper spread out by two characteristics of MTO/MOS:First, the paper proposes a DBR production control mode based on the theory of constraints for MOS's many varieties and small batch production environment. Having a deep research on the detect of bottleneck, the scheduling of bottleneck, the settings of buffer size and management, continuous improvement and real-time monitoring etc. by using the technologies and methods of theory of constraints. This production mode can realize Closed-loop control between the planning layer and state layer in enterprises. It can find out the constraint of the system effectively, and then making out the optimization scheme to utilize and eliminate these constraints, as a result, greatly excavating the potential capacity of manufacturing system, and reducing operating costs. Second, a personnel organization optimization method is to be developed for the characteristic of MOS's flexible and changeable personnel organization. Smes system itself exists the problem of low efficiency in personnel organization, and especially in the MTO/MOS production mode. Personnel distribution--the best match between work and labor in particular time is a core problem. This paper proposes a method for personnel self-organization optimization which depends on the work-in-process coefficient, to improve production system's logistics balance, and finally to improve the effective output of the system.
On the basis of theoretical analysis, a model for a Stationery enterprise has been carried out by using WITNESS simulation software. Through the comparative analysis between mainstream production mode--first come, first service and the production control model based on the theory of constraint, the result shows that the second one has superiority. The paper also points out the problems and the direction of future research.
全文围绕订单式生产MOS的两个特点展开：一,针对MOS多品种小批量的生产环境,提出基于约束理论的DBR生产控制模式。运用约束理论的技术与方法对其实施的细则如瓶颈的侦测、瓶颈的排产、缓冲大小的设置与管理,以及持续改善和实时监控等方面进行了深入研究。运用DBR的生产控制模式能够使企业的运作在计划层和状态层两个层次上实现闭环控制,可快速、有效地查找到系统中的约束,并且制定出利用和消除这些约束的整体优化方案,这极大地挖掘出了制造系统的潜在产能,提高系统产能的同时降低运营费用。二,针对MOS生产模式人员组织灵活多变的特点,提出作业人员的组织优化方法。中小制造企业系统本身存在的人员组织方面效率低下的问题,而对于MTO/MOS生产模式尤为明显,人员分配—在特定的时间,如何找到工作集合和人员集合之间的最佳匹配是一个核心的问题。本文提出一种针对在制品库存系数的人员自组织优化方法,用以改善生产系统的物流平衡,最终提高系统的有效产出。
在理论研究的基础上,本文借助系统仿真软件WITNESS以某文具用品生产企业的现实生产线和订单建立模型蓝本,通过主流生产模式—先来先服务模式和本文提出的基于约束理论的生产控制模式进行对比分析,结果显示基于约束理论的生产控制模式在MOS多品种小批量生产环境下具有明显的优越性。最后,在总结全文的基础上,针对如何进一步完善此生产控制模式进行了展望。
The 21st century is an era full of competition and opportunities. As the competition intensifies, product updates speed up, and the needs of customer constantly changed, Manufacturing enterprises have to use the mode of many varieties and small batch to produce. According to the statistics of relevant information, the industrial enterprises in our country, small and medium-size enterprise (smes) account for 95%, MTO/MOS is the production model used by most smes enterprises. Therefore, this paper explore a mode which adapt to the production environment for MOS-the production control system based on constraint theory, In order to achieve the lean production in the environment of many varieties and small batch.
The paper spread out by two characteristics of MTO/MOS:First, the paper proposes a DBR production control mode based on the theory of constraints for MOS's many varieties and small batch production environment. Having a deep research on the detect of bottleneck, the scheduling of bottleneck, the settings of buffer size and management, continuous improvement and real-time monitoring etc. by using the technologies and methods of theory of constraints. This production mode can realize Closed-loop control between the planning layer and state layer in enterprises. It can find out the constraint of the system effectively, and then making out the optimization scheme to utilize and eliminate these constraints, as a result, greatly excavating the potential capacity of manufacturing system, and reducing operating costs. Second, a personnel organization optimization method is to be developed for the characteristic of MOS's flexible and changeable personnel organization. Smes system itself exists the problem of low efficiency in personnel organization, and especially in the MTO/MOS production mode. Personnel distribution--the best match between work and labor in particular time is a core problem. This paper proposes a method for personnel self-organization optimization which depends on the work-in-process coefficient, to improve production system's logistics balance, and finally to improve the effective output of the system.
On the basis of theoretical analysis, a model for a Stationery enterprise has been carried out by using WITNESS simulation software. Through the comparative analysis between mainstream production mode--first come, first service and the production control model based on the theory of constraint, the result shows that the second one has superiority. The paper also points out the problems and the direction of future research.
引文
[1]张毕西.基于订单式生产下的产品计划投产量决策[J],系统工程理论与实践,2008(7)：165.
[2]谢祥添.多品种、小批量、订单式生产系统优化研究[D],广东工业大学硕士学位论文,2008.
[3]Seonmin Kim,K.Roscoe Davis,James F.Cox Ⅲ. An investigation of output flow control, bottleneck flow control and dynamic flow control mechanisms in various simple lines scenarios. Production Planning&Control 2003,14(1):15～24
[4]Yuan K J,Sheng-Hung Chang,Rong-Kwei Li. Enhancement of Theory of Constraints replenishment using a novel generic buffer management procedure. International Journal of Production Research,2003,41(4):725～740
[5]Uzsoy R,Wang C.S. Performance of decomposition procedures for job shop scheduling problems with bottleneck machines. International Journal of Production Research,2000,38(6):15～20
[6]王军强,孙树栋等.基于约束理论的制造单元管理与控制研究[J].计算机集成制造系统,2006,7(7)：1108-1115.
[7]曹振新,张士杰.基于约束理论的制造单元瓶颈分析及对策[J].机械设计与制造,2004,5(4)：109-111.
[8]李浩,沈祖志,邓明荣.订货型企业基于约束理论的订单排产优化研究[J].中国机械工程,2004,5(15)：865-868.
[9]王晶,荣超.基于精益生产方式与约束理论的企业过程动态改进.北京航空航天大学学报.社会科学版,2001(14)：31-35
[10]Techawiboonwong, Atthawit; Yenradee, Pisal; Das, Sanchoy K. A master scheduling model with skilled and unskilled temporary workers[J], International Journal of Production Economics,2006,103(2),798～809;
[11]Suer, Gursel A.; Dagli, Cihan, Intra-cell manpower transfers and cell loading in labor-intensive manufacturing cells[J], Computers and Industrial Engineering,2005,48(3),643-655；
[12]Suer, Gursel A. Cosner, Jeremy; Patten, Amanda, Models for cell loading and product sequencing in labor-intensive cells[J], Computers and Industrial Engineering,2009,56(1):97-105;
[13]Odiaka,Emeka, Process and performance optimization strategies by labor-intensive, small- and medium-sized industries:Cross-cultural cases from America and Nigeria[D], Walden University. Applied Management and Decision Sciences.2008.
[14]Suer,G.A.;Tummaluri,R.R.,Multi-period operator assignment considering skills,learning and forgetting in labour-intensive cells[J],International Journal of Production Research, January,2008,46(2):69-93.
[15]Chua, T.J.; Cai, T.X.; Low, Joyce M.W., Dynamic operations and manpower scheduling for high-mix, low-volume manufacturing[C], Proceedings of the 13th IEEE International Conference on Emerging Technologies and Factory Automation, ETFA 2008,54-57;
[16]Lakshminarayana, Ramaprasad E.,Takai, Shun, Effects of non-geometric features and incentive schemes on manual assembly of system variants:An experimental study[J], ASME International Mechanical Engineering Congress and Exposition, Proceedings, Proceedings of the ASME International Mechanical Engineering Congress and Exposition, IMECE 2008,535-544.
[17]Lassalle, S.; Wang, Q.; Owen, G.W.; Milenam, A.R., A study of in-process waiting time on a linear walking worker assembly line[J], Journal of Engineering Manufacture,2007,221(12),1763-1770.
[18]Coffey,D.,Thornley,C. Automation, motivation and lean production reconsidered[J], Assembly Automation,2006,26(2):98-103.
[19]Hata, Seiji,Anezaki, Takashi, Human friendly production system[C], Proceedings of the 2007 IEEE International Conference on Mechatronics and Automation, ICMA2007，3196-3201
[20]Riley, M.,Lockwood, A., Strategies and measurement for workforce flexibility:an application of functional flexibility in a service setting[J], International Journal of Operations & Production Management,1997,17(3):13-19.
[21]李霄,郭予红,关于广东中小企业发展问题的思考[J],生产力研究,2006(6), 248-250
[22]李捷,关于广东中小企业发展问题的思考[J],岭南学刊,2003(4),59-62；
[23]王玉荣,孔祥云.TOC简介.AMT企业资源管理研究中心2003.8
[24]杨依依,JIT与TOC的比较研究,管理科学文摘,2004(12),52
[25]姜文炳,约束条件的理论(TOC)简介,工程建设与设计,1998(4),30-31
[26]曲立,基于约束的设备维修方式选择,北京机械工业学院学报,2002(4),60-61
[27]宋俊平Promodel与TOC在制造系统优化中的应用研究[D].山西财经大学硕士学位论文,2005.
[28]刘骏良.基于约束理论的多品种小批量混流生产控制模式研究[D].华中科技大学硕士学位论文,2007.
[29]张宇.基于约束理论的车间生产负荷控制研究[D].华中科技大学硕士学位论文,2007.
[30]曹振兴,张士杰.基于约束理论的制造单元瓶颈分析及对策.机械设计及制造,2005(2),48.
[31]Joseph Adams, Egon Balas, Daniel Zawack. The Shifting Bottleneck Procedure for Job Shop Scheduling. Management Science,1988,34(3):5-12
[32]Roser C, Nakano M, Tanaka M. Shifting bottleneck detection [A]. Proceeding of the 2002 Winter Simulation Conference [C]. New York, NY, USA:IEEE,2002. 1079-1086.
[33]S.-Y. Chiang, C.-T. Kuo, and S.M. Meerkov. DT-Bottlenecks in Serial Production Lines:Theory and Application. IEEE Transactions on Robotics and Automation, 2000,16(5):567-580.
[34]Rommel Cosmo D'Souza. A throughput-based technique for identifying production system bottlenecks. PHD thesis of Mississippi State University.2004.
[35]李爱华,尹柳营.DBR技术中确定缓冲大小的模型.中国管理科学,1998,3(6),
[36]胡珊珊.央行基层机构员工胜任力评价研究[D].兰州大学硕士学位论文,2009.
[37]F. Leymann, D.Roller. Production Workflow:Concepts and Techniques.1st ed. New York, NY,USA:Prentice Hall PTR,1999.
[38]刘英博.工作流运行时人员只能分配技术研究[D].清华大学博士学位论文,2008.
[39]M. Pinedo. Scheduling:Theory, Algorithms, and Systems.2nd ed.:Prentice Hall,2001.
[40]J.Eder,P.Horst,G.Wolfgang,N.Michael.Personal Schedules for Workflow Systems. Proceedings of International Conference on Business Process Management(BPM 2003). Eindhoven,The Netherlands.2003.
[41]檀润华.创新设计：TRIZ发明问题解决理论[M].北京：机械工业出版社,2002.
[42]王军强,孙树栋,司书宾,考虑外包能力拓展的TOC产品组合优化研究,系统仿真学报,2006(12).
[43]余华,基于TOC与计算智能的生产调度问题研究[D],大连理工大学,2006
[2]谢祥添.多品种、小批量、订单式生产系统优化研究[D],广东工业大学硕士学位论文,2008.
[3]Seonmin Kim,K.Roscoe Davis,James F.Cox Ⅲ. An investigation of output flow control, bottleneck flow control and dynamic flow control mechanisms in various simple lines scenarios. Production Planning&Control 2003,14(1):15～24
[4]Yuan K J,Sheng-Hung Chang,Rong-Kwei Li. Enhancement of Theory of Constraints replenishment using a novel generic buffer management procedure. International Journal of Production Research,2003,41(4):725～740
[5]Uzsoy R,Wang C.S. Performance of decomposition procedures for job shop scheduling problems with bottleneck machines. International Journal of Production Research,2000,38(6):15～20
[6]王军强,孙树栋等.基于约束理论的制造单元管理与控制研究[J].计算机集成制造系统,2006,7(7)：1108-1115.
[7]曹振新,张士杰.基于约束理论的制造单元瓶颈分析及对策[J].机械设计与制造,2004,5(4)：109-111.
[8]李浩,沈祖志,邓明荣.订货型企业基于约束理论的订单排产优化研究[J].中国机械工程,2004,5(15)：865-868.
[9]王晶,荣超.基于精益生产方式与约束理论的企业过程动态改进.北京航空航天大学学报.社会科学版,2001(14)：31-35
[10]Techawiboonwong, Atthawit; Yenradee, Pisal; Das, Sanchoy K. A master scheduling model with skilled and unskilled temporary workers[J], International Journal of Production Economics,2006,103(2),798～809;
[11]Suer, Gursel A.; Dagli, Cihan, Intra-cell manpower transfers and cell loading in labor-intensive manufacturing cells[J], Computers and Industrial Engineering,2005,48(3),643-655；
[12]Suer, Gursel A. Cosner, Jeremy; Patten, Amanda, Models for cell loading and product sequencing in labor-intensive cells[J], Computers and Industrial Engineering,2009,56(1):97-105;
[13]Odiaka,Emeka, Process and performance optimization strategies by labor-intensive, small- and medium-sized industries:Cross-cultural cases from America and Nigeria[D], Walden University. Applied Management and Decision Sciences.2008.
[14]Suer,G.A.;Tummaluri,R.R.,Multi-period operator assignment considering skills,learning and forgetting in labour-intensive cells[J],International Journal of Production Research, January,2008,46(2):69-93.
[15]Chua, T.J.; Cai, T.X.; Low, Joyce M.W., Dynamic operations and manpower scheduling for high-mix, low-volume manufacturing[C], Proceedings of the 13th IEEE International Conference on Emerging Technologies and Factory Automation, ETFA 2008,54-57;
[16]Lakshminarayana, Ramaprasad E.,Takai, Shun, Effects of non-geometric features and incentive schemes on manual assembly of system variants:An experimental study[J], ASME International Mechanical Engineering Congress and Exposition, Proceedings, Proceedings of the ASME International Mechanical Engineering Congress and Exposition, IMECE 2008,535-544.
[17]Lassalle, S.; Wang, Q.; Owen, G.W.; Milenam, A.R., A study of in-process waiting time on a linear walking worker assembly line[J], Journal of Engineering Manufacture,2007,221(12),1763-1770.
[18]Coffey,D.,Thornley,C. Automation, motivation and lean production reconsidered[J], Assembly Automation,2006,26(2):98-103.
[19]Hata, Seiji,Anezaki, Takashi, Human friendly production system[C], Proceedings of the 2007 IEEE International Conference on Mechatronics and Automation, ICMA2007，3196-3201
[20]Riley, M.,Lockwood, A., Strategies and measurement for workforce flexibility:an application of functional flexibility in a service setting[J], International Journal of Operations & Production Management,1997,17(3):13-19.
[21]李霄,郭予红,关于广东中小企业发展问题的思考[J],生产力研究,2006(6), 248-250
[22]李捷,关于广东中小企业发展问题的思考[J],岭南学刊,2003(4),59-62；
[23]王玉荣,孔祥云.TOC简介.AMT企业资源管理研究中心2003.8
[24]杨依依,JIT与TOC的比较研究,管理科学文摘,2004(12),52
[25]姜文炳,约束条件的理论(TOC)简介,工程建设与设计,1998(4),30-31
[26]曲立,基于约束的设备维修方式选择,北京机械工业学院学报,2002(4),60-61
[27]宋俊平Promodel与TOC在制造系统优化中的应用研究[D].山西财经大学硕士学位论文,2005.
[28]刘骏良.基于约束理论的多品种小批量混流生产控制模式研究[D].华中科技大学硕士学位论文,2007.
[29]张宇.基于约束理论的车间生产负荷控制研究[D].华中科技大学硕士学位论文,2007.
[30]曹振兴,张士杰.基于约束理论的制造单元瓶颈分析及对策.机械设计及制造,2005(2),48.
[31]Joseph Adams, Egon Balas, Daniel Zawack. The Shifting Bottleneck Procedure for Job Shop Scheduling. Management Science,1988,34(3):5-12
[32]Roser C, Nakano M, Tanaka M. Shifting bottleneck detection [A]. Proceeding of the 2002 Winter Simulation Conference [C]. New York, NY, USA:IEEE,2002. 1079-1086.
[33]S.-Y. Chiang, C.-T. Kuo, and S.M. Meerkov. DT-Bottlenecks in Serial Production Lines:Theory and Application. IEEE Transactions on Robotics and Automation, 2000,16(5):567-580.
[34]Rommel Cosmo D'Souza. A throughput-based technique for identifying production system bottlenecks. PHD thesis of Mississippi State University.2004.
[35]李爱华,尹柳营.DBR技术中确定缓冲大小的模型.中国管理科学,1998,3(6),
[36]胡珊珊.央行基层机构员工胜任力评价研究[D].兰州大学硕士学位论文,2009.
[37]F. Leymann, D.Roller. Production Workflow:Concepts and Techniques.1st ed. New York, NY,USA:Prentice Hall PTR,1999.
[38]刘英博.工作流运行时人员只能分配技术研究[D].清华大学博士学位论文,2008.
[39]M. Pinedo. Scheduling:Theory, Algorithms, and Systems.2nd ed.:Prentice Hall,2001.
[40]J.Eder,P.Horst,G.Wolfgang,N.Michael.Personal Schedules for Workflow Systems. Proceedings of International Conference on Business Process Management(BPM 2003). Eindhoven,The Netherlands.2003.
[41]檀润华.创新设计：TRIZ发明问题解决理论[M].北京：机械工业出版社,2002.
[42]王军强,孙树栋,司书宾,考虑外包能力拓展的TOC产品组合优化研究,系统仿真学报,2006(12).
[43]余华,基于TOC与计算智能的生产调度问题研究[D],大连理工大学,2006