定制型制造企业绿色制造实施模型及实施方法研究
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摘要
我国是世界制造大国,制造业是国民经济的主要支柱产业。但是,制造业基础薄弱,创新能力不强;在制造过程中,资源、能源消耗大,污染严重。因此,《国家中长期科学和技术发展规划纲要(2006-2020年)》把“发展绿色制造,加快相关技术应用,大力推进绿色制造的实施”确定为制造业领域发展的三大思路之一。
“发展绿色制造”是一个复杂的系统工程,既要强调绿色制造应用技术的研发,也要注重共性技术(如绿色制造的实施模型、实施方法、标准体系、基础数据等)的深入研究。同时,随着传统的以产品为中心的批量生产模式向以客户为中心的定制生产模式的转变,定制生产模式逐渐成为越来越多企业所采用的主导生产模式。因此,有必要结合定制生产的特点进行绿色制造实施模型与实施方法的研究。
本文在国家科技支撑计划重大项目课题“绿色制造技术体系与运行模式研究”(2006BAF02A01-01)、国家自然科学基金项目“废旧机电产品大批量定制化绿色再制造过程模型及优化技术研究”(50605066)和重庆市自然科学基金重点项目“绿色制造基础理论与系统方法”(2004-47-19)等课题的资助下,对定制型制造企业绿色制造实施模型及实施方法展开研究。
首先,在综合分析现有相关研究文献的基础上,从实施绿色制造需要有实施模型的指导这个问题出发,围绕绿色制造的基本思想,分析了绿色制造实施模型及定制型制造企业绿色制造实施模型的概念。在此基础上,结合定制生产的特点以及定制型制造企业实施绿色制造的特殊需求,提出一种定制型制造企业绿色制造实施模型。鉴于实施模型的复杂性,建立了包括功能视图、产品生命周期视图、制造过程视图、结构视图、资源视图、环境影响视图等六个视图的定制型制造企业绿色制造实施模型的系统视图,以便于从不同的角度分析和理解实施模型;为了方便指导实施,构建了包括支撑层、生命周期主线层、目标层等三层结构的定制型制造企业绿色制造实施模型的系统框架,并对实施技术体系进行了阐述。
接着,从实施绿色制造的方法论、实施系统方法和实施总体思路等几个方面,对定制型制造企业绿色制造实施方法的总体框架进行探讨。
进而,着重对定制产品的绿色设计方法和制造过程环境影响分析方法进行研究。在定制产品绿色设计方面,针对目前产品定制方式中选配型定制和变型定制最为常见、最为主要,而特殊定制即全新型定制较少的情形,以及绿色设计涉及的内容非常复杂,诸多因素的影响很难量化等情况,把基于实例进行产品设计的方法引入到定制产品的绿色设计中,设计了一种基于实例的定制产品绿色设计流程。并且,分别对该流程中的客户需求分析方法、产品实例方案的匹配方法、产品方案环境属性分析方法和集成环境属性的产品方案选择方法进行研究。该设计流程的基本思路是根据客户需求检索相关实例,在相近实例的基础上集成资源消耗、环境影响、可拆卸等因素选择产品方案,然后进行详细设计。在制造过程环境影响分析方面,针对制造过程环境影响分析中参考评价标准各异,难以进行有效的定量分析等问题,提出了一种基于生态指示器99的制造过程环境影响分析模型。通过对该模型进行数学描述,提出制造过程环境影响值的计算方法,建立单元制造过程的环境影响矩阵,从综合值评价、不同排放物的环境影响评价和不同环境效应评价三个方面对制造过程的环境影响进行分析,为制造过程环境友好性的改善提供数据参考。
最后,基于上述部分研究成果,对某一定制型电器开关柜产品制造企业进行了应用分析和绿色制造的初步实践,并对实施情况进行了介绍。
Manufacturing industry is the main pillar industries of national economy. But the foundation of manufacturing industry in our country is weak; the innovation ability is not strong, and the consumption of resources and energy during manufacturing process is huge, accompany with severe pollution problems. Therefore, the idea of“developing green manufacturing, speeding up relevant technology application, promoting green manufacturing implementation”is be considered as one of the three thoughts leading the development of manufacturing written in National Outline for Medium and Long Term S&T Development (2006-2020).
“Developing green manufacturing”is the complicated system engineering. It calls for both the emphasis on the green manufacturing technology, and the attention to the common technology (such as the green manufacturing implementation model, implementation method, standard system, the basic data, etc.). At the same time, along with the production focus transferring form product to customer, customization production mode gradually become dominant production mode adopt by more and more enterprises. Therefore, it is necessary to do the research on green manufacturing implementation model and implementation methods for custom-manufacturing enterprises based on the characteristics of customization production.
With the foundation of National Key Project of Scientific and Technical Supporting Programs of China (Project No. 2006BAF02A01), National Natural Science Foundation of China (Project No. 50605066) and Chongqing Natural Science Foundation, this paper studied on green manufacturing implementation model and implementation methods for custom-manufacturing enterprises. The details of the contents are presented below.
First, aiming at the implementation of green manufacturing needs the guiding of the implementation model, based on the analysis of the existing research and the basic idea of green manufacturing, the concept of the green manufacturing implementation model for custom-manufacturing enterprises is analyzed. On this basis, combining the characteristics of customization production and the special demand of custom-manufacturing enterprises, a green manufacturing implementation model for custom-manufacturing enterprises is proposed. Due to the complexity of the implementation model, the system views, including functional view, product life cycle views, manufacturing process view, structural view, resources and environment influence views, of the implementation model is established. By the system views, the implementation model can be understood from different aspect. In order to facilitate the implementation, a three-layer framework of the model, including goal layer, product life cycle layer and supporting layer, is construct. And the technical systems are expounded.
Second, the methodology, the system engineering method and the general ideas of the green manufacturing implementation method for custom-manufacturing enterprises is discussed. And then, focuses on the product scheme green design method for custom product and the environmental impact of manufacturing process analysis method. On the product scheme green design method, a case-based product scheme green design method for custom product is designed. For this method, the customer demand analysis method, case-based product scheme matching method, product scheme environmental attributes analysis method and customized product design scheme selection method with a focus on integration of environmental attributes are studied respectively. The basic idea of the method is that choose the similar case according to the customer demand, and design the product scheme with a focus on integration of environmental attributes(resource consumption, environmental impact, easy disassemble, etc.), then design the product in detail. On the environmental impact of manufacturing process analysis method, taking Eco-indicator 99 as a reference standard, an analysis model for environmental impact in manufacturing process is presented. Then, the solving processes of the model are briefly described and the environmental impact assessment matrix of a cellular manufacturing process is established. The model can be used to calculate the environmental impact value of manufacturing process which is compatible with the eco-indicator 99. This value can be used to improve the environmental friendliness of manufacturing process and product design programs.
Finally, analyzed the application program for a certain type of electric switchgear product custom-manufacturing enterprise based on the research results, and introduced the implementation.
“发展绿色制造”是一个复杂的系统工程,既要强调绿色制造应用技术的研发,也要注重共性技术(如绿色制造的实施模型、实施方法、标准体系、基础数据等)的深入研究。同时,随着传统的以产品为中心的批量生产模式向以客户为中心的定制生产模式的转变,定制生产模式逐渐成为越来越多企业所采用的主导生产模式。因此,有必要结合定制生产的特点进行绿色制造实施模型与实施方法的研究。
本文在国家科技支撑计划重大项目课题“绿色制造技术体系与运行模式研究”(2006BAF02A01-01)、国家自然科学基金项目“废旧机电产品大批量定制化绿色再制造过程模型及优化技术研究”(50605066)和重庆市自然科学基金重点项目“绿色制造基础理论与系统方法”(2004-47-19)等课题的资助下,对定制型制造企业绿色制造实施模型及实施方法展开研究。
首先,在综合分析现有相关研究文献的基础上,从实施绿色制造需要有实施模型的指导这个问题出发,围绕绿色制造的基本思想,分析了绿色制造实施模型及定制型制造企业绿色制造实施模型的概念。在此基础上,结合定制生产的特点以及定制型制造企业实施绿色制造的特殊需求,提出一种定制型制造企业绿色制造实施模型。鉴于实施模型的复杂性,建立了包括功能视图、产品生命周期视图、制造过程视图、结构视图、资源视图、环境影响视图等六个视图的定制型制造企业绿色制造实施模型的系统视图,以便于从不同的角度分析和理解实施模型;为了方便指导实施,构建了包括支撑层、生命周期主线层、目标层等三层结构的定制型制造企业绿色制造实施模型的系统框架,并对实施技术体系进行了阐述。
接着,从实施绿色制造的方法论、实施系统方法和实施总体思路等几个方面,对定制型制造企业绿色制造实施方法的总体框架进行探讨。
进而,着重对定制产品的绿色设计方法和制造过程环境影响分析方法进行研究。在定制产品绿色设计方面,针对目前产品定制方式中选配型定制和变型定制最为常见、最为主要,而特殊定制即全新型定制较少的情形,以及绿色设计涉及的内容非常复杂,诸多因素的影响很难量化等情况,把基于实例进行产品设计的方法引入到定制产品的绿色设计中,设计了一种基于实例的定制产品绿色设计流程。并且,分别对该流程中的客户需求分析方法、产品实例方案的匹配方法、产品方案环境属性分析方法和集成环境属性的产品方案选择方法进行研究。该设计流程的基本思路是根据客户需求检索相关实例,在相近实例的基础上集成资源消耗、环境影响、可拆卸等因素选择产品方案,然后进行详细设计。在制造过程环境影响分析方面,针对制造过程环境影响分析中参考评价标准各异,难以进行有效的定量分析等问题,提出了一种基于生态指示器99的制造过程环境影响分析模型。通过对该模型进行数学描述,提出制造过程环境影响值的计算方法,建立单元制造过程的环境影响矩阵,从综合值评价、不同排放物的环境影响评价和不同环境效应评价三个方面对制造过程的环境影响进行分析,为制造过程环境友好性的改善提供数据参考。
最后,基于上述部分研究成果,对某一定制型电器开关柜产品制造企业进行了应用分析和绿色制造的初步实践,并对实施情况进行了介绍。
Manufacturing industry is the main pillar industries of national economy. But the foundation of manufacturing industry in our country is weak; the innovation ability is not strong, and the consumption of resources and energy during manufacturing process is huge, accompany with severe pollution problems. Therefore, the idea of“developing green manufacturing, speeding up relevant technology application, promoting green manufacturing implementation”is be considered as one of the three thoughts leading the development of manufacturing written in National Outline for Medium and Long Term S&T Development (2006-2020).
“Developing green manufacturing”is the complicated system engineering. It calls for both the emphasis on the green manufacturing technology, and the attention to the common technology (such as the green manufacturing implementation model, implementation method, standard system, the basic data, etc.). At the same time, along with the production focus transferring form product to customer, customization production mode gradually become dominant production mode adopt by more and more enterprises. Therefore, it is necessary to do the research on green manufacturing implementation model and implementation methods for custom-manufacturing enterprises based on the characteristics of customization production.
With the foundation of National Key Project of Scientific and Technical Supporting Programs of China (Project No. 2006BAF02A01), National Natural Science Foundation of China (Project No. 50605066) and Chongqing Natural Science Foundation, this paper studied on green manufacturing implementation model and implementation methods for custom-manufacturing enterprises. The details of the contents are presented below.
First, aiming at the implementation of green manufacturing needs the guiding of the implementation model, based on the analysis of the existing research and the basic idea of green manufacturing, the concept of the green manufacturing implementation model for custom-manufacturing enterprises is analyzed. On this basis, combining the characteristics of customization production and the special demand of custom-manufacturing enterprises, a green manufacturing implementation model for custom-manufacturing enterprises is proposed. Due to the complexity of the implementation model, the system views, including functional view, product life cycle views, manufacturing process view, structural view, resources and environment influence views, of the implementation model is established. By the system views, the implementation model can be understood from different aspect. In order to facilitate the implementation, a three-layer framework of the model, including goal layer, product life cycle layer and supporting layer, is construct. And the technical systems are expounded.
Second, the methodology, the system engineering method and the general ideas of the green manufacturing implementation method for custom-manufacturing enterprises is discussed. And then, focuses on the product scheme green design method for custom product and the environmental impact of manufacturing process analysis method. On the product scheme green design method, a case-based product scheme green design method for custom product is designed. For this method, the customer demand analysis method, case-based product scheme matching method, product scheme environmental attributes analysis method and customized product design scheme selection method with a focus on integration of environmental attributes are studied respectively. The basic idea of the method is that choose the similar case according to the customer demand, and design the product scheme with a focus on integration of environmental attributes(resource consumption, environmental impact, easy disassemble, etc.), then design the product in detail. On the environmental impact of manufacturing process analysis method, taking Eco-indicator 99 as a reference standard, an analysis model for environmental impact in manufacturing process is presented. Then, the solving processes of the model are briefly described and the environmental impact assessment matrix of a cellular manufacturing process is established. The model can be used to calculate the environmental impact value of manufacturing process which is compatible with the eco-indicator 99. This value can be used to improve the environmental friendliness of manufacturing process and product design programs.
Finally, analyzed the application program for a certain type of electric switchgear product custom-manufacturing enterprise based on the research results, and introduced the implementation.
引文
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