多品种混流制造车间运作控制方法研究与应用
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摘要
客户多样化的需求,使得制造模式从传统的大批量、重复型生产逐渐转变为多品种小批量生产,其生产需求的不确定性及生产过程的不稳定性给车间运作控制带来了严峻的挑战。混流制造技术在基本不改变现有生产条件的前提下,可以在同一生产系统或单元中生产多种不同型号、不同数量、但工艺基本相似的产品,因而具有较高的灵活性。然而,传统的混流制造技术仍然无法适用于产品品种变换更为频繁、需求波动更大的生产环境。为此,本文探讨了适合于多品种小批量生产环境下新的混流制造模式及其运作控制方法。
首先,综述了目前制造系统运作控制相关领域的研究现状,分析了多品种小批量生产环境的特点与困难,指出了多品种小批量混流制造与传统混流制造所运用精益技术的区别,并建立了一个基于约束管理的多品种小批量混流制造系统的总体运作框架。
接着,围绕着总体运作框架中不同层次的相关技术进行了深入研究,具体包括：
(1)在车间总体运作控制层次上,提出了基于虚拟制造单元的混流路径动态规划与管理模式。该模式在继承传统混流路径的简化物流、易于管理等优势的同时,结合了虚拟制造单元的逻辑重构和设备可共享的特点,可提高设备的利用率,能适应多品种小批量生产环境下多变的需求。在混流路径的具体规划方法上,首先生成零件族,然后为相应的零件族分配合适的设备资源,最终形成具有资源共享特征的混流生产路径。在零件族的生成过程中,根据零件的工艺相似性,运用相似系数法建立数学模型并求解。在路径资源分配过程中,提出了混流路径资源分配的数学模型,以产出最大化和共享资源数目最小化为优化目标,该模型强调了共享资源的运用,并且考虑了切换时间在各个设备上所占有的比例。
(2)围绕资源共享的混流路径间基于有限产能的负荷平衡,研究了任务负荷在资源时间段上的合理分配。本文充分考虑产品的柔性路径以及转换时间等因素,建立了更为完善的数学模型来描述负荷分配问题。该模型可以描述不同资源的不同成组规则,并合理地估算切换时间的大小；在描述工序与资源的对应关系时,考虑到可替代资源的情形。这些因素的考虑使得模型描述更加贴合生产实际,尤其适合于多品种小批量的柔性作业车间。此外,针对大规模的问题,本文提出了一种启发式方法对问题进行求解,该方法通过将产能约束进行松弛得到初始解,然后通过资源卸载、时间前拉、时间后推三种方式调整负荷,使得产能约束重新被满足。启发式方法的运用使得负荷分配问题求解速度足以满足实际生产现场的规模需求,并能得到较优解。
(3)针对具体的混流路径上单元层次的生产运作控制,研究了基于约束理论的作业计划调度与控制方法。重点探讨了以瓶颈资源为中心的任务成组加工调度问题,通过成组调度实现将同类零件成组加工,可以大大降低切换时间,提高瓶颈资源的利用率。本文运用减少最大拖期的启发式方法来平衡切换时间与交货期之间的冲突,以达到减少工件最大拖期的优化目标。同时分析了三种不同的物料投放控制策略,并对缓冲管理开展讨论。
然后,作为上述研究结果的应用验证与示范,针对某船舶建造企业的管子加工车间的生产现状和需求,借助自主研制开发的高级计划与排程系统X-Planner,对上述新型生产运作控制模式进行了初步的实施应用,以期实现对于车间生产管理现状的改进和完善,并运用仿真系统验证了新的运作控制方法预期的应用效果。
最后对全文进行了总结,指出了进一步的研究方向。
Nowadays, variable demands of customers have gradually made the production mode shift from high-volume and repetitive to high-mix and low-volume. The uncertainty of demands and turbulence in production process have brought great challenges to the operation management in high-mix and low-volume environment. Flow manufacturing technology enables manufacturing various types of similar products with different volume mix in the same production system (or cell), with seldom or just a few changes to the current production environment. However, the traditional flow manufacturing technology is not adaptable to the production environment with frequently changed production mix and higher demand variability. Therefore, a new mode of flow manufacturing as well as its operation and control method in high-mix and low-volume environment are discussed in this paper.
Firstly, this thesis provides a systematic literature review on the methods for operation and control in manufacturing system and its related fields, and points out the characteristics and difficulties in the high-mix and low-volume production environment. The differences of flow manufacturing between the traditional environment and high-mix environment are analyzed. Based on this, the operation framework for high-mix and low-volume production is established.
Then, the related techniques in the different levels of the operation framework are studied in detail as follows:
(1) In the overall operation and control level, the dynamic formation and management based on virtual manufacturing cell are presented. It simplifies the material flow and makes the production system easy to manage. Meanwhile, in combination of the machine sharing, it improves the utilization of equipments, which is suitable to the variable demand in high-mix and low-volume production. The flow path design process is divided into two stages. Part families are formed in the first stage. A mathematical model based on similarity coefficient is established. In the second stage, machines are allocated to the flow paths corresponding to part families. The machine sharing is feasible by using a novel mathematical programming approach. The objective is to maximize the throughput of the system and minimize the number of shared machines. It addresses the machine sharing, and setup times on each machine are also considered.
(2) To balance the workload on a flow paths with machine sharing based on finite capacity, the reasonable workload allocation on the proper resource in the proper time bucket is studied. Considering flexible routing and setup times, a mathematical model is established to describe the workload allocation problem. This model describes different group rules on different machines and estimates the setup times reasonably. The alternate resources are considered when corresponding operation to resources. All these factors make this model practical, especially to the flexible job shop in high-mix and low-volume production. Besides, a heuristic algorithm is proposed to deal with the large-scale problem. This algorithm initiates with the relaxation of capacity constraint, and then adjusts the workload by offloading, pulling and pushing, to make capacity constraint satisfied again. This algorithm reaches a good solution at an acceptable speed for the real shop floor.
(3) As to the operation and control of cellular level in a specific flow path, the production scheduling and control methods based on theory of constraints (TOC) are studied. The thesis emphasizes on the group scheduling problem on bottleneck. Group scheduling decreases the setup times so as to improve the utilization of bottleneck. A heuristic algorithm with the objective of minimizing the maximum tardy time is utilized to balance the conflict between the setup time and due date. Then, three different material release control policies are analyzed and buffer management is discussed.
After that, to validate and demonstrate the application of the results above, the proposed new mode of operation and control has been preliminarily implemented in a tube manufacturing shop of a shipyard based on its production conditions and requirements. It tries to improve the shop floor by using an advanced planning and scheduling system X-Planner which is developed independently. The expected application effect of the improvement is verified by a simulation system.
Finally, some conclusions are drawn with some of the further research directions being anticipated.
首先,综述了目前制造系统运作控制相关领域的研究现状,分析了多品种小批量生产环境的特点与困难,指出了多品种小批量混流制造与传统混流制造所运用精益技术的区别,并建立了一个基于约束管理的多品种小批量混流制造系统的总体运作框架。
接着,围绕着总体运作框架中不同层次的相关技术进行了深入研究,具体包括：
(1)在车间总体运作控制层次上,提出了基于虚拟制造单元的混流路径动态规划与管理模式。该模式在继承传统混流路径的简化物流、易于管理等优势的同时,结合了虚拟制造单元的逻辑重构和设备可共享的特点,可提高设备的利用率,能适应多品种小批量生产环境下多变的需求。在混流路径的具体规划方法上,首先生成零件族,然后为相应的零件族分配合适的设备资源,最终形成具有资源共享特征的混流生产路径。在零件族的生成过程中,根据零件的工艺相似性,运用相似系数法建立数学模型并求解。在路径资源分配过程中,提出了混流路径资源分配的数学模型,以产出最大化和共享资源数目最小化为优化目标,该模型强调了共享资源的运用,并且考虑了切换时间在各个设备上所占有的比例。
(2)围绕资源共享的混流路径间基于有限产能的负荷平衡,研究了任务负荷在资源时间段上的合理分配。本文充分考虑产品的柔性路径以及转换时间等因素,建立了更为完善的数学模型来描述负荷分配问题。该模型可以描述不同资源的不同成组规则,并合理地估算切换时间的大小；在描述工序与资源的对应关系时,考虑到可替代资源的情形。这些因素的考虑使得模型描述更加贴合生产实际,尤其适合于多品种小批量的柔性作业车间。此外,针对大规模的问题,本文提出了一种启发式方法对问题进行求解,该方法通过将产能约束进行松弛得到初始解,然后通过资源卸载、时间前拉、时间后推三种方式调整负荷,使得产能约束重新被满足。启发式方法的运用使得负荷分配问题求解速度足以满足实际生产现场的规模需求,并能得到较优解。
(3)针对具体的混流路径上单元层次的生产运作控制,研究了基于约束理论的作业计划调度与控制方法。重点探讨了以瓶颈资源为中心的任务成组加工调度问题,通过成组调度实现将同类零件成组加工,可以大大降低切换时间,提高瓶颈资源的利用率。本文运用减少最大拖期的启发式方法来平衡切换时间与交货期之间的冲突,以达到减少工件最大拖期的优化目标。同时分析了三种不同的物料投放控制策略,并对缓冲管理开展讨论。
然后,作为上述研究结果的应用验证与示范,针对某船舶建造企业的管子加工车间的生产现状和需求,借助自主研制开发的高级计划与排程系统X-Planner,对上述新型生产运作控制模式进行了初步的实施应用,以期实现对于车间生产管理现状的改进和完善,并运用仿真系统验证了新的运作控制方法预期的应用效果。
最后对全文进行了总结,指出了进一步的研究方向。
Nowadays, variable demands of customers have gradually made the production mode shift from high-volume and repetitive to high-mix and low-volume. The uncertainty of demands and turbulence in production process have brought great challenges to the operation management in high-mix and low-volume environment. Flow manufacturing technology enables manufacturing various types of similar products with different volume mix in the same production system (or cell), with seldom or just a few changes to the current production environment. However, the traditional flow manufacturing technology is not adaptable to the production environment with frequently changed production mix and higher demand variability. Therefore, a new mode of flow manufacturing as well as its operation and control method in high-mix and low-volume environment are discussed in this paper.
Firstly, this thesis provides a systematic literature review on the methods for operation and control in manufacturing system and its related fields, and points out the characteristics and difficulties in the high-mix and low-volume production environment. The differences of flow manufacturing between the traditional environment and high-mix environment are analyzed. Based on this, the operation framework for high-mix and low-volume production is established.
Then, the related techniques in the different levels of the operation framework are studied in detail as follows:
(1) In the overall operation and control level, the dynamic formation and management based on virtual manufacturing cell are presented. It simplifies the material flow and makes the production system easy to manage. Meanwhile, in combination of the machine sharing, it improves the utilization of equipments, which is suitable to the variable demand in high-mix and low-volume production. The flow path design process is divided into two stages. Part families are formed in the first stage. A mathematical model based on similarity coefficient is established. In the second stage, machines are allocated to the flow paths corresponding to part families. The machine sharing is feasible by using a novel mathematical programming approach. The objective is to maximize the throughput of the system and minimize the number of shared machines. It addresses the machine sharing, and setup times on each machine are also considered.
(2) To balance the workload on a flow paths with machine sharing based on finite capacity, the reasonable workload allocation on the proper resource in the proper time bucket is studied. Considering flexible routing and setup times, a mathematical model is established to describe the workload allocation problem. This model describes different group rules on different machines and estimates the setup times reasonably. The alternate resources are considered when corresponding operation to resources. All these factors make this model practical, especially to the flexible job shop in high-mix and low-volume production. Besides, a heuristic algorithm is proposed to deal with the large-scale problem. This algorithm initiates with the relaxation of capacity constraint, and then adjusts the workload by offloading, pulling and pushing, to make capacity constraint satisfied again. This algorithm reaches a good solution at an acceptable speed for the real shop floor.
(3) As to the operation and control of cellular level in a specific flow path, the production scheduling and control methods based on theory of constraints (TOC) are studied. The thesis emphasizes on the group scheduling problem on bottleneck. Group scheduling decreases the setup times so as to improve the utilization of bottleneck. A heuristic algorithm with the objective of minimizing the maximum tardy time is utilized to balance the conflict between the setup time and due date. Then, three different material release control policies are analyzed and buffer management is discussed.
After that, to validate and demonstrate the application of the results above, the proposed new mode of operation and control has been preliminarily implemented in a tube manufacturing shop of a shipyard based on its production conditions and requirements. It tries to improve the shop floor by using an advanced planning and scheduling system X-Planner which is developed independently. The expected application effect of the improvement is verified by a simulation system.
Finally, some conclusions are drawn with some of the further research directions being anticipated.
引文
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