机加车间准时制生产监控系统的研制与实现
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摘要
通过对××公司各管理部门和各车间运作情况的调研分析,提出了结合准时制(JIT,Just In Time)生产模式思想的机加车间作业运行模型,开发了××公司精益生产管理系统(LPMS,Lean Production Management System)的核心子系统――机加车间准时制生产监控系统,以达到对产品各零部件在车间的生产进度进行监控的目的。
首先对准时化生产的理论、研究现状和发展趋势作了概要性地分析,提出准时化生产对企业的现实意义。接着,总结了××公司现行的车间作业管理模型,分析了现行的车间作业管理手段及其存在的弊端,为克服这些存在的问题,引入了基于准时制的生产监控方法。在确定了车间基于准时制思想的作业模式以后,结合研究目的,即建立机加车间的生产监控系统,本文描述了机加车间准时制生产监控系统的硬件和软件模型。确定车间工序计划管理模块、现场数据采集模块和作业状态监视模块是监控系统的主要组成部分。其中,重点研究了在设计车间工序计划管理模块过程中涉及到的设备负荷分配算法和车间工序计划生成算法。作业计划的生成过程是一个生产的静态调度过程,即由生产系统的生产任务、生产能力、工艺路线来确定产品的各个组成零部件的加工先后次序和加工时间段。在系统的实现部分,首先采用统一建模语言(Unified Modeling Language,UML)对系统进行了需求分析和功能建模;使用Power Designer对生产管理数据库进行了建模和实现;系统基于B/S(Browser/Server,浏览器/服务器)模式,采用JEE技术进行开发。最后给出了系统的运行实例,对研究工作和所取得的成果进行了总结,并对下一步的研究提出了建议和设想。
机加车间准时制生产监控系统已投入试运行,用户表示该系统实现了生产信息透明化,自动生成的车间工序计划避免了人工制定的盲目和疏漏,减少了车间在制品库存,使得产品的生产进度得到了有效地监督控制。
According to the investigation and analysis of the departments, especially of the machining workshop in XX Co., Ltd., the paper puts forward the job-running mode based on Just-in-Time (JIT) mode to create the JIT-based Manufacturing Monitor System (JMMS), which is one of core subsystems of Lean Production Management System (LPMS). The purpose of JMMS is to monitor the progress production of every product’s parts in the machining workshop.
In the beginning of this paper, a general analysis is conducted on the theory, research status and development trend of JIT mode and its practical significance to enterprise is specified. Then the workshop job management model of XX Co., Ltd. and the disadvantages of the previous system are summarized after analyzing the workshop job management means. To avoid these disadvantages, the production schedule monitor means based on JIT is researched. After these, the paper describes the hardware architecture and the software operating model of JMMS which is composed mainly by Workshop Job Management Module, Field Data Collection Module and Manufacturing Monitor Module. Subsequently, workload assignment algorithm and procedure plans generation algorithm based on JIT which is the core part of the Workshop Job Management Module are mainly researched. The process of generating procedure plans is the process of production static scheduling during which the processing orders and the processing duration of every parts of the product are figured out by using the data of production tasks, production capability and processing routes. In the part of system implementation, requirement analysis and function modeling for the system are done by using Unified Modeling Language (UML); the database of the system is designed by using Power Designer. JMMS is developed based on Browser/Server (B/S) architecture using JAVA Enterprise Edition (JEE). In the end, the application and running examples of the system are given, conclusions and summaries are made, suggestions and plans for the future work are proposed.
At the present, JMMS has been put into test run in XX Co., Ltd., and is in a good state.
首先对准时化生产的理论、研究现状和发展趋势作了概要性地分析,提出准时化生产对企业的现实意义。接着,总结了××公司现行的车间作业管理模型,分析了现行的车间作业管理手段及其存在的弊端,为克服这些存在的问题,引入了基于准时制的生产监控方法。在确定了车间基于准时制思想的作业模式以后,结合研究目的,即建立机加车间的生产监控系统,本文描述了机加车间准时制生产监控系统的硬件和软件模型。确定车间工序计划管理模块、现场数据采集模块和作业状态监视模块是监控系统的主要组成部分。其中,重点研究了在设计车间工序计划管理模块过程中涉及到的设备负荷分配算法和车间工序计划生成算法。作业计划的生成过程是一个生产的静态调度过程,即由生产系统的生产任务、生产能力、工艺路线来确定产品的各个组成零部件的加工先后次序和加工时间段。在系统的实现部分,首先采用统一建模语言(Unified Modeling Language,UML)对系统进行了需求分析和功能建模;使用Power Designer对生产管理数据库进行了建模和实现;系统基于B/S(Browser/Server,浏览器/服务器)模式,采用JEE技术进行开发。最后给出了系统的运行实例,对研究工作和所取得的成果进行了总结,并对下一步的研究提出了建议和设想。
机加车间准时制生产监控系统已投入试运行,用户表示该系统实现了生产信息透明化,自动生成的车间工序计划避免了人工制定的盲目和疏漏,减少了车间在制品库存,使得产品的生产进度得到了有效地监督控制。
According to the investigation and analysis of the departments, especially of the machining workshop in XX Co., Ltd., the paper puts forward the job-running mode based on Just-in-Time (JIT) mode to create the JIT-based Manufacturing Monitor System (JMMS), which is one of core subsystems of Lean Production Management System (LPMS). The purpose of JMMS is to monitor the progress production of every product’s parts in the machining workshop.
In the beginning of this paper, a general analysis is conducted on the theory, research status and development trend of JIT mode and its practical significance to enterprise is specified. Then the workshop job management model of XX Co., Ltd. and the disadvantages of the previous system are summarized after analyzing the workshop job management means. To avoid these disadvantages, the production schedule monitor means based on JIT is researched. After these, the paper describes the hardware architecture and the software operating model of JMMS which is composed mainly by Workshop Job Management Module, Field Data Collection Module and Manufacturing Monitor Module. Subsequently, workload assignment algorithm and procedure plans generation algorithm based on JIT which is the core part of the Workshop Job Management Module are mainly researched. The process of generating procedure plans is the process of production static scheduling during which the processing orders and the processing duration of every parts of the product are figured out by using the data of production tasks, production capability and processing routes. In the part of system implementation, requirement analysis and function modeling for the system are done by using Unified Modeling Language (UML); the database of the system is designed by using Power Designer. JMMS is developed based on Browser/Server (B/S) architecture using JAVA Enterprise Edition (JEE). In the end, the application and running examples of the system are given, conclusions and summaries are made, suggestions and plans for the future work are proposed.
At the present, JMMS has been put into test run in XX Co., Ltd., and is in a good state.
引文
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[25]顾明.软件工程中几种常用软件生命周期模型的简介[J].计算机时代. 2003(1): 20-21.
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[33] Amasaka, Kakuro. New JIT: A new management technology principle at Toyota[J]. Int.J.Production Economics. 2002, 80: 135-144.
[34]胡立德,张秉铝,梁锡昌等.柔性制造系统负荷最优分配的Leaf-Root-Weight图算法[J].组合机床与自动化加工技术, 1993(1): 12-20.
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[38] Valerie tardif, Lars Maaseidvaag. An Adaptive Approach to Controlling Kanban Systems[J]. European Journal of Operational Research. 2001, 132: 411-424.
[39]熊锐,吴澄.车间生产调度问题的技术现状与发展趋势[J].清华大学学报(自然科学版). 1998, 38(10): 55-60.
[40]孙志峻,潘全科,朱剑英.基于遗传算法的多资源作业车间智能优化调度[J].中国机械工程. 2002, 13(24): 2104-2107.
[41]姜思杰,徐晓飞,李全龙.基于遗传优化算法求解作业车间调度问题[J].计算机集成制造系. 2002, 8(3): 229-232.
[42]卫军胡,孙国基一种新的制造系统仿真调度规则[J].系统仿真学报. 1999, 11(5): 354-357.
[43]熊光楞,高红.基于规则的工厂仿真调度环境[J].信息与控制. 1994, 23(4): 193-199.
[44]王万良,吴启迪,徐新黎.基于Hopfield神经网络的作业车间生产调度方法[J].自动化学报. 2002, 28(5): 838-844.
[45]黄启春,陈奇,俞瑞钊.一种面向作业的快速调度算法[J].软件学报. 1999, 10(10): 1073-1077.
[46] Chung-Hosing, Yeah. A fast finite loading algorithm for job oriented scheduling[J]. Computers and Operations Research. 1997, 24(2): 193-198.
[47] Henry W.Thornto, John L.Hunsucker. A new heuristic for minimal makespan in flow shops with multiple processors and no intermediate storage[J]. European Journal of Operational Research. 2004, 152: 96-114.
[48] Tagawa, Shinichi. A new concept of job shop scheduling system-hierarchical decision model[J]. Int.J.Production Economics. 1996, 44: 17-26.
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[2] John O.Mcclain, L.Joseph Thomas, Joseph B.Mazzola. Operations Management: Production of goods and Services (3rd ed.) [M] . Prentice Hall Inc , 1992.
[3]肖智军等.精益生产方式JIT [M].深圳海天出版社, 2002.
[4]李钢,彭金梅,邓修权. Just-in-time的研究现状与发展趋势[J].工业工程与管理, 1997(6):40-41, 50.
[5]梁红月.丰田生产方式的起源与演化[J].中国质量, 2004(4): 36-38.
[6] W.C.Benton, Hojung Shin. Manufacturing planning and control: The evolution of MRP and JIT integration [M]. European Journal of Operational Research. 1998, 110: 411-440.
[7]齐二石.推动与拉动式生产系统建模及其性能分析[D].天津.天津大学, 1992.
[8]齐二石,邓修权,霍艳芳,潘涛.装配型拉动生产系统离散事件模型及扰动分析[J].系统工程学报. 1998, 13(4): 52-57.
[9]潘涛. JIT环境下的拉动生产系统建模及其应用研究[D].天津.天津大学, 1996.
[10]倪伟英,杨光薰. JIT最终装配计划中投产顺序的研究[J].中国机械工程. 2002, 13(7): 589-591.
[11]陈绍文.精益企业价值--精益思想的新发展[J]. CAD/CAM与制造业信息化. 2004(3): 29-33.
[12] Randy Tofteland.让企业精益化[J].经理人. 2004(4): 46.
[13]栗贺友,郝建男.看板管理运行过程中调控方法的研究[J].工业工程与管理. 2003(8): 72-74.
[14]周勇,钟毅芳,万立,熊模华. MRP/JIT混合系统的研究[J].组合机床与自动化加工技术. 1998(5): 22-27.
[15]方建华,林财兴,方明伦.基于MRP-II和JIT的混合控制的设计与实现[J].机电一体化. 2000(6): 23-26.
[16]郑志民,郭伟.基于MRP-II和JIT的复合生产控制策略[J].辽宁工学院学报. 2003, 23(6): 38-40.
[17]汪定伟.实验性Push/Pull生产管理系统的研究与开发[J].高技术通讯. 1994(7): 12-15.
[18]熊刚. CIMS企业中应用Push/Pull生产方式的研究[J].计算机工程与应用. 2000(10): 4-10.
[19]余建峰.浅谈精益制造过程中的目视管理[J].西飞科技. 2003(4): 30-31.
[20]陈绍文.丰田JIT生产方式遭遇中国困境[J].经济观察报. 2002, 57(5).
[21]宋克勤,陈文安.工业企业生产管理与控制[M].立信会计出版社. 1997: 223.
[22]王玖河.精益生产方式下的质量控制研究.科技与管理[J]. 2002(14): 27-30.
[23] Peter Bruun, Robert N. Mefford. Lean production and the Internet [J]. International Journal of Production Economics. 2004, 89: 247-260.
[24]陈爱玲,王宁.精益制造对软件开发的启示[J].科技进步与对策. 2003(8): 77-78.
[25]顾明.软件工程中几种常用软件生命周期模型的简介[J].计算机时代. 2003(1): 20-21.
[26]陈荣秋,马士华,生产运作管理[M].北京:机械工业出版社,2003: 302-341.
[27] Liker, Jeffrey.走出精益生产的误区[J].中国汽车. 2002(1).
[28]刘洪,王嗣俊.正在改变世界的精益生产方式[J].汽车工业研究. 1994(1): 14-16.
[29]苏宝华,祁国宁.订单生产模式下的产品设计方法研究[J].机械工业自动化,1998,20(5):16-20.
[30]戚晓耀.及时生产制(JIT)应用的探讨[J].工业工程. 2004, 7(1): 47-51.
[31]刘健.我们所了解的丰田生产方式[J].工业工程与管理. 2000(1): 45-49.
[32]魏大鹏.准时化生产方式的技术支撑体系[J].工业工程与管理. 1998, 3(3): 30-35.
[33] Amasaka, Kakuro. New JIT: A new management technology principle at Toyota[J]. Int.J.Production Economics. 2002, 80: 135-144.
[34]胡立德,张秉铝,梁锡昌等.柔性制造系统负荷最优分配的Leaf-Root-Weight图算法[J].组合机床与自动化加工技术, 1993(1): 12-20.
[35] K. E. Steche. A Hierarchical Approach to Solving Machine Grouping and Loading Problems of Flexible Manufacturing Systems[J]. European Journals of Operational Research. 1986(24): 369-378.
[36] K. E. Steche, J. J. Solberg. Loading and Control Policies for Flexible Manufacturing Systems[J]. Int. J. Prod. Res.. 1981(19): 481-190.
[37]黄德才,胡立德,杨丹等.柔性制造系统负荷最优分配的一个新算法[J].组合机床与自动化加工技术, 1994(6): 11-14.
[38] Valerie tardif, Lars Maaseidvaag. An Adaptive Approach to Controlling Kanban Systems[J]. European Journal of Operational Research. 2001, 132: 411-424.
[39]熊锐,吴澄.车间生产调度问题的技术现状与发展趋势[J].清华大学学报(自然科学版). 1998, 38(10): 55-60.
[40]孙志峻,潘全科,朱剑英.基于遗传算法的多资源作业车间智能优化调度[J].中国机械工程. 2002, 13(24): 2104-2107.
[41]姜思杰,徐晓飞,李全龙.基于遗传优化算法求解作业车间调度问题[J].计算机集成制造系. 2002, 8(3): 229-232.
[42]卫军胡,孙国基一种新的制造系统仿真调度规则[J].系统仿真学报. 1999, 11(5): 354-357.
[43]熊光楞,高红.基于规则的工厂仿真调度环境[J].信息与控制. 1994, 23(4): 193-199.
[44]王万良,吴启迪,徐新黎.基于Hopfield神经网络的作业车间生产调度方法[J].自动化学报. 2002, 28(5): 838-844.
[45]黄启春,陈奇,俞瑞钊.一种面向作业的快速调度算法[J].软件学报. 1999, 10(10): 1073-1077.
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