基于Flexsim的W公司涡旋空压机生产仿真研究
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摘要
随着计算机技术的发展,建模与仿真越来越多的被应用到优化领域之中。Flexsim建模与仿真也已成为解决由高度离散的事件组成的系统的优化问题的重要工具。
本文以W公司涡旋空压机生产系统为研究对象,对其加工工艺流程进行了分析；同时,应用新的数据拟合工具ExpertFit对现场搜集的数据进行了分析拟合,得到了Flexsim代码；然后,采用Petri网对系统的各加工单元进行了建模,经初步分析,了解了系统之中的顺序与冲突事件；最后,在Petri网模型和ExpertFit拟合结果的基础上,建立了Flexsim二维与三维模型,通过仿真与结果分析,发现了w公司生产系统中存在的不足与瓶颈：操作员平均工时空闲率很高、三坐标检测处存在严重的瓶颈。
针对分析得到的生产系统的不足与瓶颈,本文通过修改原有模型,建立了Flexsim实验器,并分别以操作员数目和三坐标台数为控制变量,进行了仿真实验；同时,辅以恰当的绩效指标对实验的结果进行了评价：最后,得到了最优化的资源配置方案,即操作员数目减少为3个,设置4台三坐标。
通过改进,在W公司涡旋空压机的产量基本保持不变的情况下,操作员的平均工时空闲率由71.6%降至45.1%,三坐标检测处暂存区中临时实体的平均等待时间由原来的5459s降至723s；在消除瓶颈的同时,也大幅度地节省了公司的直接人工成本。
本文采用Petri网建模与Flexsim仿真相结合的方法对离散系统进行建模分析与改进,取得了良好的效果,为企业合理配置资源和类似的研究提供了一种思路。
With the development of computer technology, modeling and simulation have been applied into the field of the optimization more and more widely. Modeling and simulation based on Flexsim has been an important tool in solving optimization problem of the systems that made up of highly discrete events.
This paper took scroll air compressor machine production system of W company as research object, and analyzed its processing process. Meanwhile, a new data fitting tools which named ExpertFit was used to analyze and fit the data which collected on the spot, and then Flexsim code was acquired. Then this paper used Petri network to model all processing units of the system. Via preliminary analysis, the order and conflict events were grasped. At last, two-dimensional and three-dimensional models of Flexsim were established based on the Petri network model and ExpertFit's fitting results. After simulation and analysis, this paper found shortcomings and bottlenecks of W company in production systems. One is that the average idle rate of operators is very high, and another is that the Coordinate Measuring Machine (CMM) has a serious bottleneck.
With the inadequate and bottlenecks taken in consideration, this paper modified the original model, established the Flexsim experimental tool, and carried out simulation experiments, operator number and CMM number taken as control variables. Meanwhile, evaluation was made base on the experiment after appropriate performance indexes were done. At last, the most optimization of resources configuration scenarios were gained, namely, set three operators and four CMMs.
Via improving, on the circumstance of almost the same output of W scroll air compressor, the average idle rate of operators was cut down from71.6%to45.1%, and the average waiting time of temporary entities in the CMM queue was reduced from5459seconds to723seconds. The company's direct labor cost was substantially saved with the elimination of bottlenecks at the same time.
The method that combines Petri net modeling with the Flexsim simulation for modeling and analysis in this paper achieved good results, and provided a good idea for the company's rational allocation of resources and some similar research.
本文以W公司涡旋空压机生产系统为研究对象,对其加工工艺流程进行了分析；同时,应用新的数据拟合工具ExpertFit对现场搜集的数据进行了分析拟合,得到了Flexsim代码；然后,采用Petri网对系统的各加工单元进行了建模,经初步分析,了解了系统之中的顺序与冲突事件；最后,在Petri网模型和ExpertFit拟合结果的基础上,建立了Flexsim二维与三维模型,通过仿真与结果分析,发现了w公司生产系统中存在的不足与瓶颈：操作员平均工时空闲率很高、三坐标检测处存在严重的瓶颈。
针对分析得到的生产系统的不足与瓶颈,本文通过修改原有模型,建立了Flexsim实验器,并分别以操作员数目和三坐标台数为控制变量,进行了仿真实验；同时,辅以恰当的绩效指标对实验的结果进行了评价：最后,得到了最优化的资源配置方案,即操作员数目减少为3个,设置4台三坐标。
通过改进,在W公司涡旋空压机的产量基本保持不变的情况下,操作员的平均工时空闲率由71.6%降至45.1%,三坐标检测处暂存区中临时实体的平均等待时间由原来的5459s降至723s；在消除瓶颈的同时,也大幅度地节省了公司的直接人工成本。
本文采用Petri网建模与Flexsim仿真相结合的方法对离散系统进行建模分析与改进,取得了良好的效果,为企业合理配置资源和类似的研究提供了一种思路。
With the development of computer technology, modeling and simulation have been applied into the field of the optimization more and more widely. Modeling and simulation based on Flexsim has been an important tool in solving optimization problem of the systems that made up of highly discrete events.
This paper took scroll air compressor machine production system of W company as research object, and analyzed its processing process. Meanwhile, a new data fitting tools which named ExpertFit was used to analyze and fit the data which collected on the spot, and then Flexsim code was acquired. Then this paper used Petri network to model all processing units of the system. Via preliminary analysis, the order and conflict events were grasped. At last, two-dimensional and three-dimensional models of Flexsim were established based on the Petri network model and ExpertFit's fitting results. After simulation and analysis, this paper found shortcomings and bottlenecks of W company in production systems. One is that the average idle rate of operators is very high, and another is that the Coordinate Measuring Machine (CMM) has a serious bottleneck.
With the inadequate and bottlenecks taken in consideration, this paper modified the original model, established the Flexsim experimental tool, and carried out simulation experiments, operator number and CMM number taken as control variables. Meanwhile, evaluation was made base on the experiment after appropriate performance indexes were done. At last, the most optimization of resources configuration scenarios were gained, namely, set three operators and four CMMs.
Via improving, on the circumstance of almost the same output of W scroll air compressor, the average idle rate of operators was cut down from71.6%to45.1%, and the average waiting time of temporary entities in the CMM queue was reduced from5459seconds to723seconds. The company's direct labor cost was substantially saved with the elimination of bottlenecks at the same time.
The method that combines Petri net modeling with the Flexsim simulation for modeling and analysis in this paper achieved good results, and provided a good idea for the company's rational allocation of resources and some similar research.
引文
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[8]许晨.基于Flexsim的某汽车装配车间物流建模与仿真的研究[D].山东大学,2008.
[9]肖江波.基于Flexsim的配送中心系统仿真与优化[D].北京邮电大学,2008.
[10]石晓辉.基于Flexsim的生产流程建模与仿真研究[D].安徽理工大学,2009.
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[12]王雪兰.基于Flexsim的凸轮轴生产物流系统仿真[D].武汉科技大学,2008.
[13]孙洪华,陈红霞,庞如英,岳志勇.基于Flexsim的制造单元仿真研究[J].中国现代教育装备,2009(7)：48-50.
[14]胡学刚.基于Flexsim的自动化立体仓库仿真与优化[D].南京林业大学,2009.
[15]石宇强.基于达宝易与Flexsim的生产线优化研究[J].机械设计与制造,2011(2)：130-132.
[16]谢国栋.制造工厂内物料自动化搬送作业之模拟研究[D].国立成功大学,2008.
[17]William B. Nordgren. FLEXSIM SIMULATION ENVIRONMENT [J]. Proceedings of the 2002 Winter Simulation Conference,2002:250-252.
[18]Lisa Patvivatasiri, Elliot J. Montes, Jr., Ouyang Xi. MODELING BIOTERRORISM PREPAREDNESS WITH SIMULATION IN RURAL HEALTHCARE SYSTEM[J]. Proceedings of the 2007 Winter Simulation Conference,2002:1155-1160.
[19]Gabriel A. Burnett, D. J. Medeiros, Daniel A. Finke, Mark T. Traband. AUTOMATING THE DEVELOPMENT OF SHIPYARD MANUFACTURING MODELS[J].2008:1761-1767.
[20]Joes M. Garrido. Introduction to Flexsim[J]. Object Oriented Simulation,2009, part 1, pp31-42.
[21]Wood C, Kite S, Taylor S J E, Mustafee N. Developing a grid computing system for commercial-off-the-shelf simulation packages[J]. Proceedings of the Operational Research Society Simulation Workshop 2010, Worcestershire, March 2010, pp.184-191.
[22]周国华.生产作业调度问题的软计算方法研究[D].西南交通大学,2003.
[23]张国辉.柔性作业车间调度方法研究[D].华中科技大学,2009.
[24]庞庆华,潘郁AJ-System生产作业调度系统的柔性设计及其实现[J].电脑开发与应用,2003,16(3)：5-6.
[25]顾恒平,单泪源,蒲黎达.大规模定制企业生产作业调度优化问题研究[J].工业技术经济,2006,25(11)：54-56.
[26]吕韶义,刘智敏,刘复岩.多目标优化生产作业调度计划系统开发[J].电子科技大学学报,1998,27(3)：316-320.
[27]涂桂禄,万艳春,全石川.转弯型堆垛机作业循环周期和作业效率的计算[J].中国储运,2009(3)：105-108.
[28]舒国云,涂桂禄,陈文钊.基于Flexsim的转弯型堆垛机作业效率仿真研究[J].物流工程与管理,2009,31(5)：120-123.
[29]唐国庆.基于交货期的模具生产作业调度规划研究及软件实现[D].汕头大学,2000.
[30]葛茂根.基于微粒群优化的车间生产作业调度方法研究[D].合肥工业大学,2006.
[31]贺向阳.天津港装卸船生产线作业效率研究[D].武汉理工大学,2004.
[32]陈亮,马柯.遗传算法在生产作业调度中的应用[J].西安工程科技学院学报,2002,16(3)：251-255.
[33]郑玉军.企业生产作业调度优化研究[J].魅力中国,2009(29)：106.
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