基于AHP的看板系统绩效与仿真设计研究
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摘要
近年来,经济危机使制造业的竞争越来越激烈,为了在严酷的竞争中站稳脚步,精益生产方式在我国受到了制造企业的推崇。虽然精益生产的理论比较成熟,但是企业在推行的过程中总是存在着难于实践的问题。
本文从企业对精益生产实施的角度出发,在应用层面上对看板管理系统及其绩效指标进行了深入研究。首先对看板管理系统进行了介绍,对几种常用的看板系统(Kanban,CONWIP,HYBRID)进行了比较分析和研究。其次对看板系统运行中的不同看板的数量进行了分析,考虑到看板管理实施过程中的几种变异,对系统中变异源及其影响进行了分析,提出了在生产实践中对变异源的考虑和估算方法,提出了考虑变异的看板系统控制策略。由于变异源的存在,看板系统的参数不断变化,进而影响了看板系统的绩效,本文基于层次分析法对看板系统的绩效指标进行设计,解决了企业对变异参数选择的问题。
本文针对天津某机械制造公司装配线的看板导入过程进行了实证研究,运用Witness物流仿真软件对其运作流程进行仿真设计,应用层次分析法对看板系统绩效进行分析,确定了看板系统的选择方案。
In recent years, the competition between manufacturing enterprises becomes more and more fierce because of the economic crisis. In order to exist and win victory in competition, the trend of carrying out the Lean Production has been highly praised among the manufacturing enterprises in our country. Altough the theory of Lean Production is mature, there are difficulties in implementing it in reality.
In the application level this paper makes some intensive study of Kanban management and its evaluation system from the practice angel for enterprise. First this paper introduces the Kanban management system systematically, and then makes some comparative analysis and researchx on the several common Kanban systems—Kanban, Conwip, HYBRID. Second, in this paper, the numbers of different kanbans in the Kanban system are analyzed. Taking the several variations which emerged in the process of implementing Kanban management into account, this paper analyzes the different variations and their impacts, presents the method to consider and estimate the variations in the production practice, and puts forward the Kanban control strategy to response the variations. The exists of the variations bring about the constantly changing of the kanban parameters, thereby affect the performance of kanban systems. Based on the AHP, the performance indexes of kanban system are designed, so as to help the managers to choose the variant parameters.
This paper does research on the implementation of the kanban system to the assembly streamline of a machinery manufacturing company in Tianjin. The process of the kanban operation is analyzed based on the simulation software—Witness, the performance of the kanban system is analyzed using AHP, and the parameters of the kanban system are determined.
本文从企业对精益生产实施的角度出发,在应用层面上对看板管理系统及其绩效指标进行了深入研究。首先对看板管理系统进行了介绍,对几种常用的看板系统(Kanban,CONWIP,HYBRID)进行了比较分析和研究。其次对看板系统运行中的不同看板的数量进行了分析,考虑到看板管理实施过程中的几种变异,对系统中变异源及其影响进行了分析,提出了在生产实践中对变异源的考虑和估算方法,提出了考虑变异的看板系统控制策略。由于变异源的存在,看板系统的参数不断变化,进而影响了看板系统的绩效,本文基于层次分析法对看板系统的绩效指标进行设计,解决了企业对变异参数选择的问题。
本文针对天津某机械制造公司装配线的看板导入过程进行了实证研究,运用Witness物流仿真软件对其运作流程进行仿真设计,应用层次分析法对看板系统绩效进行分析,确定了看板系统的选择方案。
In recent years, the competition between manufacturing enterprises becomes more and more fierce because of the economic crisis. In order to exist and win victory in competition, the trend of carrying out the Lean Production has been highly praised among the manufacturing enterprises in our country. Altough the theory of Lean Production is mature, there are difficulties in implementing it in reality.
In the application level this paper makes some intensive study of Kanban management and its evaluation system from the practice angel for enterprise. First this paper introduces the Kanban management system systematically, and then makes some comparative analysis and researchx on the several common Kanban systems—Kanban, Conwip, HYBRID. Second, in this paper, the numbers of different kanbans in the Kanban system are analyzed. Taking the several variations which emerged in the process of implementing Kanban management into account, this paper analyzes the different variations and their impacts, presents the method to consider and estimate the variations in the production practice, and puts forward the Kanban control strategy to response the variations. The exists of the variations bring about the constantly changing of the kanban parameters, thereby affect the performance of kanban systems. Based on the AHP, the performance indexes of kanban system are designed, so as to help the managers to choose the variant parameters.
This paper does research on the implementation of the kanban system to the assembly streamline of a machinery manufacturing company in Tianjin. The process of the kanban operation is analyzed based on the simulation software—Witness, the performance of the kanban system is analyzed using AHP, and the parameters of the kanban system are determined.
引文
[1]陈国华,现代生产系统——JIT在我国运用存在的问题及对策,企业经济,2001,(7):58~59
[2]李钢、彭金梅、邓修权,Just-in-time的研究现状与发展趋势,工业工程与管理,1997,(6):40~41
[3]杨先知,准时制生产方式及其应用,企业改革与管理,2002,(12):45~46
[4]何海燕,看板管理——实施准时化生产的有效手段,上海汽车,2005,(1):33~34
[5]Benton W. C. , Shin H. J. . Manufacturing planing and control: The evolution of MRP and JIT integration. European Journal of Oreaational Research. 1998, 110(3): 411~440
[6]刘玉霞,基于JIT的电子看板的设计与实现,硕士学位论文,天津大学,2006
[7] Monden Y. . Toyota Production System 3rd ed. Georgia: Chapman and Hall. 1998, (3): 1~35
[8]Valerie Tardif, Lars Maaseidvaag. An adaptive approach to controlling kanban systems. European Journal of Operation Research. 2001, (132): 411~424
[9]Katsuhiko Takahashi, Nobuto Nakamura. Decentradized reactive kanban system. European Journal of Operation Research. 2002, (139): 262~276
[10]So K. C. , Pinault S. C. . Allocating buffer storage in a pull system. International Journal of Production Research. 1988, 26(12): 1959~1980
[11]华中生,随机生产系统安全库存的JIT控制策略,运筹与管理,1994,3(2):8~12
[12]Robert A. Leitch. Effect of stochasticity, capacity and lead time cost drivers on WIP and throughput in a pull production environment. Management Accounting Reach. 2001, (12): 167~196
[13]Christelle Duri, Yannick Frein, Hyo-seong Lee. Performance evaluation and design of a CONWIP system with inspections. Int.J. Production Economics. 2000, (64): 219~229
[14]Jie Chen F. , Frank Chen. Adaptive scheduling in random flexible manufacturing systems subject to machine breakdowns. International Journal of Production Research. 2003, 41(9): 1927~1951
[15]Spearman M. L. , Woodruff D. L. , Hopp W. J. . CONWIP: a pull alternative to KANBAN. International Journal of Production Research. 1990, 28(5): 879~894
[16]Marek R. P. , Elkins D. A. , Smith D. R. . Understanding the fundamentals of Kanban and CONWIP pull systems using simulation. Proceedings of the 33nd Conference on Winter Simulation, Arlington, Virginia. 2001, 921~929
[17]Wanf D. , Xu C. . Hybrid push/pull production control strategy simulation and its applications. Production Planning and Control. 1997, 8(2): 142~151
[18]Tayur S. R. . Structural results and a heuristic for kanban controlled serial lines. Management Science. 1993, 39(11): 1347~1368
[19]Glasserman P. T. , Yao D. D. . Structured buffer-allocation problems: Discrete Event Dynamic Systems. Theory and Applications. 1996, 6(1): 9~41
[20]康杰、徐作宁、任欣欣,实施精益制造的控制策略的比较分析,计算机应用研究,2001,18(12):21~22
[21]周延虎,精益六西格玛集成应用的若干问题研究,博士学位论文,天津大学,2007
[22]林勇、乐晓娟、付秋芳,Push-Pull和CONWIP-Pull生产控制模式对比分析,工业工程,2006(3):22~26
[23]Qi Hao, Weiming Shen. Implementing a hybrid simulation model for a kanban-based material handing system. Robotics and Computer-integrated Manufacturing. 2008, 24(5): 635~646
[24]Akturk M. S. , Erhun F. . An overview of design and operational issues of kanban systems. International Journal of Production Research. 1999, 37(17): 358~381
[25]杜战其,看板管理在JIT生产中的应用分析,科技情报开发与经济,2005,15(20):210~212
[26]Golhar D. Y. , Stsmm C. L. . The Just-in-time philosophy: a literature Review. International Journal of Production Research. 1991, 29(4): 657~676
[27]田志章,流水型CONWIP生产控制系统研究,硕士学位论文,武汉理工大学,2007
[28]康杰,精益生产方式中控制策略的研究与实现,博士学位论文,西南交通大学,2004
[29]杨连娜,看板系统导入与仿真设计研究,硕士学位论文,天津大学,2008
[30]杜玉强,看板管理(JIT)系统的设计与研究,硕士学位论文,华中科技大学,2003
[31]叶国洪,随机需求下的模具电极拉式看板控制系统研究,硕士学位论文,广东工业大学,2009
[32]米翠兰,二次指数平滑法的研究与应用,华北煤炭医学院学报,2000(5):524~525
[33]李占凯、何玉林,看板管理在企业中的应用研究,工业工程与管理,2009,14(4):132~137
[34]Chan F. T. S. Effect of Kanban Size on Just-in-time Manufacturing Systems. Journal of Materials Processing Technology. 2001, 1(16): 146~160.
[35]胡卫星,采用层次分析法对项目管理的研究,硕士学位论文,同济大学,2008
[36]刘立存、周凌云,层级分析法在物流信息系统开发模式决策中的应用,物流世界,2005(2):17~19
[37]赵静,看板管理在供应链系统的研究及其应用,硕士学位论文,浙江工业大学,2008
[38]Price W. , Gravel M. , Nsakanda A. L. . Modeling the performance of a kanban assembly shop. International Journal of Production Research. 1995, 33(4): 1171~1177
[39]Bruce A. , Henderson, Jorge L. Larco. How to change your business into a lean enterprise. Rawson Ass. 1999, 35~37
[40]李胜强、李华,目视管理365,深圳:海天出版社,2006,121~127
[41]Lanner北京代表处,Witness物流方针平台基础教程,2004,52~53
[42]王小芳,基于Witness仿真技术的6σ管理应用研究,硕士学位论文,天津工业大学,2006
[43]王亚超,生产物流系统建模与仿真——Witness系统及应用,北京:科学出版社,2006,234~270
[44]王建华、黄贤凤、马汉武,JIT生产系统Petri Net建模与仿真研究,机械设计与制造,2006,(3):126~128
[2]李钢、彭金梅、邓修权,Just-in-time的研究现状与发展趋势,工业工程与管理,1997,(6):40~41
[3]杨先知,准时制生产方式及其应用,企业改革与管理,2002,(12):45~46
[4]何海燕,看板管理——实施准时化生产的有效手段,上海汽车,2005,(1):33~34
[5]Benton W. C. , Shin H. J. . Manufacturing planing and control: The evolution of MRP and JIT integration. European Journal of Oreaational Research. 1998, 110(3): 411~440
[6]刘玉霞,基于JIT的电子看板的设计与实现,硕士学位论文,天津大学,2006
[7] Monden Y. . Toyota Production System 3rd ed. Georgia: Chapman and Hall. 1998, (3): 1~35
[8]Valerie Tardif, Lars Maaseidvaag. An adaptive approach to controlling kanban systems. European Journal of Operation Research. 2001, (132): 411~424
[9]Katsuhiko Takahashi, Nobuto Nakamura. Decentradized reactive kanban system. European Journal of Operation Research. 2002, (139): 262~276
[10]So K. C. , Pinault S. C. . Allocating buffer storage in a pull system. International Journal of Production Research. 1988, 26(12): 1959~1980
[11]华中生,随机生产系统安全库存的JIT控制策略,运筹与管理,1994,3(2):8~12
[12]Robert A. Leitch. Effect of stochasticity, capacity and lead time cost drivers on WIP and throughput in a pull production environment. Management Accounting Reach. 2001, (12): 167~196
[13]Christelle Duri, Yannick Frein, Hyo-seong Lee. Performance evaluation and design of a CONWIP system with inspections. Int.J. Production Economics. 2000, (64): 219~229
[14]Jie Chen F. , Frank Chen. Adaptive scheduling in random flexible manufacturing systems subject to machine breakdowns. International Journal of Production Research. 2003, 41(9): 1927~1951
[15]Spearman M. L. , Woodruff D. L. , Hopp W. J. . CONWIP: a pull alternative to KANBAN. International Journal of Production Research. 1990, 28(5): 879~894
[16]Marek R. P. , Elkins D. A. , Smith D. R. . Understanding the fundamentals of Kanban and CONWIP pull systems using simulation. Proceedings of the 33nd Conference on Winter Simulation, Arlington, Virginia. 2001, 921~929
[17]Wanf D. , Xu C. . Hybrid push/pull production control strategy simulation and its applications. Production Planning and Control. 1997, 8(2): 142~151
[18]Tayur S. R. . Structural results and a heuristic for kanban controlled serial lines. Management Science. 1993, 39(11): 1347~1368
[19]Glasserman P. T. , Yao D. D. . Structured buffer-allocation problems: Discrete Event Dynamic Systems. Theory and Applications. 1996, 6(1): 9~41
[20]康杰、徐作宁、任欣欣,实施精益制造的控制策略的比较分析,计算机应用研究,2001,18(12):21~22
[21]周延虎,精益六西格玛集成应用的若干问题研究,博士学位论文,天津大学,2007
[22]林勇、乐晓娟、付秋芳,Push-Pull和CONWIP-Pull生产控制模式对比分析,工业工程,2006(3):22~26
[23]Qi Hao, Weiming Shen. Implementing a hybrid simulation model for a kanban-based material handing system. Robotics and Computer-integrated Manufacturing. 2008, 24(5): 635~646
[24]Akturk M. S. , Erhun F. . An overview of design and operational issues of kanban systems. International Journal of Production Research. 1999, 37(17): 358~381
[25]杜战其,看板管理在JIT生产中的应用分析,科技情报开发与经济,2005,15(20):210~212
[26]Golhar D. Y. , Stsmm C. L. . The Just-in-time philosophy: a literature Review. International Journal of Production Research. 1991, 29(4): 657~676
[27]田志章,流水型CONWIP生产控制系统研究,硕士学位论文,武汉理工大学,2007
[28]康杰,精益生产方式中控制策略的研究与实现,博士学位论文,西南交通大学,2004
[29]杨连娜,看板系统导入与仿真设计研究,硕士学位论文,天津大学,2008
[30]杜玉强,看板管理(JIT)系统的设计与研究,硕士学位论文,华中科技大学,2003
[31]叶国洪,随机需求下的模具电极拉式看板控制系统研究,硕士学位论文,广东工业大学,2009
[32]米翠兰,二次指数平滑法的研究与应用,华北煤炭医学院学报,2000(5):524~525
[33]李占凯、何玉林,看板管理在企业中的应用研究,工业工程与管理,2009,14(4):132~137
[34]Chan F. T. S. Effect of Kanban Size on Just-in-time Manufacturing Systems. Journal of Materials Processing Technology. 2001, 1(16): 146~160.
[35]胡卫星,采用层次分析法对项目管理的研究,硕士学位论文,同济大学,2008
[36]刘立存、周凌云,层级分析法在物流信息系统开发模式决策中的应用,物流世界,2005(2):17~19
[37]赵静,看板管理在供应链系统的研究及其应用,硕士学位论文,浙江工业大学,2008
[38]Price W. , Gravel M. , Nsakanda A. L. . Modeling the performance of a kanban assembly shop. International Journal of Production Research. 1995, 33(4): 1171~1177
[39]Bruce A. , Henderson, Jorge L. Larco. How to change your business into a lean enterprise. Rawson Ass. 1999, 35~37
[40]李胜强、李华,目视管理365,深圳:海天出版社,2006,121~127
[41]Lanner北京代表处,Witness物流方针平台基础教程,2004,52~53
[42]王小芳,基于Witness仿真技术的6σ管理应用研究,硕士学位论文,天津工业大学,2006
[43]王亚超,生产物流系统建模与仿真——Witness系统及应用,北京:科学出版社,2006,234~270
[44]王建华、黄贤凤、马汉武,JIT生产系统Petri Net建模与仿真研究,机械设计与制造,2006,(3):126~128