沈阳机床制造系统的精益生产研究
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摘要
针对沈阳机床集团生产过程的“高成本、高库存、低效率”的二高一低问题,作者对多品种小批量生产方式和批量生产方式两种典型生产方式进行了深入研究。
在广泛查阅了相关领域的国内外专题文献,了解精益生产的国内外研究动态。论文工作取得的研究成果主要是：
对精益生产方式的内涵、技术体系以及多品种小批量生产的特点进行了分析,分别指出了在多品种小批量生产环境与批量生产环境下精益生产方式的生产特点与各自的局限性。对精益生产方式的改善体系进行了叙述与分析,并各自结合沈阳机床集团内部实施案例说明了体系建立的过程,同时验证了方法的有效性。
在丰田管理方式的基础上建立了符合XXX机床集团运行管理特点的“制造体系”。在一定程度上能够为全行业共同实施精益生产管理体系起到引导与借鉴作用。
Recent years,following with the current annual rapid development in Shenyang Machine Tool Group Corporation, many problems occur continuously such as contract adjusting, excessive inventory of work in process and finished products and the long cycle of match-production,which has affected the whole operation of the corporation. Aimming at changing this kind of production, the corporation must first solve the high cost, high inventory and low efficiency which exists in the manufacturing process.The shenyang industry clusters are implementing the lean production mode firstly, which hope to explore a SMTCL Production System according with the China's national conditions and the actual operation of Shenyang Machine Tool Group Corporation. This manufacturing system will change Shenyang Machine Tool Group Corporation to an international and world-class corporation.
This paper details the process of system and the effectiveness of the proposed method through introducing two typical production mode in the machine tool industry(namely, multi-varieties and small-batch production mode and batch production mode) and combining the improved case respectively. Hoping to the introduction of the implement experience and effect, all industries can practice the lean production management system alltogether, which could make the Chinese manufacturing industry really become bigger and stronger.
在广泛查阅了相关领域的国内外专题文献,了解精益生产的国内外研究动态。论文工作取得的研究成果主要是：
对精益生产方式的内涵、技术体系以及多品种小批量生产的特点进行了分析,分别指出了在多品种小批量生产环境与批量生产环境下精益生产方式的生产特点与各自的局限性。对精益生产方式的改善体系进行了叙述与分析,并各自结合沈阳机床集团内部实施案例说明了体系建立的过程,同时验证了方法的有效性。
在丰田管理方式的基础上建立了符合XXX机床集团运行管理特点的“制造体系”。在一定程度上能够为全行业共同实施精益生产管理体系起到引导与借鉴作用。
Recent years,following with the current annual rapid development in Shenyang Machine Tool Group Corporation, many problems occur continuously such as contract adjusting, excessive inventory of work in process and finished products and the long cycle of match-production,which has affected the whole operation of the corporation. Aimming at changing this kind of production, the corporation must first solve the high cost, high inventory and low efficiency which exists in the manufacturing process.The shenyang industry clusters are implementing the lean production mode firstly, which hope to explore a SMTCL Production System according with the China's national conditions and the actual operation of Shenyang Machine Tool Group Corporation. This manufacturing system will change Shenyang Machine Tool Group Corporation to an international and world-class corporation.
This paper details the process of system and the effectiveness of the proposed method through introducing two typical production mode in the machine tool industry(namely, multi-varieties and small-batch production mode and batch production mode) and combining the improved case respectively. Hoping to the introduction of the implement experience and effect, all industries can practice the lean production management system alltogether, which could make the Chinese manufacturing industry really become bigger and stronger.
引文
[1]刘丽文.生产与运作管理(第二版).北京：清华大学出版社,2002.
[2]Karmarkar U S.Lot sizes, manufacturing lead times and in-processinventories. ManagementScience,1987,33(3):409-418.
[3]Karmarkar U S, Kekre S, Kekre S. Lot sizing in multi-machine job shops, IIETransactions,1985,17(3):290-298.
[4]Zipkin P H. Models for design and control of stochastic multi-item batch production systems, Operations Research,1983,34(1):91-104.
[5]Shanthikumar J G, Buzacott J A. Open queueing network models of dynamic job shops, Inteinational Journal of Production Research,1981,19(3):255-266.
[6]Baker K R., Scudder G D.Sequencing with earliness and tardiness penalties:a review. Operations Research,1990, 38(1):22-36.
[7]Baker K R. Heuristic procedures for scheduling job families with setups and due dates. Naval Research Logistics,1999, 46(8):978-991.
[8]Palekar N.Job sequencing & WIP level determination in a cyclic CONWIP flowshop with blocking. Master Dissertation of Virginia Polytechnic Institute and State University,2005.
[9]何桢,朱礼仁,曹捷,等.并行加工条件下作业排序方法研究.工业工程,2005,8(2)：42-44,60.
[10]何桢,齐二石,王恒毅.成组流水线上零件排序的优化算法.管理工程学报,1996,10(4)：243-248.
[11]何桢,齐二石.一般作业车间零件排序方法研究.系统工程理论与
实践,1996,16(12)：11-16.
[12]何桢,李从东,刘子先,等.n/m/F/C排序问题的启发式算法.系统工程学报,1996,11(2)：75-80.
[13]王玮,汪定伟,王晓琦.基于模糊交货期的单件制造业准时化生产计划.系统工程学报,1998,13(2)：63-69.
[14]毛建忠,吴智铭.基于准时生产制的Job-Shop成组调度方法.控制与决策,1995,10(5)：411-416.
[15]赵伟,韩文秀,罗永泰.准时生产方式下混流装配线的调度问题.管理科学学报,2000,3(4)：23-28.
[16]牛海军,孙树栋.JIT方式下的单机分批调度问题研究.西安电子科技大学学报(自然科学版),2002,29(4)：444-460.
[17]陈伟达,达庆利.工艺路线可变的Job-Shop准时生产调度研究.管理工程学报,2003,17(1)：61-64
[18]余忠华,吴昭同.面向多品种、小批量制造环境的SPC实施模型的研究.工程设计,2000,(3)：28-31.
[19]Hillier F S. Small sample probability limits for range chart. Journal of the American Statistical Association,1967,62(320):1488-1493.
[20]Quesenberry C P. SPC Q-charts for start-up processes and short or long runs. Journal of Quality Technology,1991,23(3):213-224.
[21]Salti M M, Statham A. A review of the literature on the use of SPC in batch production. Quality and Reliability Engineering International,1994,10:49-61.
[22]苗瑞,王东鹏,姚英学.基于小批量多品种生产环境的统计过程质量控制研究.高技术通讯,2003,13(11)：48-50.
[23]王建稳.多品种小批量生产情形下的工序质量控制图.数理统计与管理,2002,21(4)：34-37.
[24]Silver E A,Bischak D P.Bayesian estimation of the rate at which a process, monitored by an X-chart, goes out of control. International Journal of Production Research,2004,42(6):1227-1242.
[25]余忠华,吴昭同.面向小批量制造过程的质量控制方法研究.机械工程学报,2001,37(8)：60-64.
[26]朱慧明,韩玉启.小批量生产的贝叶斯质量控制模型.运筹与管理,2003,12(5)：66-70.
[27]张文生.小批量生产过程中产品质量控制的研究.系统工程理论与实践,2002,22(5)：24-30.
[28]Hwarng H B, Hubele N F. X control chart pattern identification through efficient off-line neural net-work training.IIE Transactions, 1993,25 (3):27-39.
[29]Hwarng H B, Hubele N F. Back-propagation pattern recognizers for control charts:methodology and performance. Computers and Industrial Engineering,1993,24(2):219-235.
[30]陈平,高清,马玉林,等.基于神经网络的质量控制图模式识别技术的研究.高技术通讯,1997,7(3)：21-24.
[31]Cheng C S. A neural network approach for the analysis of control chartpatterns. International Journal of Production Research. 1997,35 (3):667-697.
[32]余忠华,吴昭同.控制图模式及其智能识别方法.浙江大学学报(工学版),2001,35(5)：521-525.
[33]陈庆新,毛宁,陈秋扬,等.加工过程质量仿真.机械科学与技术,1999,18(3)：449-453.
[34]毛宁,陈庆新.基于可制造性设计的小批量产品制造质量控制系统.计算机集成制造系统,1999,5(6)：41-46,54.
[35]殷建军,余忠华,吴昭同,等.面向零件成组加工的EWMA控制图及其性能分析,系统工程理论与实践,2004,24(9)：61-64.
[36]Kasul R A, Motwani J G. Successful implementation of TPS in amanufacturing setting:a case study Industrial Management&Data Systems 1997,97(7):274-279
[37]王玖河.精益生产方式下的质量控制研究.科技与管理(哈尔滨)2002,4(2)：27-30.
[38]牟永善,赵文波.成组加工质量控制中工序诊断调节法与公差百分数控制图的应用.工业工程与管理,2005,10(2)：81-85,88.
[39]Corbett C, Yucessn E. Modeling Just-in-time production system:a critical review Proceedings of the 1993 Winter Simulation Conference, 1993:819-828.
[40]邓修权,齐二石.精益生产方式拉动生产系统设计程序的研究.工业工程与管理,2000,5(5)：28-31.
[41]魏大鹏.准时化生产方式的技术支撑体系.工业工程与管理,1998,3(2)：30-33
[42]孔造杰,张海娟.准时化生产方式所采用技术的互动原理研究.计算机集成制造系统,2001,7(1)：69-71.
[43]赵晓波,周兆英.丰田生产系统特性分析.中国机械工程,1997,8(1)：62-65.
[44]齐二石.丰田生产方式及其在中国的应用分析.工业工程与管理1997,2(4)：37-39.
[45]龚其国,赵晓波,王永县.JIT生产控制策略的研究现状与进展.系统工程学报,2001,16(6)：456-464
[46]车建国,何桢.多品种小批量下精益生产系统的研究.天津大学,2006：16
[47]Askin R G, Goldberg J B.Design and analysis of lean production system. JohnWiley&Sons. Inc,2002.
[2]Karmarkar U S.Lot sizes, manufacturing lead times and in-processinventories. ManagementScience,1987,33(3):409-418.
[3]Karmarkar U S, Kekre S, Kekre S. Lot sizing in multi-machine job shops, IIETransactions,1985,17(3):290-298.
[4]Zipkin P H. Models for design and control of stochastic multi-item batch production systems, Operations Research,1983,34(1):91-104.
[5]Shanthikumar J G, Buzacott J A. Open queueing network models of dynamic job shops, Inteinational Journal of Production Research,1981,19(3):255-266.
[6]Baker K R., Scudder G D.Sequencing with earliness and tardiness penalties:a review. Operations Research,1990, 38(1):22-36.
[7]Baker K R. Heuristic procedures for scheduling job families with setups and due dates. Naval Research Logistics,1999, 46(8):978-991.
[8]Palekar N.Job sequencing & WIP level determination in a cyclic CONWIP flowshop with blocking. Master Dissertation of Virginia Polytechnic Institute and State University,2005.
[9]何桢,朱礼仁,曹捷,等.并行加工条件下作业排序方法研究.工业工程,2005,8(2)：42-44,60.
[10]何桢,齐二石,王恒毅.成组流水线上零件排序的优化算法.管理工程学报,1996,10(4)：243-248.
[11]何桢,齐二石.一般作业车间零件排序方法研究.系统工程理论与
实践,1996,16(12)：11-16.
[12]何桢,李从东,刘子先,等.n/m/F/C排序问题的启发式算法.系统工程学报,1996,11(2)：75-80.
[13]王玮,汪定伟,王晓琦.基于模糊交货期的单件制造业准时化生产计划.系统工程学报,1998,13(2)：63-69.
[14]毛建忠,吴智铭.基于准时生产制的Job-Shop成组调度方法.控制与决策,1995,10(5)：411-416.
[15]赵伟,韩文秀,罗永泰.准时生产方式下混流装配线的调度问题.管理科学学报,2000,3(4)：23-28.
[16]牛海军,孙树栋.JIT方式下的单机分批调度问题研究.西安电子科技大学学报(自然科学版),2002,29(4)：444-460.
[17]陈伟达,达庆利.工艺路线可变的Job-Shop准时生产调度研究.管理工程学报,2003,17(1)：61-64
[18]余忠华,吴昭同.面向多品种、小批量制造环境的SPC实施模型的研究.工程设计,2000,(3)：28-31.
[19]Hillier F S. Small sample probability limits for range chart. Journal of the American Statistical Association,1967,62(320):1488-1493.
[20]Quesenberry C P. SPC Q-charts for start-up processes and short or long runs. Journal of Quality Technology,1991,23(3):213-224.
[21]Salti M M, Statham A. A review of the literature on the use of SPC in batch production. Quality and Reliability Engineering International,1994,10:49-61.
[22]苗瑞,王东鹏,姚英学.基于小批量多品种生产环境的统计过程质量控制研究.高技术通讯,2003,13(11)：48-50.
[23]王建稳.多品种小批量生产情形下的工序质量控制图.数理统计与管理,2002,21(4)：34-37.
[24]Silver E A,Bischak D P.Bayesian estimation of the rate at which a process, monitored by an X-chart, goes out of control. International Journal of Production Research,2004,42(6):1227-1242.
[25]余忠华,吴昭同.面向小批量制造过程的质量控制方法研究.机械工程学报,2001,37(8)：60-64.
[26]朱慧明,韩玉启.小批量生产的贝叶斯质量控制模型.运筹与管理,2003,12(5)：66-70.
[27]张文生.小批量生产过程中产品质量控制的研究.系统工程理论与实践,2002,22(5)：24-30.
[28]Hwarng H B, Hubele N F. X control chart pattern identification through efficient off-line neural net-work training.IIE Transactions, 1993,25 (3):27-39.
[29]Hwarng H B, Hubele N F. Back-propagation pattern recognizers for control charts:methodology and performance. Computers and Industrial Engineering,1993,24(2):219-235.
[30]陈平,高清,马玉林,等.基于神经网络的质量控制图模式识别技术的研究.高技术通讯,1997,7(3)：21-24.
[31]Cheng C S. A neural network approach for the analysis of control chartpatterns. International Journal of Production Research. 1997,35 (3):667-697.
[32]余忠华,吴昭同.控制图模式及其智能识别方法.浙江大学学报(工学版),2001,35(5)：521-525.
[33]陈庆新,毛宁,陈秋扬,等.加工过程质量仿真.机械科学与技术,1999,18(3)：449-453.
[34]毛宁,陈庆新.基于可制造性设计的小批量产品制造质量控制系统.计算机集成制造系统,1999,5(6)：41-46,54.
[35]殷建军,余忠华,吴昭同,等.面向零件成组加工的EWMA控制图及其性能分析,系统工程理论与实践,2004,24(9)：61-64.
[36]Kasul R A, Motwani J G. Successful implementation of TPS in amanufacturing setting:a case study Industrial Management&Data Systems 1997,97(7):274-279
[37]王玖河.精益生产方式下的质量控制研究.科技与管理(哈尔滨)2002,4(2)：27-30.
[38]牟永善,赵文波.成组加工质量控制中工序诊断调节法与公差百分数控制图的应用.工业工程与管理,2005,10(2)：81-85,88.
[39]Corbett C, Yucessn E. Modeling Just-in-time production system:a critical review Proceedings of the 1993 Winter Simulation Conference, 1993:819-828.
[40]邓修权,齐二石.精益生产方式拉动生产系统设计程序的研究.工业工程与管理,2000,5(5)：28-31.
[41]魏大鹏.准时化生产方式的技术支撑体系.工业工程与管理,1998,3(2)：30-33
[42]孔造杰,张海娟.准时化生产方式所采用技术的互动原理研究.计算机集成制造系统,2001,7(1)：69-71.
[43]赵晓波,周兆英.丰田生产系统特性分析.中国机械工程,1997,8(1)：62-65.
[44]齐二石.丰田生产方式及其在中国的应用分析.工业工程与管理1997,2(4)：37-39.
[45]龚其国,赵晓波,王永县.JIT生产控制策略的研究现状与进展.系统工程学报,2001,16(6)：456-464
[46]车建国,何桢.多品种小批量下精益生产系统的研究.天津大学,2006：16
[47]Askin R G, Goldberg J B.Design and analysis of lean production system. JohnWiley&Sons. Inc,2002.