摘要
大规模定制的目的是以大规模生产的成本和速度提供给客户个性化的定制产品,它逐渐成为21世纪主流的生产方式。本文在探讨了实现大规模定制相关技术的基础上,研究了大规模定制模式下,面向生产过程的产品族扩展信息模型、柔性供应链组织结构、供应商选择与采购计划分配以及柔性生产计划与控制的相关理论和方法。
敏捷性是大规模定制的外在特征,柔性是实现其敏捷性的内在驱动力,本文从产品、制造、生产运作、组织、人员、信息系统等几个方面论述了提高企业柔性的主要策略。在对精益供应链与敏捷供应链对比分析的基础上,提出了大规模定制供应链的概念。针对大规模定制供应链这一新的组织形式,构建了面向订单的供应链资源计划管理系统,并介绍了其主要功能框架和体系结构框架。
针对大规模定制下产品信息的特点,提出了产品族扩展信息模型的概念,它由产品族结构模型和产品信息模型两部分构成。在通用物料清单(GenericBill of Materials,GBOM)的基础上,建立了产品族结构模型。将产品信息从传统的设计领域扩展到采购、计划、制造、库存、销售等阶段,建立了产品六域信息模型。采用面向对象方法对产品族扩展信息模型进行建模,抽象出实体对象类、对象管理类、对象集合类三大对象类,描述了产品信息模型中各对象类之间的关系。建立了产品族扩展信息的数据库模型,将产品族扩展信息模型从逻辑模型映射为物理模型。研究了客户订单物料清单(Order Billof Materials,OBOM)的实现及管理方法,建立了基于约束满足问题的产品优化配置模型及配置算法,提高了产品配置的效率。建立了基于可扩展标记语言(Extensible Markup Language,XML)的产品信息集成规范和产品族配置信息集成规范,为分布在异地的不同制造商、经销商、供应商等提供了一个产品族信息集成的标准。
分析了大规模定制下采购管理的特征,并指出了多源供应策略存在的必然性和可行性。针对多源供应的两种实现方式,以平均采购成本最低为目标,考虑需求约束、能力约束、质量约束,分别建立了多源供应下的供应商选择和采购计划优化分配集成模型。针对多源同时供货模型,设计了基于分支定界算法的综合求解算法。对单源供应以及两种多源供应方式进行了对比分析。将大规模定制下的供应商分为关键供应商和通用供应商两类,并针对通用供应商,建立了多源供应下的供应链双层构建过程模型,提高了供应链组织结构柔性和采购计划柔性,降低了采购成本。
分析了大规模定制下生产计划与控制的特征,将供应链生产计划分为战略层、战术层与操作层,建立了大规模定制下供应链层次化、柔性生产计划与控制模型。针对通用件生产计划建立了实现柔性与稳定性相结合的计划控制策略;针对订单排程计划建立了实时动态滚动控制机制,提高了订单计划的柔性。采用面向对象方法建立了订单信息模型和订单生命周期模型,并给出了订单类对象的状态图。针对多订单、多产品、多制造资源的订单优化排程问题,建立了多目标优化整数规划模型,并设计了基于精英选择和个体迁移的多目标遗传算法,实例验证表明算法具有高效率和有效性。
采用组件式开发技术设计并实现了面向订单的供应链资源计划管理系统,将系统的构成组件分为界面型组件、业务逻辑组件以及数据维护组件三类。组件式系统能够根据企业需求的变化实现快速重构,提高了信息系统的柔性。
以山东五征集团有限公司为应用对象,分别介绍了产品族信息管理、面向配置的订单管理与订单计划管理、多源供应下的采购计划管理、面向订单的成品库存管理与零部件库存管理等系统的主要功能模块以及应用情况,验证了本文理论的有效性。
Mass customization (MC) aims to provide individualized products to every customers with the cost and speed of mass production, and it wins a great popularity in 21st century. In the context of MC, related technologies covering the modeling of product family extended information, flexible organization of supply chain, supplier selection and order splitting, and theories and methodologies of production planning and control are investigated in depth.
Agility is the main external characteristic of mass customization, and flexibility is the internal power to realize agility. The main methods to enhance agility are prescribed from the facets of products, manufacturing, production and operation, information system, organization, and human resources. The concept of supply chain under MC (MCSC) is defined based on the comparison of agile supply chain and lean supply chain. Further, functional and architectural frames of the resource planning system oriented to assembly to order environments in the MCSC are built by taking the characteristics of production control in MC into account.
With a focus on the characteristics of product information in MC, the author defines the extended product family information model, which consists of product family structure model based on Generic Bill of Materials (GBOM) and product information model. The extended model enables the structural model to include the product family information related to the design, procurement, planning, manufacturing, stocking and marketing. It is mapped to six different domains. Product family extended information models are built using the object-oriented technology and are mapped from logical models into physical models. Three types of classes, i.e. entity object class, object management class and object collection class are abstracted. To enhance the efficiency of product configuration, the optimized configuration model and relative algorithm are made based on Constraint satisfaction problem (CSP). For product family extended information models, XML Schema-based product information integration schema and product family configuration information integration schema are established. These schemas serve as the standards for integrating the product family information physically distributed among various manufacturers, distributors and suppliers.
Based on the characteristics of the purchasing management under MC, a multi-sourcing policy is proposed to reduce the risks that may appear in supply chains. For either implementation method of multiple sourcing, specific models of suppliers' selection and procurement order splitting on the multi-sourcing basis are built to obtain the lowest average purchasing cost, considering constraints of demand, supplier's capacity and quality. A synthetical algorithm based on branch and bound algorithm is presented for simultaneous supply model. A comparative analysis between single- and multi-sourcing settings is conducted. In particular, the suppliers under MC are treated as key ones and normal ones. With normal ones, a double-layer process model for supply chains in a multi-supplier environment is proposed to improve the flexibility of supply chain and to lower the procurement cost.
The characteristics of production planning under MC are analyzed and a flexible and layered production planning and control system is built. The production plan in a supply chain is discussed from the perspective of strategic-, tactic- and operational layers. A planning control strategy enables flexibility and stability is adopted for the production planning of common parts, while an order-rolling control mechanism is used for the order scheduling process. With the object-oriented method, order information models and order lifecycle models are built, and the order object status diagram is proposed consequently. In the context of multi-order multi-product and multi-resource of manufacturing, the order scheduling problem are discussed by building a multi-objective integer programming model and devising a multi-objective genetic algorithm based on pareto selection and individual transference. Finally, a case study validates its high efficiency.
The supply chain resource planning system, which consists of three types of components including interface components, business logic components, and data maintenance components, is designed and coded using the Component-based Development (CBD) method, the method enables rapid reconstruction depending on the changes of business requirements and improves the flexibility of information system.
Finally, the supply chain resource planning system is put in practice in Shandong Wuzheng Group. The practical and successful operations of customer order management oriented to configuration, production planning, purchase planning under multi-supplier environments, optimal scheduling, final products and common parts' inventory management are introduced. The results validate the theories forwarded in the thesis.
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