硕士论文-混流制造系统生产运作控制仿真研究

华中科技大学硕士学位论文混流制造系统生产运作控制仿真研究姓名：江华申请学位级别：硕士专业：工业工程指导教师：邵新宇;管在林20080527IeM-PlanteM-PlantSimTalkeM-PlantIIAbstractNowadays,competitioninmarketisbecomingfiercer,andtheindividualityanddiversityofconsumers’demandisincreasing.Inthisenvironment,productionupdatespeedisacceler-ated,productionvarietyisextendedandthecycletimeisreduced.Thesenewfeatureschal-lengethetraditionalproductionmodelandmakeashiftfromthehighvolume,repetitivemassproductiontohigh-mixandlowvolumemasscustomizedproduction.Thetraditionalflowmanufacturingtechnologyfacedtohighvolumeandrepetitivemassproductionishardtoex-tendtohigh-mixandlowvolumeproduction.Inordertorealizetheimprovementofthesys-temperformanceinnewenvironment,thisthesismainlystudiesthenewoperationandcontrolmodeofflowmanufacturinganditsrealizationinsimulationsystem.TheoperationandcontrolframeworkbuiltinthisthesisaggregatesthetheoriesandtechnologiesincludingTOC,JIT,flowmanufacturingandvirtualmanufacturingcell.Theop-erationandcontrolmechanisminthisnewframeworkisintroducedcomprehensively.Itsmaincharacteristicsareasfollowing:withtheutilizationofgrouptechnology,theproductobjectsarechangedfrompartstopartfamilies,consequently,theequipmentutilizationisin-creasedandthecapacitywastebecauseoffrequentlysetupisreduced,integratedwithtech-nologiesofthedesignofvirtualmanufacturingcellsandflowpaths,thelayoutmethodcom-binedwiththedynamicflowpathsandstaticflowpathsprovidesthebasisforthemanufacturingwithmaterialbalanceandfastresponse.Applythepull-pushproductioncontrolmethodbasedonthebottleneck’staktonflowpathtoreachsystemicoptimization,otherthanindividualoptimizationorientedorganizationmethod.Intraditionalsimulationmodels,partsarejustflowedaccordingtotheconnectingdirec-tionofmachines,andtheprocesstimesofpartsonthesamemachinearefixed.Toovercomethesedisadvantages,anewpart-drivenprocesssimulationmethodwhichissuitableforsimu-lationinthehighmixandlowvolumeproductionenvironmentispresent.WiththeutilizationofSimTalklanguageineM-Plant,theplanningalgorithmbasedonbottleneckiscarriedout.Insertingthecalculateprocessofthebottleneckplanninginthesimulationsoftwarereducestheoptimizationprocessandtime,andmeanwhiledecreasesthecostforapplicationofsimu-lationtechnology.Facedtotheproblemonhowtodesignandrealizetheflowmanufacturingmode,thisthesisstudiesandsummarizestherelatedkeytechnologiessuchasthedivisionofflowpaths,determinationofbottleneckandsoon.Withtheutilizationofsimulationsoftware–eM-Plant,thesimulationmodelbasedonthenewoperationandcontrolmodewasbuilt.Andthecom-IIIparisonresultshowsitssuperioritytotraditionaloperationandcontrolmode.Finally,basedonthesummaryofthisthesis,thefutureresearchonhowtoimprovethismodeandhowtosystematizationandsoftwareispresent.Keywords:Flowmanufacturing,CellularManufacturing,VirtualManufacturingCell,FlowPath,ModelingandSimulation111.19732005CB7241078632007AA04Z110707720561.22[1]JITeM-Plant1.3eM-Plant31.4ProgramEvaluationandReviewTechnique,PERT(ManufacturingResourcePlanning,MRPII)[2][3](JustInTime,JIT)[4][5][6](CellularManufactur-ing)[7][8][9][10][11](FlowManufacturing)[12][13][14]TheoryOfCon-straints,TOC[15][16][17][18]CriticalPathMethod,CPMMRPOliver.W.WightMaterialRequirementPlanning,MRPMRPMRPMRPMRP1234MRP[19]JITJITJITJIT4JITJIT1JIT2JIT3JIT4JITJIT[20][21]80[22](FlowManufacturing)JIT5123JIT4[23]OptimizedProductionTechnology,OPTTOCTOCCriticalChain,CCPERTTOCTOCAdvancedPlanningandScheduling,APSTOCTOC123[24][25]eM-Plant61.51.5.1eM-Plant123eM-Plant41.5.27eM-PlanteMPlanteM-Plant822.1JIT//JIT1TPSJITFlowPathManagement92.2CellularManufacturingSystem,CMS[26][27]GroupTechnologyGT[28]VirtualManufacturingCellSystem,VMCS2.2.12.12080[29][30],10[31][32]2.12.12.2[33][34]112.22.2.2[35][36][22]11221232.2.3[37][38]121331FCFS(FirstComeFirstServed)2EDD(EarliestDueDate)3SPT(ShortestProcessingTime)4SCR(SmallestCriticalRatio)5MWKR(MostWorkRemaining)6LWKR(LeastWorkRemaining)7MOPNR(MostOperationsRemaining)8RANDOM9EDDFCFSSPTSCRMWKRLWKR142.3JITKaban[39](1)(2)(3)()[40][41][42](1)15(2)2.32.32.3XXC,D,,H,I(ParetoPrinciple)20-802.3CD2.3EI162.3KabanCONWIP2.41733.13.1.13.118GT3.2A-G186812345678ABCDEFG3.23.2ACD6BFEG3.31912345678ACDBFEG3.33.1.2[43][8]203.23.2.1ChristophRoser[44]ShuYinChiang[45]blockagestarvationDT-BNDowntimeBottlenecksRommelC.D’Souza[46]DITDropinThroughputDIT[47]VAT[48][49]Q-GERT[49]213.1(1)12mnniT−=∑3.2123…i…mnnnTn3.2.2[50]123…i…n123…j…mijBeforeiTijBufferiT22ijAfteriTiTiBeforeiBufferiAfteriTTTTi=++3.3λ510λ≤≤duedayiTijityi××duedayiAfteriBufferiiytTTTλ=−+3.4itktjj1t1startT111××startBeforeytTTλ=−3.5kstartkT(1)(1)××kstartkBufferkBeforekytTTTλ−−=+−3.6startiT××startiduedayiiyTTTλ=−3.73.3234eM-Plant4.1eM-Plant4.1.1eM-PlanteM-PlantTecnomatixeM-PlanteM-Plantattribute(operation)eM-Plant4.1eM-PlantSingleProcParallelProcBufferLineFlowControlSourceDrainContainerEntityTransporterDialogsChartPlotterInterfaceFilelinkTablefileCardfileMethodTriggerVariableTrackStore4.1eM-Plant24eM-PlantMoveableUnitsMUStaticObjectsMaterialFlowObjectsInformationFlowObjectsUserInterfaceOb-jects1MaterialFlowObjectsSingleProcParalleProcBufferLineStoreTrack2Infor