面向大规模定制的扩展制造执行系统及其关键技术研究
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摘要
制造执行系统是位于上层计划管理与底层工业控制之间,面向车间制造过程管理与控制的信息系统。制造执行系统一经提出便得到了学术界和工业界的广泛关注,近年来国内外围绕制造执行系统所进行的研究和应用已取得不少成果,但是对面向大规模定制的制造执行系统所进行的研究还远远不够。论文在国家863项目资助下,结合企业的实际需求,对面向大规模定制的扩展制造执行系统及其关键技术进行了研究。
环境的变化是永恒和不可预测的,制造系统生存发展的能力取决于其对环境变化的响应能力。随着产品品种日趋多样,制造过程日趋复杂,仅仅依靠车间自身制造资源完成生产任务变得越来越困难,将地域上分散的制造资源动态集成,构建跨地域的、资源分布的扩展车间,成为制造系统提高快速响应能力,赢得市场竞争的一条重要途径。论文分析了车间制造系统的发展变化,指出大规模定制环境下的车间是一种建立在广泛合作基础之上,具有灵活组织结构和快速响应能力的扩展车间,其生产活动已经延伸到跨度多个地点、多个合作伙伴的广阔制造空间,其生产管理与控制需要一种建立在制造技术、信息技术和现代管理技术有机结合基础之上的扩展制造执行系统来支撑。为此,依据扩展车间生产管理与控制的要求,遵循有关标准,提出了一种由功能层、工具层和信息交互层组成的扩展制造执行系统的框架结构。该框架下的扩展制造执行系统着眼于对广阔制造空间中的生产活动进行管理与控制,注重车间层面的生产协同和更大范围内资源的优化利用,重视与现场设备和人员的信息交互;其特点表现为纵向支持上层设计、管理等系统与车间底层生产设备和人员的集成运行,横向支持跨地域的协同制造。
大规模定制环境下的扩展车间任务变化频繁,制造资源分散,产品种类多,生产批量小,难以有效制定作业计划。相似性是事物之间共性的一种表现形式,对于将个性化产品的定制生产问题转化或部分转化为批量生产问题具有重要意义,基于这一认识,论文提出了一种基于工艺过程相似性分组的扩展车间分级作业规划方法。该方法将扩展车间作业规划分为三个阶段,第一阶段对扩展车间进行逻辑制造单元重组,把作业任务归并为在资源使用方面具有相似性的作业任务组,从而将个性化产品的定制生产问题转化为逻辑制造单元内的批量生产问题;第二阶段对逻辑制造单元进行作业规划,实现逻辑制造单元内作业任务的优化排产;第三阶段对外协加工任务进行作业规划,实现外协加工任务在外部制造资源上的优化分配。
论文对扩展车间分级作业规划每一阶段的问题进行了深入研究。针对扩展车间第一阶段逻辑制造单元重组问题,提出了一种基于资源约束的扩展车间逻辑制造单元重组方法,以实现资源与生产任务的合理匹配。针对扩展车间第二阶段逻辑制造单元作业规划问题,建立了以资源负荷均衡和任务完成时间最短为目标函数的扩展车间逻辑制造单元作业规划模型,以优化单元内的生产作业计划。针对扩展车间第三阶段外协加工作业规划问题,建立了以外协加工成本最小为目标函数的外协加工任务优化分配模型,以实现外协加工任务在外部制造资源上的优化分配。
基于本论文研究内容所开发的扩展制造执行系统原型系统已经在重庆卡福汽车制动转向系统有限公司试点应用,取得了较好的应用效果。
Manufacturing Execution System, located between the upper production planning management and lower industrial control, is a real-time information system oriented for workshop manufacturing management and control. Manufacturing Execution System attracts widespread attention from both the academia and industrial sector once it’s been proposed. Recent years have witnessed a lot of achievements on research and application of manufacturing execution system both at home and abroad, but there is still a lack of research concerning manufacturing execution system for mass customization. With the support of national 863 high-tech program, and in order to meet the real needs of business community, this paper investigates the key technologies of extended manufacturing execution system for mass customization.
The change of environment is eternal and unpredictable, the survival and development of manufacturing system is depended on its responding ability to changes. With the increasingly diverse product variety and the growing complexity of the manufacturing process, it’s becoming more and more difficult for enterprises to complete production tasks solely on its own manufacturing resource in mass customization environment. Dynamically integrating geographically dispersed manufacturing resource to establish a cross-boundary workshop puts forward an important way for manufacturing system to enhance rapid response capacity to win market competition in mass customization environment. This paper discusses the development and changes of workshop manufacturing systems, and points out that the workshop under mass customization environment is based on extensive cooperation with flexible organizational structure and the ability to quickly respond to changes. Operation of such a system requires the support from the extended manufacturing execution system which integrates manufacturing technology, information technology and modern management technology as a whole. For this reason, this paper develops a framework of extended manufacturing execution system for mass customization in accordance with international standards. The extended manufacturing execution systems under the guidance of the proposed formwork focuses on the management and control of production activities involved in the cross-boundary extended workshop, and emphasizes the workshop level production collaboration and resource optimization, it also pays high attention to the information exchange at the scene. The characteristics of the extended manufacturing execution are reflected vertically in the integration of the upper design, management systems with the production equipment and personnel at the bottom, and horizontally in the support of cross-boundary collaborative manufacturing.
Under the environment of mass customization, issues such as task changing, scattering of manufacturing resource and small production batch, make it hard to achieve an effective production plan. Similarity is a common form of expression for things. Similarity research boasts significant meanings for transforming individual customized production to batch production. For this reason, a multiple layer workshop production schedule based on process similarity and resource constraints is put forward. The method decomposes the extended workshop production planning process into three phases. The first phase chiefly addresses the issues of logic manufacturing cell reconfiguration. By grouping the tasks in accordance with the similarity of process and resource constraints, it transforms individual customized production to inter-cell batch production. The second phase mainly addresses the issues of production schedule for logic manufacturing cells. The third phase principally investigates the issues of production schedule of outsourcing tasks.
Issues addressed in each phases are discussed in details. To solve the problem of cell reconfiguration at the first phase of planning, a logic manufacturing cell reconfiguration method is developed to partitioning the extended work shop into logic manufacturing cells. As for the production schedule at the second phase of planning, a mathematical model with the objective of balancing workload and minimizing the make span is built. As for the assignment of outsourcing tasks at the third phase of planning, a mathematical model with the aim of minimizing the total cost is developed to optimize the task assignment.
The prototype of extended manufacturing execution system developed based on this research has been introduced to Chongqing CAFF Automotive Brake Systems Company, and the experimental application indicates a better effect.
环境的变化是永恒和不可预测的,制造系统生存发展的能力取决于其对环境变化的响应能力。随着产品品种日趋多样,制造过程日趋复杂,仅仅依靠车间自身制造资源完成生产任务变得越来越困难,将地域上分散的制造资源动态集成,构建跨地域的、资源分布的扩展车间,成为制造系统提高快速响应能力,赢得市场竞争的一条重要途径。论文分析了车间制造系统的发展变化,指出大规模定制环境下的车间是一种建立在广泛合作基础之上,具有灵活组织结构和快速响应能力的扩展车间,其生产活动已经延伸到跨度多个地点、多个合作伙伴的广阔制造空间,其生产管理与控制需要一种建立在制造技术、信息技术和现代管理技术有机结合基础之上的扩展制造执行系统来支撑。为此,依据扩展车间生产管理与控制的要求,遵循有关标准,提出了一种由功能层、工具层和信息交互层组成的扩展制造执行系统的框架结构。该框架下的扩展制造执行系统着眼于对广阔制造空间中的生产活动进行管理与控制,注重车间层面的生产协同和更大范围内资源的优化利用,重视与现场设备和人员的信息交互;其特点表现为纵向支持上层设计、管理等系统与车间底层生产设备和人员的集成运行,横向支持跨地域的协同制造。
大规模定制环境下的扩展车间任务变化频繁,制造资源分散,产品种类多,生产批量小,难以有效制定作业计划。相似性是事物之间共性的一种表现形式,对于将个性化产品的定制生产问题转化或部分转化为批量生产问题具有重要意义,基于这一认识,论文提出了一种基于工艺过程相似性分组的扩展车间分级作业规划方法。该方法将扩展车间作业规划分为三个阶段,第一阶段对扩展车间进行逻辑制造单元重组,把作业任务归并为在资源使用方面具有相似性的作业任务组,从而将个性化产品的定制生产问题转化为逻辑制造单元内的批量生产问题;第二阶段对逻辑制造单元进行作业规划,实现逻辑制造单元内作业任务的优化排产;第三阶段对外协加工任务进行作业规划,实现外协加工任务在外部制造资源上的优化分配。
论文对扩展车间分级作业规划每一阶段的问题进行了深入研究。针对扩展车间第一阶段逻辑制造单元重组问题,提出了一种基于资源约束的扩展车间逻辑制造单元重组方法,以实现资源与生产任务的合理匹配。针对扩展车间第二阶段逻辑制造单元作业规划问题,建立了以资源负荷均衡和任务完成时间最短为目标函数的扩展车间逻辑制造单元作业规划模型,以优化单元内的生产作业计划。针对扩展车间第三阶段外协加工作业规划问题,建立了以外协加工成本最小为目标函数的外协加工任务优化分配模型,以实现外协加工任务在外部制造资源上的优化分配。
基于本论文研究内容所开发的扩展制造执行系统原型系统已经在重庆卡福汽车制动转向系统有限公司试点应用,取得了较好的应用效果。
Manufacturing Execution System, located between the upper production planning management and lower industrial control, is a real-time information system oriented for workshop manufacturing management and control. Manufacturing Execution System attracts widespread attention from both the academia and industrial sector once it’s been proposed. Recent years have witnessed a lot of achievements on research and application of manufacturing execution system both at home and abroad, but there is still a lack of research concerning manufacturing execution system for mass customization. With the support of national 863 high-tech program, and in order to meet the real needs of business community, this paper investigates the key technologies of extended manufacturing execution system for mass customization.
The change of environment is eternal and unpredictable, the survival and development of manufacturing system is depended on its responding ability to changes. With the increasingly diverse product variety and the growing complexity of the manufacturing process, it’s becoming more and more difficult for enterprises to complete production tasks solely on its own manufacturing resource in mass customization environment. Dynamically integrating geographically dispersed manufacturing resource to establish a cross-boundary workshop puts forward an important way for manufacturing system to enhance rapid response capacity to win market competition in mass customization environment. This paper discusses the development and changes of workshop manufacturing systems, and points out that the workshop under mass customization environment is based on extensive cooperation with flexible organizational structure and the ability to quickly respond to changes. Operation of such a system requires the support from the extended manufacturing execution system which integrates manufacturing technology, information technology and modern management technology as a whole. For this reason, this paper develops a framework of extended manufacturing execution system for mass customization in accordance with international standards. The extended manufacturing execution systems under the guidance of the proposed formwork focuses on the management and control of production activities involved in the cross-boundary extended workshop, and emphasizes the workshop level production collaboration and resource optimization, it also pays high attention to the information exchange at the scene. The characteristics of the extended manufacturing execution are reflected vertically in the integration of the upper design, management systems with the production equipment and personnel at the bottom, and horizontally in the support of cross-boundary collaborative manufacturing.
Under the environment of mass customization, issues such as task changing, scattering of manufacturing resource and small production batch, make it hard to achieve an effective production plan. Similarity is a common form of expression for things. Similarity research boasts significant meanings for transforming individual customized production to batch production. For this reason, a multiple layer workshop production schedule based on process similarity and resource constraints is put forward. The method decomposes the extended workshop production planning process into three phases. The first phase chiefly addresses the issues of logic manufacturing cell reconfiguration. By grouping the tasks in accordance with the similarity of process and resource constraints, it transforms individual customized production to inter-cell batch production. The second phase mainly addresses the issues of production schedule for logic manufacturing cells. The third phase principally investigates the issues of production schedule of outsourcing tasks.
Issues addressed in each phases are discussed in details. To solve the problem of cell reconfiguration at the first phase of planning, a logic manufacturing cell reconfiguration method is developed to partitioning the extended work shop into logic manufacturing cells. As for the production schedule at the second phase of planning, a mathematical model with the objective of balancing workload and minimizing the make span is built. As for the assignment of outsourcing tasks at the third phase of planning, a mathematical model with the aim of minimizing the total cost is developed to optimize the task assignment.
The prototype of extended manufacturing execution system developed based on this research has been introduced to Chongqing CAFF Automotive Brake Systems Company, and the experimental application indicates a better effect.
引文
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