混合流程企业生产过程管理系统研究
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摘要
混合流程企业(Hybrid Manufacturing Enterprise, HME)的生产过程包括连续和离散两种生产方式,各生产阶段之间的约束关系更为复杂。随着以需求多样性等为特征的现代市场的发展,HME生产管理的复杂性与创新不足的矛盾日渐突出。本文在分析HME生产过程突出特点及其典型管理问题的基础上,对混合流程企业生产过程管理系统(Production Process Management System Oriented to HME, PPMS-HME)展开研究。
建立了一种面向HME的生产过程管理功能体系,以混合型生产制造过程为主线,集成了各生产阶段中与计划、组织和控制等管理职能相对应,分布于各应用领域和管理部门的重要功能模块。提出了一种结构简单灵活的矩阵式系统架构,减少了功能层之间的耦合关系,从根本上降低了生产过程管理系统开发和实施过程中的风险。
建立了面向HME的推拉结合的生产计划与控制层级模型,设计了基于生产进度等启发式规则的简化模拟退火算法(Simplified Simulated Annealing Algorithm, SSA)和适合现场调度的能力平衡模型及动态调度算法。以综合生产需求为起点,拉动生产计划,据工艺流程图等进行连续工序计划和离散工序计划的预分解,考虑各生产节点产能,通过SSA算法获得有限产能的优化生产作业计划和更加可行的车间级物料需求计划等；在生产执行层面则结合工序流转卡等方式进行推动式生产。为提高特定条件下相邻的同类生产单元的作业效率,建立了相邻生产单元能力平衡模型,并开发了动态调度规则和算法。
针对HME生产过程中存在分批、合批工序和物料替代等多种特殊环节的多样性特点,建立了物料转换的批次映射关系模型,包括对应特殊物料转换环节的构造映射和动态映射模型,采取类似软件工程中钩子技术的方法求解多环节物料跟踪追溯的复合映射,提高了系统对多环节物料转换过程的物料跟踪追溯的信息集成能力和计算速度。
基于HME多形态作业的过程集成信息,通过作业转换等数据处理过程,建立了面向作业管理法(Activity-Based Management, ABM)的作业数据集市,进而建立了三维作业分析模型。据不同侧重点的作业管理需求,可选取相应的作业分类,确认源于过程集成信息的作业成本库和作业成本动因,获得多种成本视图。实现了快速的自动化成本数据提交和成本核算过程,为实施作业管理法等现代管理方法提供了数据基础和技术支撑。
结合企业实践,说明了混合流程企业生产过程管理系统的实施应用过程及其实效。混合流程企业生产过程管理系统的研究有利于促进我国混合流程企业采用信息化技术进行管理创新,对信息化建设工作具有重要的理论价值和现实指导意义。
The Hybrid Manufacturing Enterprise (HME) incorporates both continuous processes and discrete processes in an integrated way, with complex constraints during multiple production periods. The conflict, between complexity of production management and deficient management innovation, becomes increasingly fierce along with the development of a contemporary market which is mainly characterized by diverse demands, etc. The Production Process Management System Oriented to HME (PPMS-HME) was explored, based on the analysis of special characteristics and typical problems in the production processes in HME.
A comprehensive functional framework for PPMS-HME was proposed, including a series of functional modules responsible for planning, organizing or controlling in each department while including the whole process. In order to reduce the coupling among layers, an agile Matrix System Architecture was designed. Consequently the system complexity was decreased and the average risks were radically lowered in developing and implementing the PPMS-HME.
A HME-oriented hierarchy model for push-pull production planning and control was proposed. A Simplified Simulated Annealing Algorithm (SSA), based on heuristic rules such as production progress, and a Dynamic Scheduling Algorithm (DSA) were designed for efficient optimization of planning and scheduling respectively. The planning model adopted SSA to achieve optimized feasible master plans, MRP, etc., pulled by integrative production demands, with constrains of limited capacities and special rules at workshops, preplanning for both continuous and discrete processes according to the craft networks. The actual production processes were designed to be pushed by such approaches as process circulation card, etc. To advance efficiencies in neighbor workshops with the same type of capacities and special conditions, a shared capacities balancing model was proposed, symbolized as connected vessels in hydromechanics, and the scheduling rules and DSA were developed.
The general, constructed and dynamic material transition mapping models were presented respectively, aiming at the diversity, e.g., material substitution and lot merging/splitting, in the HME. The simulated Hook technology in software engineering was employed for speedy compound mapping calculation, improving the information-integrating abilities of material tracking and tracing in complex materials transition processes in the HME.
Based on the integrated extensive process information, an activity data mart, oriented to Activity-Based Management (ABM), was established using data processing approach such as defined activity transformation, and the tri-dimensional activity analysis model was further developed. Depending upon the different activity management demands, different activity categories can be chosen and the rational cost drivers can be measured to select the corresponding costing view. Therefore, costing information collection and cost accumulation can be realized as instant automated procedures, providing foundation data and technical support to implement advanced modern management approaches such as activity based management.
A case study was conducted at an actual business, explaining the implement, application and effectiveness of PPMS-HME. This research helps the HME to adopt information technologies for management innovation, and is of theoretical and practical significance to the informationization in China.
建立了一种面向HME的生产过程管理功能体系,以混合型生产制造过程为主线,集成了各生产阶段中与计划、组织和控制等管理职能相对应,分布于各应用领域和管理部门的重要功能模块。提出了一种结构简单灵活的矩阵式系统架构,减少了功能层之间的耦合关系,从根本上降低了生产过程管理系统开发和实施过程中的风险。
建立了面向HME的推拉结合的生产计划与控制层级模型,设计了基于生产进度等启发式规则的简化模拟退火算法(Simplified Simulated Annealing Algorithm, SSA)和适合现场调度的能力平衡模型及动态调度算法。以综合生产需求为起点,拉动生产计划,据工艺流程图等进行连续工序计划和离散工序计划的预分解,考虑各生产节点产能,通过SSA算法获得有限产能的优化生产作业计划和更加可行的车间级物料需求计划等；在生产执行层面则结合工序流转卡等方式进行推动式生产。为提高特定条件下相邻的同类生产单元的作业效率,建立了相邻生产单元能力平衡模型,并开发了动态调度规则和算法。
针对HME生产过程中存在分批、合批工序和物料替代等多种特殊环节的多样性特点,建立了物料转换的批次映射关系模型,包括对应特殊物料转换环节的构造映射和动态映射模型,采取类似软件工程中钩子技术的方法求解多环节物料跟踪追溯的复合映射,提高了系统对多环节物料转换过程的物料跟踪追溯的信息集成能力和计算速度。
基于HME多形态作业的过程集成信息,通过作业转换等数据处理过程,建立了面向作业管理法(Activity-Based Management, ABM)的作业数据集市,进而建立了三维作业分析模型。据不同侧重点的作业管理需求,可选取相应的作业分类,确认源于过程集成信息的作业成本库和作业成本动因,获得多种成本视图。实现了快速的自动化成本数据提交和成本核算过程,为实施作业管理法等现代管理方法提供了数据基础和技术支撑。
结合企业实践,说明了混合流程企业生产过程管理系统的实施应用过程及其实效。混合流程企业生产过程管理系统的研究有利于促进我国混合流程企业采用信息化技术进行管理创新,对信息化建设工作具有重要的理论价值和现实指导意义。
The Hybrid Manufacturing Enterprise (HME) incorporates both continuous processes and discrete processes in an integrated way, with complex constraints during multiple production periods. The conflict, between complexity of production management and deficient management innovation, becomes increasingly fierce along with the development of a contemporary market which is mainly characterized by diverse demands, etc. The Production Process Management System Oriented to HME (PPMS-HME) was explored, based on the analysis of special characteristics and typical problems in the production processes in HME.
A comprehensive functional framework for PPMS-HME was proposed, including a series of functional modules responsible for planning, organizing or controlling in each department while including the whole process. In order to reduce the coupling among layers, an agile Matrix System Architecture was designed. Consequently the system complexity was decreased and the average risks were radically lowered in developing and implementing the PPMS-HME.
A HME-oriented hierarchy model for push-pull production planning and control was proposed. A Simplified Simulated Annealing Algorithm (SSA), based on heuristic rules such as production progress, and a Dynamic Scheduling Algorithm (DSA) were designed for efficient optimization of planning and scheduling respectively. The planning model adopted SSA to achieve optimized feasible master plans, MRP, etc., pulled by integrative production demands, with constrains of limited capacities and special rules at workshops, preplanning for both continuous and discrete processes according to the craft networks. The actual production processes were designed to be pushed by such approaches as process circulation card, etc. To advance efficiencies in neighbor workshops with the same type of capacities and special conditions, a shared capacities balancing model was proposed, symbolized as connected vessels in hydromechanics, and the scheduling rules and DSA were developed.
The general, constructed and dynamic material transition mapping models were presented respectively, aiming at the diversity, e.g., material substitution and lot merging/splitting, in the HME. The simulated Hook technology in software engineering was employed for speedy compound mapping calculation, improving the information-integrating abilities of material tracking and tracing in complex materials transition processes in the HME.
Based on the integrated extensive process information, an activity data mart, oriented to Activity-Based Management (ABM), was established using data processing approach such as defined activity transformation, and the tri-dimensional activity analysis model was further developed. Depending upon the different activity management demands, different activity categories can be chosen and the rational cost drivers can be measured to select the corresponding costing view. Therefore, costing information collection and cost accumulation can be realized as instant automated procedures, providing foundation data and technical support to implement advanced modern management approaches such as activity based management.
A case study was conducted at an actual business, explaining the implement, application and effectiveness of PPMS-HME. This research helps the HME to adopt information technologies for management innovation, and is of theoretical and practical significance to the informationization in China.
引文
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