现代造船模式下的造船企业生产物流管理研究
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摘要
近年来,中国造船业得到迅猛发展,主要表现在：设施规模不断扩大,设计手段日益先进,管理方法逐步完善,建造方法不断进步,生产总量不断提高。据统计,2010年,中国造船完工量达到6560万载重吨,是2001年290万吨的近22.6倍,是2006年1425万吨的4.6倍,是2009年4243万吨的1.5倍。这些数据充分表明,中国造船企业的发展速度很快。但是,造船业迅速发展,市场份额不断扩大,并没有为中国造船企业带来可观的利润。据统计,2010年1-11月份,全国规模以上船舶工业企业实现主营业务收入5271亿元,而利润总额仅为408亿元,中国造船业的行业利润不足8%。究其原因,除了物价因素外,主要还是中国造船企业生产技术和管理水平落后,造船周期较长,延期交船的问题经常发生。
面对这一困局,中国造船企业不断改进生产工艺,推动现代造船模式建设,努力提高生产技术水平,逐渐在世界造船市场占据了重要的地位。在生产技术不断进步的情况下,中国造船企业的物流管理也必须不断完善,以期适应现代造船模式的发展需要。造船企业生产周期长,物料消耗巨大,使得造船企业的生产物流管理尤其重要。基于此,本文开展了现代造船模式下的造船企业生产物流管理的相关研究。
(1)分析了现代造船模式下的造船企业物流,结合企业生产物流理论,探讨了造船企业生产物流的相关理论,对传统模式和现代造船模式下的生产物流进行对比分析。
(2)在研究现代造船模式下的造船生产流程的基础上,构建了依附于船舶建造主线、以“壳、舾、涂”一体化为基础、以集配中心为流转核心的造船企业生产物流系统,并进行深入分析。
(3)分析了“推式”和“拉式”生产管理模式,探讨了MRP Ⅱ和JIT生产管理技术及其集成机制,构建了基于MRPⅡ/JIT的现代造船企业生产物流管理模式,并从总装化造船体系、看板管理、供应链管理、托盘管理等四个方面探讨了相关的实施基础。
(4)分析了造船企业生产物流的相关优化问题：运用粒子群算法,探讨了某造船企业分段生产过程中的资源合理配置问题；以平面分段流水线为例,利用SIMIO仿真工具,对平面分段的生产流程进行仿真,提出相应的优化方案。
将先进的生产管理模式引入造船企业的生产物流管理,可实现流程的优化和资源的合理配置,对于现代造船企业的生产组织和物流管理中具有一定的理论意义和实践价值。
In recent years, China shipbuilding industry is being developed dramatically in several ways:shipbuilding facilities more amplified, design means more advanced, management methods more perfect, manufacturing ways more improved, and production amount more increased. According to statistics, China shipbuilding completion volume reached to 65.60 million deadweight tonnages in 2010, which is almost 23 times of the volume in 2001 (2.9 millions),4.6 times of the volume in 2006 (14.25 millions),1.5 times of the volume in 2009 (42.43 millions). This just shows what a rapid speed in China shipbuilding development. However, it dose not brings more profit: In 2006, the main business income of China shipbuilding enterprises is 156 billion yuan, and its total profit is only 9.6 billion yuan, which is not more than 10%. Except for the rising prices, the main reason is that the production technology and management level of China shipbuilding enterprises falls behind greatly and the shipbuilding period is very long, so ships are always not delivered in time.
Facing the dilemma, China shipbuilding enterprises devote themselves to improve productive technology continuously and adopt the modern shipbuilding mode actively, so they achieve the important position in the world ship market gradually.
Along with the advancing production technology, the logistics management of China shipbuilding enterprises has to be more perfect to meet the requirements of modern shipbuilding mode. Since the shipbuilding period is very long and the material consumption is enormous, the shipbuilding production logistics management is especially important and indispensable. So because of such, it is useful to conduct the relative research on the shipbuilding production logistics management under the modern shipbuilding mode. The following contents are included:
Firstly, the enterprise logistics under modern shipbuilding mode is analyzed, the shipbuilding production logistics theory is studied based on the general enterprise production logistics and a comparative analysis is carried on the production logistics under traditional and modern shipbuilding mode.
Secondly, on the strength of the research on the shipbuilding production process under modern shipbuilding mode, the shipbuilding production logistics system is constructed and analyzed in detail. The system is attached to the main shipbuilding process and based on the IHOP (Integrated Hull Construction, Outfitting and Painting), which has a flow kernel named concentrated supply center.
Thirdly, the production management modes of "push" and "pull" type are analyzed, the production management technology of MRPⅡand JIT are studied respectively and the integration mechanism of them is discussed. Furthermore, the modern shipbuilding production logistics management mode based on MRP II and JIT is constructed, and the foundation to implement it is studied including the assembly shipbuilding system, kanban management, supply chain management, pallet management and so on.
Finally, the relative shipbuilding production logistics optimization is discussed: the resource allocation and optimization based on PSO (particle swarm optimization) in the block assembly shop of shipbuilding enterprise is researched; the production process of panel block assembly line is simulated using SIMIO, and the proper optimization scheme is presented.
An advanced production management model is introduced in the production logistics management of shipbuilding enterprise, which is able to realize the process optimization and resource allocation. The study is provided with the theory significance and practical value in the production organization and logistics management of modern shipbuilding enterprises in China.
面对这一困局,中国造船企业不断改进生产工艺,推动现代造船模式建设,努力提高生产技术水平,逐渐在世界造船市场占据了重要的地位。在生产技术不断进步的情况下,中国造船企业的物流管理也必须不断完善,以期适应现代造船模式的发展需要。造船企业生产周期长,物料消耗巨大,使得造船企业的生产物流管理尤其重要。基于此,本文开展了现代造船模式下的造船企业生产物流管理的相关研究。
(1)分析了现代造船模式下的造船企业物流,结合企业生产物流理论,探讨了造船企业生产物流的相关理论,对传统模式和现代造船模式下的生产物流进行对比分析。
(2)在研究现代造船模式下的造船生产流程的基础上,构建了依附于船舶建造主线、以“壳、舾、涂”一体化为基础、以集配中心为流转核心的造船企业生产物流系统,并进行深入分析。
(3)分析了“推式”和“拉式”生产管理模式,探讨了MRP Ⅱ和JIT生产管理技术及其集成机制,构建了基于MRPⅡ/JIT的现代造船企业生产物流管理模式,并从总装化造船体系、看板管理、供应链管理、托盘管理等四个方面探讨了相关的实施基础。
(4)分析了造船企业生产物流的相关优化问题：运用粒子群算法,探讨了某造船企业分段生产过程中的资源合理配置问题；以平面分段流水线为例,利用SIMIO仿真工具,对平面分段的生产流程进行仿真,提出相应的优化方案。
将先进的生产管理模式引入造船企业的生产物流管理,可实现流程的优化和资源的合理配置,对于现代造船企业的生产组织和物流管理中具有一定的理论意义和实践价值。
In recent years, China shipbuilding industry is being developed dramatically in several ways:shipbuilding facilities more amplified, design means more advanced, management methods more perfect, manufacturing ways more improved, and production amount more increased. According to statistics, China shipbuilding completion volume reached to 65.60 million deadweight tonnages in 2010, which is almost 23 times of the volume in 2001 (2.9 millions),4.6 times of the volume in 2006 (14.25 millions),1.5 times of the volume in 2009 (42.43 millions). This just shows what a rapid speed in China shipbuilding development. However, it dose not brings more profit: In 2006, the main business income of China shipbuilding enterprises is 156 billion yuan, and its total profit is only 9.6 billion yuan, which is not more than 10%. Except for the rising prices, the main reason is that the production technology and management level of China shipbuilding enterprises falls behind greatly and the shipbuilding period is very long, so ships are always not delivered in time.
Facing the dilemma, China shipbuilding enterprises devote themselves to improve productive technology continuously and adopt the modern shipbuilding mode actively, so they achieve the important position in the world ship market gradually.
Along with the advancing production technology, the logistics management of China shipbuilding enterprises has to be more perfect to meet the requirements of modern shipbuilding mode. Since the shipbuilding period is very long and the material consumption is enormous, the shipbuilding production logistics management is especially important and indispensable. So because of such, it is useful to conduct the relative research on the shipbuilding production logistics management under the modern shipbuilding mode. The following contents are included:
Firstly, the enterprise logistics under modern shipbuilding mode is analyzed, the shipbuilding production logistics theory is studied based on the general enterprise production logistics and a comparative analysis is carried on the production logistics under traditional and modern shipbuilding mode.
Secondly, on the strength of the research on the shipbuilding production process under modern shipbuilding mode, the shipbuilding production logistics system is constructed and analyzed in detail. The system is attached to the main shipbuilding process and based on the IHOP (Integrated Hull Construction, Outfitting and Painting), which has a flow kernel named concentrated supply center.
Thirdly, the production management modes of "push" and "pull" type are analyzed, the production management technology of MRPⅡand JIT are studied respectively and the integration mechanism of them is discussed. Furthermore, the modern shipbuilding production logistics management mode based on MRP II and JIT is constructed, and the foundation to implement it is studied including the assembly shipbuilding system, kanban management, supply chain management, pallet management and so on.
Finally, the relative shipbuilding production logistics optimization is discussed: the resource allocation and optimization based on PSO (particle swarm optimization) in the block assembly shop of shipbuilding enterprise is researched; the production process of panel block assembly line is simulated using SIMIO, and the proper optimization scheme is presented.
An advanced production management model is introduced in the production logistics management of shipbuilding enterprise, which is able to realize the process optimization and resource allocation. The study is provided with the theory significance and practical value in the production organization and logistics management of modern shipbuilding enterprises in China.
引文
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