定制环境下订单承接关键技术的研究
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摘要
传统的大批量生产模式已不能适应现代市场的快速变化,订单制造成为越来越多的制造企业的生产模式,定制理论也成为众多科技人员的重要研究内容。本文在现有定制理论研究的基础上,对定制环境下的订单承接进行了较为系统的研究与探讨;提出了一种订单承接快速响应的系统结构,重点研究了订单生产过程的风险分析与评估、快速合理报价以及如何降低样品开发成本等订单承接过程中的三个关键技术问题。
本文描述了订单制造的含义、特点、工作流程、技术支撑及其发展趋势;分析了作为应对订单制造的主要策略——大批量定制(MC)生产方式的研究现状及其在实际应用中的局限性,同时也分析了非MC订单制造现有的研究成果。通过对订单承接在定制企业内外部运作过程中广泛影响的分析,阐明了订单承接在面向订单制造中的关键作用;分析了订单承接失败的原因,提出了定制环境中订单承接快速响应的研究框架体系以及提高承接订单敏捷性和成功率的对策与方法。
本文将风险研究引入订单制造过程,详细讨论了订单制造过程中的各种风险因素,定性地研究了订单制造过程中风险的变化规律;进而建立了订单制造过程的风险损失数学模型,利用层次分析和网络层次分析法、模糊数学对制造过程的各个阶段以及整个订单的风险水平进行了计算;通过实例说明了评估模型的使用方法并验证了其正确性。
本文阐述了报价设计在订单制造中的重要意义和面临的困难;介绍了目前国内外常用的订单产品报价方法并分析了它们各自的不足之处;在详细地研究订单产品报价的设计过程和报价工艺设计后,利用现代制造业中CAD/CAM、数控技术被大量使用的优势,并结合数控加工工序集中的特点,提出了一种基于工序单位时间产值的快速报价方法,并建立了产品定价的数学模型。
鉴于样品的试制与开发是一个无直接经济效益、高报废率的制造过程,本文提出了一种以最低报废损失为目标的工艺设计方法,建立了工艺规划优化的数学模型;并运用遗传算法进行了求解;通过实例说明了该设计方法降低报废损失的效果。
结合作者开展课题研究所在企业的具体实况,本文建立了一个定制生产订单承接快速响应系统,并介绍了系统在企业中的实施方法和取得的成效。
Since the traditional mass production can no longer adapt to the rapid changes of the modern markets, customized production has been adopted by more and more manufacturing enterprises. As a result, theories of customized production have become a research focus for many researchers. On the basis of the already-made theoretic researches into customization, this dissertation makes a systematic study of order acceptance in the context of customization, proposes a system structure of prompt response in order acceptance(OA), and focuses on three key technical issues in order acceptance, namely risk analysis and evaluation, how to make quotations promptly and reasonably to the customers, and how to lower costs in sample development.
The dissertation describes the definition,features, flow of work, technical support and development tendency of made-to-order (MTO) manufacturing. While describing the present researches into non-mass-customization, the paper analyzes the limitations of mass customization (MC), which is a major strategy in dealing with MTO manufacturig, in real practice, and the importance of order acceptance in MTO manufacturing. Then it probes into the underlying causes of failure in order acceptance, proposes a framework system of prompt response in order acceptance in the context of customization production, and the countermeasures to improve the speed and success rate of order acceptance.
The dissertation introduces risk management into the process of MTO manufacturing, elaborates the risk factors in MTO manufacturing, makes a qualitative study of the rule of risk changes in MTO, and then moves on to a mathematical model of risk loss, which can be used to calculate the risk level of different stages or of the whole process of MTO manufacturing by fuzzy mathematics,Analytic Hierarchy Process (AHP) and Analytic Network Process(ANP) . A case is also cited to exemplify how to apply the evaluation method.
The paper then discusses the great significance of quotation in MTO and the difficulties it encounters, analyzes various quotation methods widely used at home and abroad and their shortcomings. After a careful study of the designing and process planning of quotation, the author proposes a prompt quotation method based on the output value per unit time, and sets up a mathematical model of quotation.
Since the trial-manufacture and development of samples is the process of no directly ecomonic benefit and high rejection rate, this dissertation suggests a process planning method which aims at the lowest rejection loss, and sets up a mathematical model of process planning. In optimized decision-making of multi-procedure process planning, adaptive genetic algorithm is employed to search for the optimum results. An example is given to prove how to reduce the rejection loss using the method.
Combining the reality of the enterprise in which the author carries out his research and using integrated thoughtway of CIMS, the paper develops a system of prompt response in order acceptance of customization production, and describes how this system work in enterprises and the results of applying this sytem.
本文描述了订单制造的含义、特点、工作流程、技术支撑及其发展趋势;分析了作为应对订单制造的主要策略——大批量定制(MC)生产方式的研究现状及其在实际应用中的局限性,同时也分析了非MC订单制造现有的研究成果。通过对订单承接在定制企业内外部运作过程中广泛影响的分析,阐明了订单承接在面向订单制造中的关键作用;分析了订单承接失败的原因,提出了定制环境中订单承接快速响应的研究框架体系以及提高承接订单敏捷性和成功率的对策与方法。
本文将风险研究引入订单制造过程,详细讨论了订单制造过程中的各种风险因素,定性地研究了订单制造过程中风险的变化规律;进而建立了订单制造过程的风险损失数学模型,利用层次分析和网络层次分析法、模糊数学对制造过程的各个阶段以及整个订单的风险水平进行了计算;通过实例说明了评估模型的使用方法并验证了其正确性。
本文阐述了报价设计在订单制造中的重要意义和面临的困难;介绍了目前国内外常用的订单产品报价方法并分析了它们各自的不足之处;在详细地研究订单产品报价的设计过程和报价工艺设计后,利用现代制造业中CAD/CAM、数控技术被大量使用的优势,并结合数控加工工序集中的特点,提出了一种基于工序单位时间产值的快速报价方法,并建立了产品定价的数学模型。
鉴于样品的试制与开发是一个无直接经济效益、高报废率的制造过程,本文提出了一种以最低报废损失为目标的工艺设计方法,建立了工艺规划优化的数学模型;并运用遗传算法进行了求解;通过实例说明了该设计方法降低报废损失的效果。
结合作者开展课题研究所在企业的具体实况,本文建立了一个定制生产订单承接快速响应系统,并介绍了系统在企业中的实施方法和取得的成效。
Since the traditional mass production can no longer adapt to the rapid changes of the modern markets, customized production has been adopted by more and more manufacturing enterprises. As a result, theories of customized production have become a research focus for many researchers. On the basis of the already-made theoretic researches into customization, this dissertation makes a systematic study of order acceptance in the context of customization, proposes a system structure of prompt response in order acceptance(OA), and focuses on three key technical issues in order acceptance, namely risk analysis and evaluation, how to make quotations promptly and reasonably to the customers, and how to lower costs in sample development.
The dissertation describes the definition,features, flow of work, technical support and development tendency of made-to-order (MTO) manufacturing. While describing the present researches into non-mass-customization, the paper analyzes the limitations of mass customization (MC), which is a major strategy in dealing with MTO manufacturig, in real practice, and the importance of order acceptance in MTO manufacturing. Then it probes into the underlying causes of failure in order acceptance, proposes a framework system of prompt response in order acceptance in the context of customization production, and the countermeasures to improve the speed and success rate of order acceptance.
The dissertation introduces risk management into the process of MTO manufacturing, elaborates the risk factors in MTO manufacturing, makes a qualitative study of the rule of risk changes in MTO, and then moves on to a mathematical model of risk loss, which can be used to calculate the risk level of different stages or of the whole process of MTO manufacturing by fuzzy mathematics,Analytic Hierarchy Process (AHP) and Analytic Network Process(ANP) . A case is also cited to exemplify how to apply the evaluation method.
The paper then discusses the great significance of quotation in MTO and the difficulties it encounters, analyzes various quotation methods widely used at home and abroad and their shortcomings. After a careful study of the designing and process planning of quotation, the author proposes a prompt quotation method based on the output value per unit time, and sets up a mathematical model of quotation.
Since the trial-manufacture and development of samples is the process of no directly ecomonic benefit and high rejection rate, this dissertation suggests a process planning method which aims at the lowest rejection loss, and sets up a mathematical model of process planning. In optimized decision-making of multi-procedure process planning, adaptive genetic algorithm is employed to search for the optimum results. An example is given to prove how to reduce the rejection loss using the method.
Combining the reality of the enterprise in which the author carries out his research and using integrated thoughtway of CIMS, the paper develops a system of prompt response in order acceptance of customization production, and describes how this system work in enterprises and the results of applying this sytem.
引文
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