面向飞机装配的生产管理技术研究

针对飞机装配作业生产管理复杂的特点,以及难以制定合适的生产计划以及生产调度难等问题,在深入分析飞机装配作业过程的基础上,提出了一种面向订单设计的飞机装配生产管理方法.该方法以飞机装配过程为核心,利用多级网络计划技术制定适应生产现场的柔性生产计划,采用面向生产现场的生产调度方法实现生产调度优化,从而实现了生产现场能快速组织装配资源按时完成生产订单.该方法已在实际生产中得到应用,并取得良好的效果.     

基于状态树的装配流水线生产在线调度

构建了一种基于装配状态树的具有三层体系结构的在线调度模型,实现"将生产计划和调度直接做到生产线上"。首先,将产品的装配状态变迁过程表达为一棵装配状态树;其次,用状态方程来描述装配流水线生产过程,建立从装配位置空间到装配状态空间的一一映射,在此基础上构造包括决策层、连接层及执行层的三层次在线调度体系结构。通过在制品的位置信息来推算在制品的装配状态,利用状态树计算在制品的调度空间;进而以调度空间为约束,根据决策层的生产任务安排,对连接层的调度方案进行在线调整和实时控制。     

面向复杂产品装配过程的可视化生产调度技术

为解决复杂产品装配过程中出现的装配计划不合理、动态调度困难、过程监控和信息管理手段缺乏等问题,提出面向复杂产品装配过程的可视化生产调度技术.分析了复杂产品装配过程的特点,提出了基于工作流的装配过程可视化建模方法,并在此基础上建立了复杂产品装配调度模型.针对装配计划排产问题,提出了基于启发式调度规则的装配调度算法;针对装配过程中的扰动事件,提出了面向生产扰动的动态调度算法.提出了面向装配过程的可视化调度及信息管理方法,实现了装配过程的可视化监控、动态调度以及调度信息的组织与管理.通过实例验证了所提方法和技术的有效性.     

制造执行系统中基于产品队列的计划与控制衔接方案

以装配流水线生产为研究背景,探讨MES中的一种计划与控制衔接方案,构造以产品队列为中间层的计划与控制衔接体系结构,建立在制品与生产计划的映射方法,并给出实时地控制在制品状态的策略.     

船舶平面分段的非完全混合流水线调度

针对船舶平面分段流水线生产中存在的计划不准确、调度滞后、生产效率低等问题,分析平面分段流水线的特点,提出一类非完全混合流水线调度模型,并对该类调度问题进行优化研究。同时,综合考虑非完全混合流水线调度问题的特殊性及船舶建造的复杂性,以分段最大完工时问最小化为优化目标,建立两阶段的非线性整数规划模型,并利用分支定界法优化求解。结合某船厂实际数据进行实例验证和多次数值实验,并与混合遗传算法进行对比。结果表明,该模型和算法能有效解决平面分段流水线调度中存在的问题。     

装配流水线的优化设计

在大批量生产的工厂中,根据生产纲领而采用了与之相适应的各种装配流水线。为提高装配流水线的生产效率和技术经济效益,必须合理组织生产环节,使装配过程具有良好的连续性、高度的均衡性和严格的节凑性。因此对装配流水线的均衡设计,运行中变化因素对均衡性的影响和动态调整是设计中应注意解决的问题。     

基于虚拟流水线的船舶曲面分段建造调度研究

结合船舶曲面分段建造的特点,对曲面分段生产中采用虚拟流水线进行生产组织的问题进行探讨,重点研究曲面分段虚拟流水线生产的定量描述以及作业小组的调度。建立了基于虚拟流水线曲面分段生产的多功能机混合流水线调度数学模型;分析解决生产组织中可能遇到的问题,尤其是作业小组的构建与资源冲突的消解;用一种高效的调度算法即混合粒子群算法对问题加以调度。以某船厂的实际生产数据进行验证,结果表明,采用虚拟流水线的生产组织模式能有效提高船舶生产效率。     

不确定可重入定点装配车间集成生产计划与调度

为满足工厂—车间一体化管理需求,研究了不确定可重入定点装配车间生产计划与调度集成优化问题。在分析车间装配特点的基础上,利用期望值描述不确定可重入情况,建立了双层生产计划与调度集成优化随机期望值模型,上层为能力约束的生产计划模型,下层为不确定可重入定点装配车间调度模型。提出了一种具有双层结构的交替迭代式改进遗传算法,上层用精英遗传算法求解生产计划,代入下层后采用基于随机模拟技术的遗传模拟退火算法求解生产调度,然后将调度结果返回上层重新求解新计划,如此不断交替迭代以实现计划与调度的同时优化。通过算例仿真验证了模型及算法的有效性。为制定不确定可重入定点装配车间生产计划与调度提供了一种合理可行的方法。     

求解分布式混合流水线调度问题的改进双层嵌套式遗传算法

针对分布式混合流水线生产的生产调度问题,模拟实际排产中的排产到线和排产到时的排产策略,提出了基于改进双层嵌套式遗传算法的两层优化模型。外层依据流水线分配平衡和准时交货等基本原则总体上解决生产订单在流水线之间的分配问题,内层以最小生产时间为主要目的求解流水线的生产订单生产次序问题。考虑到双层嵌套式遗传算法的时间复杂性,基于模糊逻辑理论设计了一种模糊控制器来动态调整遗传算子,并采用主动检测停止方法,提高算法效率。使用某空调工厂的实际生产数据验证了算法的可行性、计算结果的准确性及排产策略的有效性,为高级计划与排程(Advanced Planning and Scheduling,APS)中大规模复杂供应链调度问题提供了可借鉴的方法。     

装配生产线Petri网模型优化算法研究

运用Petri网方法,建立了装配生产线模型,给出了装配生产线调度控制系统的优化算法:按周期计划安排生产;按日进度计划用Petri网预测缺件;关键工序点的在制品控制     

基于Plant Simulation的导弹装配生产线仿真技术研究

生产线仿真是对导弹装配生产进行生产规划、生产调度和生产计划制定的有效手段。针对某型导弹生产过程中工位分配、产能平衡、AGV数量规划和路径规划等问题,建立了基于Plant Simulation的导弹装配生产系统仿真模型,提出物流仿真技术与管理运筹学相结合的可行性操作方法,并进行理论分析与仿真实验。仿真结果验证了该方法的有效性,表明了仿真技术在导弹装配系统中的良好应用前景。     

基于多Agent的多型号生产调度系统研究

生产调度系统是多型号产品生产中的关键环节.为适应军工生产企业对生产调度系统的新要求,提出了基于多智能体技术,构筑多型号生产调度系统.首先,给出了多型号产品生产计划调度运行模式;然后,建立了基于多智能体的多型号生产调度系统模型,设计了相应的智能体的模型结构.为了解决调度冲突,将智能体之间的协商过程分为主控协商和自主协商2级协商,并给出了协商机制和相应的算法策略.最后,给出了基于Web环境的系统实现体系结构.     

Daily planning and scheduling system for the EDS process in a semiconductor manufacturing facility

Operations management in a complex manufacturing environment is practiced hierarchically: production planning and scheduling in sequence since the integrated approach is not efficient and practical. Production targets and allocation to the equipment are determined in the planning procedure by considering the only the critical factors, and the detailed scheduling is determined with more information needed to accomplish the production targets provided in the planning step. There is always, therefore, a gap between the planning and scheduling procedure, and some control parameters or factors are used to control those gaps. In this paper an approach connecting two procedures is suggested, which can be applied in the EDS (electrical die sorting) or the probe process in the semiconductor manufacturing. The EDS process requires very flexible operation management since the manufacturing processing time is relatively short and the supply of upstream fabrication and the demand of downstream assembly have to be met simultaneously. Daily planning and scheduling procedure are modeled to minimize the tester change-over within the daily target. Because of the relatively long setup change-over time, daily planning and scheduling have to be performed so that the time needed for the device and probe card change is minimized as possible. Mathematical programming is suggested for the problem, and the modified model is developed which can be solved in a practical computational time on a daily base. The scheduling heuristic with the planning data obtained from the suggested model, is designed, and their performance is evaluated through the computational experiment.     

考虑设备维修与维护的装配作业车间动态生产仿真研究

装配作业车间生产调度的关键是动态协同产品各零件的生产进度以满足产品的齐套需求。设备的随机故障将会扰乱已有的生产计划,给各零件之间的进度协同带来更高的挑战。预防性维护能够提高设备的可靠度以减少故障的发生,但过度的维护又会减少生产加工的时间。从调度规则构成属性的角度分析设备故障将带来的影响,并提出一种考虑设备故障的改进型调度规则。通过仿真试验分析了企业常见的3种预防性维护策略对车间性能的影响和7种代表性调度规则的性能。试验结果表明:预防性维护策略对车间有明显的影响;且考虑了设备故障的调度规则有一定的改进效果。     

车间调度系统的3层体系结构

提出了车间调度系统的3层体系结构。首先介绍了体系结构中各层的功能，详细讨论了体系结构中调度模型组件、调度算法组件和调度引擎的接口设计，最后分析了体系结构中各组件的工作原理。     

印制电路板组装工艺规划与调度集成建模及优化方法

针对印制电路板(Printed circuit board,PCB)组装工艺与调度集成优化问题,建立集成的优化数学模型,提出将多色集合(Polychromatic set,PS)与遗传算法(Genetic algorithm,GA)相结合的新的优化方法。利用多色集合的逻辑围道矩阵和数值围道矩阵建立集成优化问题的约束模型。将约束模型与GA的遗传编码、遗传操作和适应度值计算等结合,保证GA始终在有效的解空间中进行搜索。不仅能提高遗传搜索的效率,还可以通过约束模型的修改,动态描述设备故障和PCB组装任务变化等不确定因素的影响,使得算法具有良好的适应性。实例计算结果表明,该方法能高效地实现PCB组装工艺规划与调度的集成优化,缩短PCB组装完工时间,减少交货期延迟,平衡设备的工作负荷。     

Rule-based production planning in flexible manufacturing systems

Production planning in flexible manufacturing may require the solution of a large-scale discrete-event dynamic stochastic optimization problem, due to the complexity of the system to be optimized, and to the occurrence of discrete events (new orders and hard failures). The production planning problem is here approached for a multistage multipart-type manufacturing shop, where each work cell can share its processing time among the different types of parts. The solution of this problem is obtained by an open-loop-feedback control strategy, updated each time a new event occurs. At each event time, two coupled problems are solved: 1) a product-order scheduling problem, conditioned on estimated values of the production capacities of all component work cells; and 2) a production-capacity planning problem, conditioned on predefined sequences of the product orders to be processed. In particular, the article aims at defining a production planning procedure that integrates both analytical tools, derived from mathematical programming, and knowledge-based rules, coming from experience. The objective is to formulate a hybrid (knowledge-based/analytical) planning architecture, and to analyze its use for multicell multipart-type manufacturing systems.     

Integrated model for production planning and scheduling in a supply chain using benchmarked genetic algorithm

Production planning and scheduling is one of the core functions in manufacturing systems. Furthermore, this task is drawing even more attention in supply chain environments as problems become harder and more complicated. Most of the traditional approaches to production planning and scheduling have adopted a multi-phased, hierarchical and decompositional approach. This traditional approach does not guarantee a feasible production schedule. And even when capacity constraints are satisfied, it may generate an expensive schedule. In order to overcome the limitations of the traditional approach, several previous studies tried to integrate the production planning and scheduling problems. However, these studies also have some limitations, due to their intrinsic characteristics and the method for incorporating the hierarchical product structure into the scheduling model. In this paper we present a new integrated model for production planning and scheduling for multi-item and multi-level production. Unlike previous lot sizing approaches, detailed scheduling constraints and practical planning criteria are incorporated into our model. We present a mathematical formulation, propose a heuristic solution procedure, and demonstrate the performance of our model by comparing the experimental results with those of a traditional approach and optimal solution.     

虚拟装配工艺规划实现技术研究

对虚拟环境下的产品装配工艺规划进行了研究,分析虚拟环境下面向集成的装配工艺规划系统结构。对虚拟装配工艺规划的三个核心问题(装配模型、装配序列规划和装配路径规划)进行描述,提出虚拟环境下面向工艺设计的产品装配模型总体结构。给出虚拟环境下装配约束关系的识别方法,实现了零部件基于约束的三维空间导航运动。建立原型系统,能够为虚拟环境下的装配工艺规划奠定基础。     

A blackboard-based process planning system for the surface mount manufacture of PCBs

This paper describes a real-time computer-aided process planning (CAPP) system for printed circuit board (PCB) assembly using surface mount technology. The prototype, dynamic, realtime CAPP system described uses a blackboard to integrate multiple knowledge sources (knowledge bases) in implementing the process planning procedure. The CAPP system is implemented using the expert system environment (ESE) and structured query language (SQL). The system uses two subsystems (knowledge bases). They are a planning subsystem which performs the static process planning task and a dynamic information processing subsystem which considers the real-time changes on the shop floor and routes the PCB assembly flow. The integrated system developed generates process plans that can be implemented in real time. The use of the blackboard concept for CAPP architecture is unique and well suited for this task.