不确定环境下混流装配线动态准时制物料配送系统

针对不确定环境下混流装配线物料配送准确性和及时性的问题,构建了一种基于射频识别技术的动态准时制物料配送控制系统。分析了混流装配线的物料配送特点及物料分类,阐述了生产计划变动、生产节拍波动、线边库存及物料需求量和时间等物料配送中的不确定因素。综合考虑各类不确定因素,构建了基于射频识别的动态准时制物料配送体系架构,建立了可视化装配过程监控系统,研究了物料配送方案运算模型,设计了物料配送控制系统的硬件架构和软件体系结构。以某公司的1.5TGDI发动机工厂的混流装配线为例,应用J2EE构架开发了基于射频识别的动态准时制物料配送系统,实现了物料配送管理和控制的一体化和可视化,验证了系统的可行性和有效性。     

基于混流生产模式的装配车间物料配送路径规划方法

合理规划物料配送路径能够提升车间生产效率,降低车间物流成本和生产成本。针对混流装配车间配送不及时、费用高等问题,提出基于混流生产模式的物料配送路径规划方法。以工位为物料配送对象,对混流装配车间物料配送环境进行分析,找出混流装配线的物料消耗规律,明确物料配送数量,简化物料配送过程。在此基础上,结合生产实际的时间窗约束,以最小化物料配送总费用为目标建立了物料配送模型,采用改进蚁群算法对该模型进行求解,最后以某视频控制卡混流装配车间为实例,验证了该方法的可行性和有效性。     

Kitting物料配送在混流装配线的应用研究

对混流装配过程中由物料配送不及时引起的生产计划不连续的问题进行了研究,在分析了混流装配生产模式后,构造出了在该生产模式下的混流装配线线旁物料kitting(齐套性)算法,再根据物料kitting(齐套性)算法预求出混流装配线各个工艺点物料消耗,在此基础上求出各个工艺点物料需求,从而带动物料配送;最后通过实例,验证上述方法的可行性和实用性.     

混流汽车总装过程的物料协同配送与管理信息系统研究

文章在分析汽车生产过程的物料流的基础上,根据物料的不同形状和需求将物料划分为直接供货件、排序件及捆扎件,并建立了不同的配送方法。为实现混流汽车总装配线上物料及时准确地配送,建立了汽车装配过程的的物料拉动方法及大件物料的看板控制流程。采用基于现场总线信息融合技术,建立3层网络结构的物料信息采集与管理信息系统,实现了汽车混流装配过程的物料协同配送与精细化管理。     

混流轿车总装配线上物料配送的研究与实践

为满足混流轿车总装配线上物料及时准确的配送，分析了轿车总装工艺流程和生产特点，依据轿车零部件的形状将物料划分为3类。研究了准时生产环境下物料配送的物料拉动系统和看板运作流程，并建立了基于现场总线技术的物料ANDON系统。在分析总装线旁物料报警情况的基础上，提出了现场物料出现MIN／MAX时的处理方式，提出了物料断点的概念并建立了实施流程。根据某轿车总装配流水线的实际物料需求，设计了混流装配线分布式物料管理信息系统的功能模块，以及基于J2EE平台的软件架构，开发的信息系统已应用于某企业。     

SPS模式下物料消耗平准化的混流装配线车型排序

在混流生产过程中,针对零部件供应不能实现JIT的问题,提出在SPS物料配送模式下,提高零部件消耗平准化程度。在汽车混流装配线中最重要的目标是零部件消耗速率平准化,建立了混流装配线车辆排序模型。结合W公司实际案例,验证了车型排序在平准化物料消耗中的重要意义。     

混合装配线平衡与物料配送的协同优化

是对混合装配线平衡和物料配送的协同优化问题进行了研究。首先描述了空间受限的混合装配线平衡问题,分析了混合装配线所需物料的需求能力和物料配送能力之间的匹配关系。在此基础上分别对混合装配线平衡和物料配送建立数学模型。运用遗传算法在仿真软件进行仿真,验证方法研究的有效性,最后进行一个概要总结。     

10kV开关柜装配线物料配送的仿真与优化

针对10 kV开关柜生产不能满足订单需求,生产过程物料配送不顺畅的问题,基于QUEST软件对10 kV开关柜装配线进行物料配送仿真与优化。在分析10 kV开关柜装配工序、装配特点及物料配送现状的基础上,提出10 kV开关柜装配线仿真模型的构建方法,建立包括并行装配工序、装配工序优先级、参数逻辑关系等在内的10 kV开关柜仿真逻辑模型,基于实际生产数据对物料配送问题进行分析与优化。对比优化前后10 kV开关柜装配线物料配送的数据,确认优化效果良好。     

基于eM-Plant的装配线物料配送仿真与优化

摘要：针对某太阳能模组装配线投产前验证原生产物流配送方案是否合理的问题,利用eM-Plant仿真平台建立了该装配线物料配送仿真系统。仿真分析后发现原方案存在不合理之处。采用试验设计方法,研究了生产计划的完成时间与装配线物料缓冲区的大小和配送小车的数量、速度以及装载量之间相互关系。根据试验的结果,选择一种最优的改进方案,确定优化有装配线暂存区的存储容量,配送小车的数量、运行速度和装载量,提高整个物流系统的输送效率,降低企业生产物流成本。     

臂式高空作业平台装配线及物料配送设计

以臂式高空作业平台为研究对象,对臂式高空作业平台的装配流程进行了分析,规划和布局臂式高空作业平台的装配线,通过对装配线大件物料进行规划研究,建立了配送车辆的路径优化模型,采用遗传算法进行了求解,基于eM-plant仿真软件对装配线进行了仿真建模,通过两因素的因子设计试验,确定了配送车辆的数量和速度的最优解,验证了臂式高空作业平台装配线和物料配送的可行性,提高了高空作业平台装配线的产能和生产效率,为企业的生产决策提供了参考。     

混流装配线负荷平衡方法研究及应用

发动机混流装配生产线是对不同型号发动机顺序装配的流水线工艺程.为了提高装配质量和生产效率,充分利用资源,对发动机混流装配生产线规划设计的平衡问题和投产顺序问题进行了研究,建立了工作站内部和工作站之间负荷均衡以及最小化工作站闲置时间的数学模型,并通过实例验证了该方法有效地提高了整个装配线的生产效率.     

Multi-objective artificial bee colony algorithm for simultaneous sequencing and balancing of mixed model assembly line

In recent years, mixed model assembly lines are gaining popularity to produce a variety of models on the single-model assembly lines. Mixed model assembly lines have two types of problems which include sequencing of different models on the line and balancing of assembly line. These two problems collectively affect the performance of assembly lines, and therefore, current research is aimed to balance the workload of different models on each station, to reduce the deviation of workload of a station from the average workload of all the stations and to minimize the total flow time of models on different stations simultaneously. A multi-objective artificial bee colony (multi-ABC) algorithm for simultaneous sequencing and balancing problem with Pareto concepts and local search mechanism is presented. Two kinds of mixed model assembly line problems are analysed. For the first and second problems, each model task time data and precedence relation data are taken from standard assembly line problems, from operation research library (ORL) and from a truck manufacturing company in China, respectively. Both problems are solved using the proposed multi-ABC algorithm on two different demand scenarios of models, and the results are compared against the results obtained from a famous algorithm in the literature, i.e. non-dominated sorting genetic algorithm (NSGA) II. Computational results of the selected problems indicate that the proposed multi-ABC algorithm outperforms NSGA II and gives better Pareto solutions for the selected problems on different demand scenarios of models.     

Balancing and scheduling of flexible mixed model assembly lines with parallel stations

In this paper, we study flexible mixed model assembly lines with serially connected stages where stages may have one or more parallel stations. Station parallelism in flexible mixed model assembly lines improves system reliability and enables rapid adaptability to customer demand fluctuations. However, in order to effectively manage such lines under real-world conditions, there is a need to extend traditional assembly line management methods. This study extends the current research by simultaneously considering the problems of task assignment and model scheduling on parallel stations. Furthermore, scheduling of assigned tasks on each station is considered. We formulate the problem context first as a mixed integer programming model and then develop a decomposition scheme for large scale applications. Finally, we compare the performance of the proposed model and decomposition scheme using various size test instances.     

Design of a just-in-time periodic material supply system for the assembly lines and an application in electronics industry

The purpose of the paper is the development of a mathematical model and a heuristic approach where the routes are constructed and the service period is determined for the design of an internal milk-run material supply system. The material supply by this system occurs on a just-in-time basis from a central warehouse to several stations of an assembly line. The objective of the proposed mathematical model is the minimization of the total material handling and inventory holding cost. Besides, the proposed heuristic approach intends to construct routes based on an initial service period value and attempts to improve the solution by considering different period values. The most suitable solution is decided on the basis of the least total material handling and WIP/inventory holding cost. The application of the proposed heuristic in a TV assembly plant demonstrates the utility of it to the real practice.     

基于混合遗传算法的混合装配线排序问题研究

为使混合装配线有效运作,研究了混合装配线的生产排序问题。以装配线上各种零部件消耗速率均匀化和最小生产循环周期最短为优化目标,描述了多目标排序问题,并建立了优化模型。针对基本遗传算法在求解排序问题时的早熟收敛问题,提出一种改进混合遗传算法。该算法借助模拟退火算法思想对适应度尺度进行调整,使遗传进化初期削弱种群中个体适应度差异,而在遗传进化后期强化种群中个体适应度差异,以提高对最优解的搜索能力。同时,根据个体适应度自动调整遗传操作参数,既保存了种群中的优良个体,又不失个体的多样性。最后通过案例分析验证了算法的有效性。     

考虑流水线平衡的混合装配线排序

针对传统平准化模型的缺陷，考虑流水线平衡对混合装配线排序的影响，以流水线平衡得到的工作站时间为基础，按照产品产出时间来衡量物流的平准化排序，建立了基于流水线平衡影响的平准化排序模型，并对一个实例进行了数值分析。提出的平准化模型克服了传统混合装配线排序研究中的不足，把流水线平衡和产品排序有机结合起来，更加符合问题的实际背景。     

Balancing–sequencing procedure for a mixed model assembly system in case of finite buffer capacity

In the last decades, the necessity to make production more versatile and flexible has forced assembly line production systems to change from fixed assembly lines to mixed model assembly lines, where the output products are variations of the same base product and only differ in specific customizable attributes. Such assembly lines allow reduced setup time, since products can be jointly manufactured in intermixed sequences (Boysen, Flieder, Scholl. Jena Research Papers in Business and Economics, Friedrich-Schiller-Universitat Jena, 1;1–11, 2007a; Boysen, Flieder, Scholl. Jena Research Papers in Business and Economics, Friedrich-Schiller-Universitat Jena, 2;1–33, 2007b). Unfortunately, the installation of customization options typically leads to variations in process times, and when the cycle is exceeded within a certain station, an overload is created, forcing other stations to wait and idle. Normally, process time variation in an un-paced line are absorbed by buffers, but in some industrial application the buffer dimensions are critical not only for the reduction of work in progress but also in reducing other constrains (space, technology, model dimensions, etc.). The problem of balancing mixed model assembly lines (MALBP), in the long term, and that of sequencing mixed model assembly lines (MMS), in the short term (Merengo, Nava, Pozetti. Int J Prod Res 37:2835–2860, 1999), are the two major problems to solve. The object of this paper is to illustrate an innovative balancing–sequencing step-by-step procedure that aims to optimize the assembly line performance and at the same time contain the buffer dimensions in function of different market demand and production mix. The model is validated using a simulation software and an industrial application is presented.     

A mathematical model and ant colony algorithm for multi-manned assembly line balancing problem

In real-world assembly lines, that the size of the product is large (e.g., automotive industry), usually there are multi-manned workstations where a group of workers simultaneously perform different operations on the same individual product. This paper presents a mixed integer programming model to solve the balancing problem of the multi-manned assembly lines optimally. This model minimizes the total number of workers on the line as the first objective and the number of opened multi-manned workstations as the second one. Since this problem is well known as NP (nondeterministic polynomial-time)-hard, a heuristic approach based on the ant colony optimization approach is developed to solve the medium- and large-size scales of this problem. In the proposed algorithm, each ant tries to allocate given tasks to multi-manned workstations in order to build a balancing solution for the assembly line balancing problems by considering the precedence relations, multi-manned assembly line configuration, task times, and cycle time constraints. Through computational experiments, the performance of the proposed ACO is compared with some existing heuristic on various problem instances. The experimental results validate the effectiveness and efficiency of the proposed algorithm.     

混合型装配线上不同制品之间的相似度

本文讨论了混合型装配线上不同制品之间的相似度的量化测度——相似指数的概念,给出了在几种不同情况下相似指数的定义、计算方法及其应用实例。