基于作业过程的钢铁企业制造资源清单模型

针对钢铁企业的产品结构、作业过程、产能资源特征和工艺流程特点,定义了钢铁企业制造资源清单的概念,建立了基于作业过程的钢铁企业制造资源清单模型.该模型采用工艺分解和特征匹配的方式,以作业工序为信息纽带,通过构造各生产阶段的“产品-作业”分配关系描述矩阵和“作业-产能”消耗关系描述矩阵,形成面向钢铁产品生产过程的“产品-作...     

基于流程的钢铁生产过程环境负荷分析与优化

叙述了生命周期评价方法在钢铁工业中应用现状和发展前景,并对钢铁生产传统工艺流程和钢铁生产新工艺流程和新技术的环境负荷进行分析和评价。基于钢铁生产新工艺流程和新技术的不断应用,对熔融还原炼铁和薄板坯连铸连轧生产工艺和流程的环境负荷进行了评价,与传统高炉流程相比,熔融还原炼铁废气污染物和废水污染物减排效果十分明显;与传统热连轧工艺相比,薄板坯连铸连轧工艺吨材煤气消耗降低2/3,吨材烟粉尘排放降低约27%。此外,针对我国钢铁生产矿物资源和能源消耗过大、环境污染问题十分突出的现状,指出通过改进原料和能源结构,加强环境排放控制和管理,有利于较大幅度地减少污染物的发生量和排放量。最后结合钢铁企业发展循环经济的实例,提出用生命周期评价方法对实施循环经济前后的环境负荷和循环经济发展程度进行分析研究。结果表明,钢铁企业采用新工艺流程和新技术,尤其是建设循环经济型企业,有利于从根本上降低钢铁生产过程环境负荷。     

关于钢铁产品市场风险管理的探讨

通过对钢铁产品市场风险的剖析,创造性的提出钢铁产品市场风险管理框架,并探索出钢铁产品市场风险管理策略与方法,这一探索的成果,成为钢铁企业构建钢铁产品市场风险管理机制,提升其在钢铁行业中的竞争力的现实根据。     

钢铁生产与氧气的关系及对制氧机的要求

介绍了钢铁生产与氧气的关系 ,分析了钢铁生产对制氧机选型的基本要求 ,最后阐述了钢铁企业氧气放散等氧气设施的几个问题     

基于实例推理的产品包装成本估算研究

快速、有效地估算产品包装成本,可及时响应顾客对产品包装的询价、报价等方面的需求,也可为产品包装设计方案的技术经济评价、成本的降低提供支持。给出了针对产品包装特点的实例检索过程,采用分层实例推理的思路,以及知识引导策略和最相邻近策略相结合的检索方法,提出了利用相似实例的成本估算方法。以汽机旁路产品的包装成本估算为例,验证了方法的可行性及有效性。     

制造业过程废品核算方法及应用研究

对制造过程中的废品进行研究,界定制造业过程废品以及废品损失的概念,并按照正常过程废品损失和非正常过程废品损失进行分类;提出了一种考虑不同坯料来源以及制造批次的过程废品损失归集方法;并改进了废品摊销方式,以产品批次为单位有针对性地摊销到性质相同或相近的产品中;利用邻域粗糙集对废品作业属性进行约减,并根据约减结果对生产过程实施控制以减少废品的产生。通过在钢铁企业的应用实例说明了该方法的具体实现过程、有效性和可行性。     

基于项目管理视角的鞍山钢铁物流优化分析

随着项目管理在钢铁物流中应用的不断深入，项目管理已经逐渐成为钢铁企业销售物流管理的一种主要方法。本文基于国内当前有关项目管理和物流管理的研究现状，结合钢铁企业当前销售物流的实际情况，从项目的团队建设、目标体系管理以及相应项目管理过程等方面对钢铁企业的销售物流进行了优化。     

论钢铁企业PLC数字化控制及其电气运行主要技术

随着社会的不断进步,PLC逐渐出现,并被广泛的应用在了我国的钢铁生产当中,且PLC在钢铁生产中的应用,也让钢铁的生产达到了数字化控制以及自动化生产的这个目的,同时也让我国的钢铁行业实现了突破性的发展。另外,电气运行技术在钢铁生产中应用,也进一步提高了钢铁生产的安全性与可靠性。因此,本文将针对钢铁企业,对其的PLC数字化控制及电气运行主要技术进行深入的分析和探究。     

关于钢铁企业的结构与钢铁工业的发展模式

基于对钢铁工业发展历史的回顾和对中国钢铁企业结构调整的现状分析, 阐述了钢铁制造流程的解析与集成以及技术进步的方向,探讨了不同类型钢材的生产工艺,分析和展望了未来钢厂结构的发展模式以及投资决策问题。指出钢铁工业的时代命题是:市场竞争力和可持续发展;21世纪钢铁生产流程的功能将朝着冶金功能--低能耗、低物耗、高效率地生产新一代钢铁产品,并降低单位产品的投资额; 能源转换功能--形成工业生态链甚至转换出新能源;社会废弃物处理功能--实现环境友好。钢厂将逐渐向都市周边型钢厂或生态工业钢厂的模式发展。     

钢铁企业CIMS生产计划管理的递阶体系

钢铁生产的复杂性决定了钢铁企业计划管理的复杂性，因而有必要采用大系统分解协调理论对钢铁生产计划系统进行时间分解与空间分解，建立生产计划的递阶体系。本文提出了ＣＩＭＳ下钢铁生产计划管理的递阶体系结构模式，研究了对计划系统进行空间分解与时间分解的原则。     

Cost estimation of a service family based on modularity

Companies are competing to offer high varieties of customised services on top of customised products to increase revenues and customer satisfaction. By adopting product family design methodologies, new concepts such as service families and service platforms are adopted in the service sectors. Despite that, increasing diversity in service offerings induces complexity and difficulty in service cost estimation. This research presents a service family cost estimation methodology that is based on service modularity and activity based costing (ABC). A service family is identified by selecting a set of similar services. Subsequently, activities of each service are identified with an activity diagram. The service family is then decomposed into functional and physical elements, where service modules are identified. Service activities are then mapped into relevant service modules using k-mean clustering algorithms, and activities of each service module are segregated into common and specific services using un-weighted pair group method with arithmetic mean. Finally, modified two-stage ABC methodology is applied to estimate the costs for a service family. To demonstrate the applicability of the proposed methodology, a case study is carried out to estimate the cost for a family of aircraft engines.     

Development of Kaizen case-base for effective technology transfer–a case of visual management technology

In this paper, focusing on visual management (VM) technology as an effective vehicle of continuous improvement activities, Kaizen case-base and its effectiveness are discussed by following three steps. For the first step, a framework of a Kaizen case transfer is placed to develop for effective VM development and transfer. For the second step, an example of VM case-base is constructed by using VM cases collected through a literature survey and factory investigations. For the third step, performance of the example VM case-base is validated by applying the proposed procedure, which consists of: (1) clarifying instances of current Kaizen problem; (2) retrieving Kaizen case-base by using established instances to detect applicable Kaizen cases; (3) developing suitable Kaizen cases to solve the current problem effectively; (4) applying suitable Kaizen cases to the current problem; and. (5) registering applied Kaizen cases for the current problem in Kaizen case-base, instances of it being clarified.     

A study on construction of a kaizen case-base and its utilisation: a case of visual management in fabrication and assembly shop-floors

In this paper, focusing on visual management (VM) as one of the kaizen technologies, a procedure for its new case development is discussed. This procedure consists of two portions. The first portion is construction of kaizen case-base, namely: (1) correction and analysis of kaizen cases; (2) establishment of drivers and instances of investigated kaizen case; and (3) analysis of proximity relationship among kaizen cases. The second portion is utilisation of kaizen case-base, namely: (4) selection of kaizen case from kaizen case-base; (5) consideration of the other related kaizen cases; and (6) new kaizen case design. A case study is performed to assure the relevance of the proposed procedure by focusing on ‘dispatching board’, a typical VM technology. Through collaboration with a factory eager to implement VM, the proposed procedure is qualified by experts as a useful method for kaizen knowledge transfer.     

Lot sizing in a production system with rework and product deterioration

Producing new and recovering defective products often takes place on a common facility, with these activities carried out in lots. Consequently, there is a necessity to coordinate the production and rework activities with respect to the timing of operations and also regarding appropriate lot sizes for both processes while completely satisfying a given demand. Thereby, it has to be taken into account whether the state of defective items may change in the course of time while they wait to be reworked. Such a deterioration of reworkable goods can result in increasing rework time and rework cost per unit. In this paper an EPQ model which addresses all of these aspects is presented. Considering set-up and inventory holding costs as well as set-up times, optimization algorithms are developed covering different planning situations. Closed-form results for optimal lot sizes can be obtained and exploited for new analytical insights into coordinated lot sizing in the case of returns and product deterioration.     

MILP-based campaign scheduling in a specialty chemicals plant: a case study

Supply chain management in chemical process industry focuses on production planning and scheduling to reduce production cost and inventories and simultaneously increase the utilization of production capacities and the service level. These objectives and the specific characteristics of chemical production processes result in complex planning problems. To handle this complexity, advanced planning systems (APS) are implemented and often enhanced by tailor-made optimization algorithms. In this article, we focus on a real-world problem of production planning arising from a specialty chemicals plant. Formulations for finished products comprise several production and refinement processes which result in all types of material flows. Most processes cannot be operated on only one multi-purpose facility, but on a choice of different facilities. Due to sequence dependencies, several batches of identical processes are grouped together to form production campaigns. We describe a method for multicriteria optimization of short- and mid-term production campaign scheduling which is based on a time-continuous MILP formulation. In a preparatory step, deterministic algorithms calculate the structures of the formulations and solve the bills of material for each primary demand. The facility selection for each production campaign is done in a first MILP step. Optimized campaign scheduling is performed in a second step, which again is based on MILP. We show how this method can be successfully adapted to compute optimized schedules even for problem examples of real-world size, and we furthermore outline implementation issues including integration with an APS.     

作业成本分析法在BPR中的应用研究

本方法是应用作业成本分析法(ABC法)解决目前企业在业务流程中存在的问题,但又不是严格遵循ABC法的计算方法,而是从产品是否增值的角度来分析业务流程中的作业及其动因类型,及应用ABC法进行业务流程重构(BPR)的方法。结合具体企业案例,运用ABC法对该企业的采购、销售及库存等物流业务流程进行了重构。结果表明,ABC法具有简化业务流程、提高业务流程运作效率和降低成本的作用。案例分析可为实施BPR的企业提供参考。     

Development of a production cost estimation framework to support product family design

The main task of a product family designer is to decide the right components/design variables to share among products to maintain economies of scale with minimum sacrifice in the performance of each product in the family. The decisions are usually based on several criteria, but production cost is of primary concern. Estimating the production cost of a family of products involves both estimating the production cost of each product in the family and the costs incurred by common and variant components/design variables in the family. To estimate these costs consistently and accurately, we propose a production cost estimation framework to support product family design based on activity-based costing (ABC), which consists of three stages: (1) allocation, (2) estimation, and (3) analysis. In the allocation stage, the production activities and resources needed to produce the entire products in a family are identified and classified with an activity table, a resource table, and a production flow. To help allocate product data for production, a product family structure is represented by a hierarchical classification of products that form the product family. In the estimation stage, production costs are estimated with cost estimation methods selected based on the type of information available. In the analysis stage, components/design variables possible for product family design are investigated with resource sharing methods through activity analysis. As an example, the proposed framework is applied to estimate the production cost of a family of cordless power screwdrivers that share different components within the family.     

针对项目式生产调度的模拟退火算法

分析了某航空航天企业生产现状,考虑到工时不确定性,建立了数学模型。提出了模拟退火启发式算法,以此制定主动调度计划,并且结合企业生产的实际情况,进行了验证。应用实践表明,相较于单纯求解工期最短的调度计划,该算法的解能很大程度上提高计划的鲁棒性,不需要过多延长工期,对于工时可变范围大的生产项目尤其适用。     

Cost effective manufacturing process of thermoplastic matrix composites for the traditional industry: the example of a carbon-fiber reinforced thermoplastic flywheel

Composite materials were successfully introduced and are now widely used for aerospace applications. Due to their high specific strength and stiffness, polymer-based composite materials should also be attractive candidates for many products of the traditional industries such as gas turbines, oil industry, or water and gas piping. The introduction of composite materials in the traditional industry is however a very slow process. Many factors can be identified as possible reasons such as the lack of previous examples on which to assess the durability of such composite products or reparability issues. However, the major factor hindering a broader use of composite materials for traditional products remains cost. Unlike the case of the aerospace industry, the use of composite materials is often not an enabling technology for traditional products: steel designs can be modified in order to increase the current product limitations. Therefore, the price of the composite system should be competitive when compared to the price of the equivalent system based on traditional materials such as steel or aluminum. In order to illustrate this concept, the case of steel risers for deepwater oil production is shortly discussed in the introduction of the present paper. When trying to reduce the price of composite products, the challenge often lies in lowering the manufacturing cost. The present paper focuses on applied manufacturing methods for various parts and products aiming to reduce cost. The associated performance of hot pressing and winding of short fiber and continuous fiber reinforced thermoplastic (AS4/PEEK) are compared for a high-speed flywheel type of application. Based on the mechanical performance and ease of fabrication, conclusions are drawn on a promising area of further investigation.     

Reliability analysis for mechanical parts considering hidden cost via the modified quality loss model

The improvement of mechanical parts inherent reliability has an impact on the reputation and performance of the company. To estimate the inherent reliability of products more conveniently and economically, a hidden quality cost-production cost (HQC-PC) reliability prediction model is put forward. To estimate the hidden quality cost (HQC) of products more accurately, a quadratic exponential quality loss function model is established, which is different from Taguchi's quadratic quality loss function (QLF) and the modified QLFs. In the new quality loss model, the growth rate of quality loss on both sides of the target value is considered. Under the condition that the quality characteristic value obeys normal distribution, the general estimation formulas of HQC in the tolerance range is obtained considering sampling error and the numerical model of inherent reliability is established. The effect of different parameters on the inherent reliability of products is discussed with practical case, such as design and production parameters. Then, the appropriate process capability index (PCI) is selected according to different production processes. The relationship between the HQC-PC reliability prediction model and PCI is derived by a numerical model of inherent reliability. A new analysis method of inherent reliability is proposed.