论产品布置形式的物料搬运设计

工厂布置是对工厂的各部门按一定方式的布置，分为产品布置、工艺布置和定位布置３种基本形式。物料搬运是指不同形式的物料移动，在各种现代化生产系统中占有极为重要的地位。物料搬运设计与布置形式是紧密相联的。本文从理论上和实践上论述产品布置形式的物料搬运系统设计。     

工厂总图设计与物流设计浅谈

工厂总图设计作为工厂建设的一个重要组成部分,应该在满足工艺和相关专业要求的前提下,合理布置工厂总平面,使之功能分区明确,工艺流程顺畅。同时,工厂实际上是用众多物料搬运设施把各种机器连接在一起的大集合,它的生产效率则取决于贯穿全厂的、迅速而顺畅的物料流程。文章将从工厂总图设计与物流设计两个方面进行分析。     

车身车间AGV物料搬运系统小车数量配置规划

随着人力成本的不断高涨以及AGV技术的发展与应用,越来越多的汽车制造企业在构建生产物流体系时都在考虑运用AGV技术实现物料搬运自动化,从而降低企业的生产物流成本,提高生产物流的技术能级。从已实施的AGV自动化物料搬运项目看,AGV小车成本占了近70%的项目总体采购成本,因此AGV系统的小车数量规划问题是成功规划与实施AGV自动化物料搬运项目的关键问题之一。以上海通用汽车X工厂车身车间AGV自动化物料搬运项目中的AGV小车数量配置问题为研究对象,对AGV系统中的小车数量计算与规划方法进行了研究,在整理总结现有研究现状的基础上,首先归纳提出一种快速简便的理论计算模型,可以帮助企业在前期规划时参考使用;其次,借助排队论模型以最小总成本为目标,建立另一种数量配置计算模型,并对两种不同模型的计算结果进行了分析讨论,为企业在后续同类项目中合理规划AGV小车数量提供了参考分析方法。     

通用机械加工车间绿色制造系统工程方法

制造业是我国经济增长的圭导领域和经济转型的基础，它是对制造资源按照顾客的要求通过制造过程转化为可供人们使用的产品，在将资源转变为产品和产品的使用、处理过程中，消耗了有限的资源并对环境造成了污染。怎样使得制造业尽可能地减少资源消耗和尽可能减少环境污染是21世纪制造业面临的重大问题之一。制造业工厂设施规划的好坏直接决定了绿色制造系统的效果，而且，设施规划是工厂一种典型的长期决策，是改善生产系统的结构基础，是提高生产效率的主要途径。基于以绿色制造的工厂设施规划为研究对象，主要完成了以下工作：梳理了设施规划的基本概念，提出了基于绿色制造的工厂设施规划目标和原则。分析了系统化设施布置方法的相关概念，归纳提炼了基于绿制造的系统化设施布置方法，并阐述了该方法系统化和绿色化的特点。     

丰田生产方式的物流系统研究

简单介绍了丰田生产方式（TPS），从工厂布置、物料搬运、物流管理与控制等方面研究了TPS的流系统，总结了TPS物流系统的特点，为进一步研究TPS物流系统设计打下了基础。     

“设施规划与物流分析”的比喻法教学

文章介绍了在“设施规划与物流分析”课程教学中采用的比喻方法：搬运与设施规划、布置方法与学生座位排序以及在制品库存与队伍行军的三个比喻，并形象地解释了本课程的难点。     

锯片生产中的设施规划

依据设施规划的原则,结合生产实际,对锯片车间的重新布局方式作了系统的阐述。以某锯业公司激光小片的生产车间为例,改进了其生产组织模式和物料输送方式,基于物流合理化原理进行了生产设备重新布置,进而布置了物料输送系统。     

基于生产物流系统分析的啤酒灌装生产线优化设计

将生产物流系统分析方法用于啤酒灌装生产线设施布置的优化设计;规划了啤酒灌装生产线平面布置图和物流流程图;通过对多方案物流系统总搬运工作量的对比,得到了啤酒灌装生产线物流设施布置的最优方案。     

制造业半成品备料区布局与物流优化研究

长期的生产实践表明,制造业的物流布局最终将对生产系统运行过程的物料搬运费用、搬运效率、实际产能和生产效率等产生重大影响。相关研究表明[1],复杂制造系统约有80%没有达到设计要求,其存在的问题60%可以归结为初期规划不合理或失误。物料搬运费用占生产经营活动总开销的比例高达20%～50%,因此高效、合理、科学化的布局设计,可使物料搬运     

制造业半成品备料区布局与物流优化的研究

以卡莱公司为例,针对该企业半成品备料区的布局状况,指出生产物流存在的问题,提出具体优化布局策略.利用工业工程改善工具对备料区域的布局与物流路线进行优化,对比改善前后的物料搬运距离、费用、耗用工时等相关指标发现,此次改善有效地解决了半成品备料布置问题,提高了生产效率,优化了生产流程,节约了成本.     

A simulated annealing algorithm based on a closed loop layout for facility layout design in flexible manufacturing systems

Facility layout design problems in flexible manufacturing systems (FMS) differ from traditional facility design problems and are more difficult to solve because there are more constraints that must be considered (i.e., cell shape, cell orientation, pick-up and drop-off point positions). The focus of this paper is on the closed loop type layout, which is based on a predetermined layout pattern. This layout pattern is commonly found in manufacturing settings since it requires a simplified material handling system configuration and since it facilitates a modular and expandable layout structure. The open-field type layout problem, where there is no predetermined layout pattern, may potentially have a more efficient configuration, since there are fewer restrictions. However, this problem is more difficult to solve and may result in configurations that are not desirable due to the lack of structure or modularity. The procedure developed in this paper improves the efficiency of the closed loop configuration by changing the rectangular shape of the loop to different sizes. In many cases, the resulting closed loop layout proves to be as efficient as the open field layout. A simulated annealing procedure (SA-CL) is used to search for the configuration that minimizes the total material handling costs. A comparison of the results with existing methods indicates that, based on solution quality and computational time, the SA-CL offers a favourable alternative for efficient layout design.     

基于损失函数的随机设施布局优化分析

现有的随机设施布局问题的优化方法或是优化总物料处理成本的均值以获得最鲁棒的布局,或是优化其方差以获得最稳定的布局,但两者均只优化了总物料处理成本随机特征中的一个方面.通过引入田口损失函数的概念,建立了新的随机设施布局优化模型,对总物料处理成本的均值和方差同时进行优化求解,相比于现有的优化方法,新方法得到的布局形式能够使系统同时获得较好的鲁棒性和稳定性.     

MULTI-HOPE: A tool for multiple floor layout problems

The objective of most facility layout problems is to minimize material handling cost, which is directly proportional to both the distance between the machines and the mix, as well as the volume of products handled. The mix and volume of products are dependent on the demand patterns, and the distance is dependent on the layout plan used for the facility. Because it is relatively difficult to change the demand patterns, and hence the mix and volume of products, the primary focus of most designers has been to deal with the distance attribute of the material handling costs. The limitations of available horizontal space create a need to explore vertical expansion of facilities. This brings up new aspects of vertical material handling and flow that need to be considered in the facility design problem. In this paper, we present a genetic algorithm-based heuristic for generating block layouts for multiple-floor layout problems. This approach produces better solutions than existing simulated annealing-based heuristics for all but one of five multiplefloor test problems available in the literature.     

周转量在物流运输成本分析中的应用

引入运输周转量叠加累计的方法,将物流运输成本量化运用于总图方案比较中。通过换算后的平均运输距离来分析高阶段总平面布置方案的合理性,继而调整整体布局和运输距离,优化方案,实现总图与运输的完美统一;同时,也增强方案实施的可行性,赢得市场。     

EXCITE: Expert consultant for in-plant transportation equipment

The cost of handling material is a vital factor in the facilities design process, whether it is for a new facility or for the redesign of an existing facility. Handling activities generally account for 30 to 40% of production costs, but in some industries they can be as high as 70%. Well designed handling systems are thus crucial for reduced costs and increased profits.

A key task in the material handling system design process is the selection and configuration of equipment for transport and storage in a facility. Material handling equipment selection is a complex, tedious task, and there is usually more than one good answer for any particular situation. A number of good quantitative techniques are available to aid the industrial engineer in determining layout design with the aim of reducing material handling cost. Unfortunately, there are few tools other than checklists to aid the engineer in the selection of appropriate, cost-effective material handling equipment. Analytical models are not often applied in industry because they generally consider only quantifiable factors such as cost and utilization and are difficult to implement.

This paper describes a knowledge-based approach for addressing the major factors that influence equipment selection. The research effort involved two major activities: compilation of a knowledge base from an in-depth review and modification of traditional checklists and published literature on equipment selection; and development of a prototype expert system for material handling equipment selection.     

An interactive approach to computer aided facility layout

In all manufacturing and service industries the layout of facilities is an important determinant of operating efficiency and costs. Whenever the flow of materials or people is complex, computerized procedures offer the only feasible means of developing and evaluating alternative arrangements.

This paper describes an interactive approach to construction and improvement procedures which utilizes a refresh graphics terminal (IMLAC)linked to a PRIME 400 computer. Input includes projected materials flow, estimates of material handling costs, 2-D templates of machines, etc., and an initial layout which can be either existing, proposed, or constructed using the procedure INLAYT. A heuristic procedure, S-ZAKY, utilizes multi-pairwise facility exchange to develop improved layouts based upon an analysis of materials flow. The improved layout is displayed in detail alongside the initial layout at the graphics terminal together with relevant material handling costs. The user may then accept, reject or modify the improved layout using the light-pen attached to the terminal before proceeding to successive iterations until satisfied. An economic evaluation of the projected savings in material handling costs against costs of relayout may be displayed at each iteration. On completion, a fully documented record including drawings may be obtained for every stage in the. procedure.     

An integrated methodology for automating the determination of layout and materials handling system

There is a severe scanty of models and solution techniques for the determination of layout and the materials handling system when neither are fixed. This is a complex problem for which this paper proposes a new integrated methodology using a knowledge-based/optimisation approach to the problem. The knowledge-base consists of facts and rules to determine the feasibility of using a materials handling equipment type for a given move. The optimisation part determines the layout of machines minimising the materials handling costs and the dead space in the layout using a multi-criteria optimisation model. The methodology aims to minimise materials handling costs, aisle space usage and dead-space in the resulting layout. It is particularly applicable to heavy manufacturing environments. The system outputs the optimum location, configuration and orientation of machines, and the material handling equipment types, their design capacities, utilisations and the assignment of moves to each item of materials handling equipment. The results of a successful application to an example problem are given.     

An integrated approach to determine the block layout,AGV flow path and the location of pick-up/delivery points in single-loop systems

Layout design and material handling system design are two of the major aspects of facility planning. Although both aspects directly influence each other, the classical approach to the layout design is carried out in two separate steps: in the first step the block layout, i.e. the location of the departments in the workshop, is constructed, and in the second step, the material handling system is designed. The separate optimisation of these two aspects of the problem leads to solutions that can be far from the global optimum. In this paper, we develop an integrated algorithm to design the facilities and material handling systems. We focus on single-loop AGV systems. The proposed algorithm determines the block layout, AGV single-loop flow path and pick-up delivery stations, simultaneously. The associated from–to chart and the area of departments are the principal inputs of the algorithm. The objective is minimising total material flow distance among all departments. The results of our computational experiments show the algorithm was coded using MATLAB 7.0, and that our integrated algorithm is more efficient in terms of both the objective function value and the runtime.     

Integrated design of the block layout and aisle structure by simulated annealing

In a manufacturing layout, it is widely agreed that the design of the layout and aisles for material handling needs to be considered simultaneously. This paper presents an integrated method to optimize the manufacturing layout and aisle structure by simulated annealing. In the method, the layout design problem is represented as a slicing floorplan and the slicing lines in the floorplan are used as the aisle structure for the material-handling system. A new representation for a sliced floorplan is provided so that it can be handled by simulated annealing to perform the optimization. The method minimizes the material-handling cost, which is calculated by the aisle distances between delivery stations, while designing the aisle structure at the same time.     

An integrated approach to the facilities and material handling system design

The facility layout problem involves the optimal location of manufacturing facilities into a workshop. The classical approach to the layout design is carried out in two separate steps: the first step is the construction of the block layout, i.e. the location of the departments into the workshop, and the second step is the design of the material handling system. The separate optimization of these two aspects of the problem leads to solutions that can be far from the total optimum. In this paper, an integrated approach to the facilities and material handling system design is proposed. Referring to a physical model, named the bay structure , and to a unidirectional AGV system, a genetic approach is proposed to individuate the locations of the departments, the positions of the pickup/delivery stations and the direction of the flow-path. The minimization of material handling cost is adopted as optimality criterion.