多产品串并联生产系统动态看板的设计和计算

针对机电产品企业普遍采用的多品种、串并联生产系统,提出了批量轮番生产方式下采用动态看板作为控制手段时看板内容的设置和看板数量的计算方法,使得看板的内容和数量能随“需求”而动态变化,实现了“多品种均衡”生产和现场在制品数量的有效控制。     

基于Witness的看板生产系统仿真与参数优化研究

以看板生产系统基本理论为基础,某发动机总装车间为实证案例,应用Witness物流仿真软件对该车间看板生产系统进行仿真与优化,实现在短时间内预见实施效果,对系统绩效如设备利用率、订单处理效率等做出评价。结果表明,实施看板系统后,订单得到及时响应,提高了客户满意度,设备平均利用率和生产效率显著提高,产品产量达到目标产量。最后对看板生产系统的隐性参数进行优化,为不同企业根据实际生产情况实施看板生产系统参数选取提供依据     

看板管理在企业的应用

借鉴实施丰田生产方式准时化的一种重要手段——看板管理的原理和方法等技术，结合实践形成了适合成批多品种生产，满足市场需求的新看板管理模式，论述了在生产现场中的具体运作方法，阐述了看板管理系统的构筑思路。     

考虑双目标的JIT生产系统看板数量设定

针对现有JIT系统看板数量决策问题研究多以单目标为主的不足,提出了一种基于实验设计的双目标JIT生产系统看板数量设定方法。该方法同时考虑了高订单满足率和低系统平均在制品水平的双目标优化,以B公司CR油嘴JIT生产系统为例,建立了该JIT生产线的Witness仿真模型以实现数据的收集,以各看板循环回路的看板数量和看板容量进行水平设定,并进行正交实验设计及数据的直观分析处理,然后采用全因子实验的方法,基于帕累托最优的思想获得生产系统看板数量帕累托最优解,形成近似最优看板数量组合的帕累托最优前沿。生产管理人员可根据不同的生产计划和绩效目标从组合中选择合适的看板数量。最后的研究结果验证了该方法的可行性和有效性。     

基于看板的生产线物料循环配送方式

研究了适用于多品种、中小批量生产环境下,基于看板的生产线物料循环配送方式,建立了具体的操作流程和数学模型.为使模型更接近实际情况,在模型中考虑了额外提前成本,求得最佳的循环周期、补货次数和看板数量等运行参数.分析了该方式下实际生产线库存情况,进行表上模拟,验证了模型的可行性.     

看板管理系统中的搬运形式

通过唐山爱信齿轮有限责任公司实施看板管理的实例,阐述了搬运在．看板管理系统中的作用;结合实践提出了适合小批多品种生产看板管理模式下的搬运形式,重点论述了吊桶搬运、定量成组搬运、吊桶一成组搬运三种搬运形式所适应的场所及在看板生产现场中的具体运作方法,并在实际应用中取得了较好的效果;文末给出的实例阐述了搬运次数的增减与最小在库的关系。     

网上看板与精益生产控制方式

针对大型机械制造企业的多阶段、多部门的复杂生产控制问题,借鉴控制工程领域中前馈和反馈控制理论,提出了网上看板与精益生产控制方式,并对该生产控制方式的适用范围和应用方式进行了讨论。在此基础上,开发了网上看板平台软件,成功应用于具有代表性的大型机械制造企业,在协调生产、减少浪费等方面取得了良好的效果,证明了该生产控制理论的可行性和有效性。     

神龙公司直送看板供应分析与应用

看板管理是准时制生产（ＪＩＴ）的主要管理工具，直送看板供应是看板管理在供应链上的具体应用。阐述了直送看板供应的原理，对神龙公司直送看板供应的一个成功案例进行了量化分析，并预测了这种供应模式在轿车整车厂的未来前景及其带来的管理效益；探索如何将ＪＩＴ管理技术转化为生产力。     

多品种小批量订单型企业生产调度优化

目的研究多品种小批量订单型企业的生产调度优化问题,方法针对S公司的生产现状,应用遗传算法思想设计调度优化方案,采用不等长矩阵的编码方式实现订单的批量生产及车间排产的方案。结果通过仿真分析和S公司生产调度的实际应用,验证了该算法的可行性及有效性。结论基于遗传算法的调度优化算法实现了多品种小批量流程型生产企业生产调度优化,达到了缩短生产周期、有效利用生产资源的目的。     

及时生产制(JIT)应用的探讨

实施JIT生产制的目的是降低库存和消除浪费。实现这一目的的手段是看板管理。看板管理需要一定的基础条件,看板管理的运用必须理解看板的概念、看板的运作程序以及应该注意的问题。实施JIT生产制是一个持续改进过程。     

An exploratory study of disaggregated clearing functions for production systems with multiple products

Clearing functions (CFs) have shown considerable promise for representing production capacity in production planning models due to their ability to capture the non-linear relationships between throughput, order releases and lead times. Most CFs developed to date use the total work in progress of all products, in units of processing time, as the state variable. In this paper, we investigate CFs for multi-product systems where the overall throughput of the system is affected by the product mix. We show that the aggregate work in process (WIP) variable used in the previous CF literature may lead to inaccurate estimates of expected throughput for individual products. To address this issue, we explore the use of multi-dimensional CFs (MDCFs) that use an extended definition of resource state based on the disaggregated WIP levels for individual products. Several new functional forms for MDCFs are postulated for single machine multi-product systems and their ability to represent system behaviour is assessed using simulation experiments. Results reveal that MDCFs are better able to predict system performance in the presence of mix-dependent capacity losses. We also discuss the extension of the MDCF approach to multi-stage production systems.     

A neural network procedure for kanban allocation in JIT production control systems

In this paper, we develop a Generalized Systematic Procedure (GSP) for determining the optimum kanban allocation in just-in-time (JIT) controlled production lines. This procedure is based on a meta-model that incorporates (1) a factorial design approach to select the appropriate kanban combinations, (2) a simulation model to simulate the JIT production line, and (3) a trained neural network model to evaluate the line performance over the entire domain of possible kanban combinations. The GSP is then applied to a case problem and the results are presented.     

Optimal method for changing the number of kanbans in the e -Kanban system and its applications

The Toyota Motor Corporation has recently developed a new kanban system called ‘e-Kanban’, which is a parts ordering information system that operates within the communications network established between Toyota and its suppliers. One of the goals for developing the e-Kanban system was to introduce an efficient means for properly changing the number of kanbans once the required number has been calculated, as changing the number of kanbans in the kanban system directly affects the order quantity. Consequently, it is very important to monitor carefully and control changes in the number of kanbans. The paper investigates and proposes an effective method for changing the number of kanbans using the e-Kanban system. Applying this method to three problems, it is shown that the e-Kanban system can be implemented more efficiently and effectively than the original kanban system.     

Performance evaluation of two-stage multi-product kanban systems

We propose an approximate evaluation procedure for a kanban-controlled production system with two stages and multiple products. In the first stage, single-product manufacturing facilities produce items that are the input material for a single multi-product manufacturing facility in the second stage. Each manufacturing facility is controlled by a distinct kanban loop with a fixed number of kanbans. Processing and setup times are exponentially distributed, demand arrivals at the output store of the second stage are Poisson and independent for each product. If a customer's demand cannot be met from stock, the customer either waits or leaves the system, depending on the admissible number of backorders and the current number of waiting customers (partial backordering). We describe a new decomposition-based approximation method for the evaluation of such systems in steady state. We focus on the performance measures average fill rate, average fraction of served demand, and average inventory level. We report the results of several numerical tests. The results indicate that the approximation is sufficiently accurate for a large variety of systems. We also illustrate the effects of increasing the maximum number of backorders on the performance of the system.     

The extended kanban control system for production coordination of assembly manufacturing systems

In assembly manufacturing systems there are points in the production process where several component parts are put together in areas called assembly cells so as to form more complex parts called subassemblies. In this paper, we present and compare two variants of the Extended Kanban Control System (EKCS) - a recently developed pull production control mechanism that combines base stock and kanban control - for the production coordination of assembly manufacturing systems. In both variants, the production of a new subassembly is authorized only when an assembly kanban is available. Assembly kanbans become available when finished subassemblies are consumed. If an assembly kanban is available, in the first variant, each component part of a subassembly is released into the assembly cell as soon as itis available (independent release). In the second variant, however, it is released only when allother component parts also become available (simultaneous release). In both variants, when a component part is released into the assembly cell, it releases its kanban, thus authorizing the production of a new component part.     

多品种小批量生产模式下基于相似元的工序能力分析

随着社会的发展和科技的进步,消费者对于产品的需求呈现多样化,因此多品种小批量生产模式成为制造业的一大主流趋势,但由此带来的加工数据量少的问题给企业生产过程的质量控制及工序能力分析带来了困难。为了解决这个问题,利用相似元理论,根据影响工序的各种因素,将与目标工序相似的其他工序合并成组,通过数据转换扩大样本容量,进而利用大样本加工数据对目标工序进行质量控制和工序能力分析。以某生产车间车削工序为例,计算出该工序的工序能力指数,所得结果与实际情况相符。结果表明,该方法可以给多品种小批量生产模式下企业的质量控制和工序能力分析工作带来许多便捷。     

Prioritization of kanbans in the case of a single station serving multiple downstream stations

When implementing the kanban method in non-serial production lines, an interesting prioritization problem arises. Often a single server station will be linked with M different downstream stations via M separate kanban loops. Then the K-priority problem may be described as determining which kanban card should be processed next, given that empty cards are waiting in more than one loop. The objective in prioritizing the kanbans is to reduce back order or shortage costs and inventory costs at the downstream stations. Utilizing the theory of Markovian decision process and dynamic programming concepts, a solution to the K-priority problem is developed. This solution is labelled the K-rule, and was found to outperform the first-come-first-served and longest queue rules, plus a cost inclusive heuristic rule, in experimental tests,     

A multi-class approximation technique for the analysis of kanban-like control systems

Analytical methods have been proposed in the literature for performance evaluation of kanban control systems. Among them, the method presented by Di Mascolo and colleagues appears to be of special interest since it can handle manufacturing stages consisting of any number of machines and it is fairly accurate. This paper presents a new way of deriving the analytical method presented by Di Mascolo et al. The approach is to see the queueing network of the kanban control system as a multiclass queueing network in which each kanban loop is represented by a class of customers. This allows one to use the general technique proposed in Baynat and Dallery for analysing multiclass queueing network using product-form approximation methods. In terms of equations, the new method is equivalent to that previously presented. However, the computational algorithm is much more efficient since it avoids the two levels of iterations involved in the original algorithm. Another major advantage of the new method over that originally proposed is that it provides a general framework for the analysis of more general kanban systems. Indeed, it is shown in this paper how this approach can easily be extended in order to handle kanban systems with multiple consumers and multiple suppliers, kanban-controlled assembly systems and generalized kanban systems.