摘要
随着全球市场竞争的加剧,客户需求的个性化和多样化,企业越来越关注如何为车间生产制定合理的调度方案,以缩短生产周期、减少在制品库存和快速响应市场。随着车间调度问题的深入研究,发现仅仅对加工时间进行优化不能满足车间生产的实际需求,调整时间、工件在设备间的运输时间、设备被其它工件占用的时间、设备故障修理时间等辅助时间对车间调度有很大的影响。多种时间因素作业车间的调度问题正越来越受到研究人员和技术人员的重视,成为研究的热点和重点。
本文对生产过程中的多种时间因素进行分析和研究,建立了作业车间生产过程的时间模型,对调整时间、运输时间、等待时间等多种时间因素进行统一、明确的定义。在此基础上,以最大完工时间为优化目标,对多种时间因素经典作业车间的调度问题进行优化建模和理论分析,并给出其遗传求解算法。相应的测试结果显示：在经典作业车间调度问题优化性能方面,考虑调整时间可平均改进6.5%；考虑运输时间可平均改进9.1%；综合考虑调整时间和运输时间可平均改进6.9%；其中运输时间比调整时间的改进效果平均多2.6%,顺序相关调整时间比顺序无关调整时间的改进效果平均多3.3%。
柔性作业车间是经典作业车间的扩展,涉及到机器选择和工序排序两个问题,其调度问题更加复杂。特别是其调整时间和运输时间具有不确定性,多时间因素对柔性作业车间调度问题的影响更大。本文在生产过程时间模型的基础上,分析了柔性作业车间遗传算法编码方式,设计了基于工序和整数机器编码的A／B分段编码方式的遗传算法,以最大完工时间为优化目标,对多种时间因素柔性作业车间的调度问题进行优化建模和理论分析。相应的测试结果显示：在柔性作业车间调度问题优化性能方面,考虑调整时间可平均改进17.4%；考虑运输时间可平均改进33.6%；综合考虑调整时间和运输时间可平均改进26.6%；其中运输时间比调整时间平均多改进16.2%,顺序相关调整时间比顺序无关调整时间平均多改进0.23%。
冲压车间是现实应用中典型的作业车间形式之一,其调度模型通常被简化为经典作业车间或柔性作业车间模型。由于没有考虑生产过程中调整时间和运输时间,冲压车间调度研究成果不能在实际生产中得到应用。本文在上述研究成果的基础上,根据汽车冲压车间的实际生产特点,特别针对经典作业车间和柔性作业车间模型作为冲压车间调度模型的缺点,如调整时间和运输时间无法获取等问题,对多时间因素的冲压车间调度问题建立优化模型并进行理论分析,提出了基于工序约束并行机模型(OCPMM)的冲压车间调度模型,并给出了一种新的混合遗传求解算法。该模型具有需要参数少、参数获取容易、可行性强等优点、避免了调整时间和运输时间的不确定性,有较好的实际应用价值。
基于上述研究成果,设计和开发了覆盖汽车整车四大工艺的MES系统中的冲压车间调度系统。该系统在安徽江淮汽车股份有限公司车身冲压车间的实际应用中,取得了良好的效果。
With intensified competition of global market, customer demands are transformed to the personalization and diversification, enterprises increasingly concern on how to design a reasonable schedule scheme to shorten production cycle, reduce work-in-process inventory and deliver just-in-time. With the further research of Job-shop Scheduling Problem (JSP), the optimism of JSP with only processing time of job can't meet to the practical demand of job shop production activity, while the setup times, the time of job routing between machines, the time of machine occupied and failure time of machine have great impact to JSP. The JSP with multi-time is paid more and more attention by the researchers and technologists, and it is becoming the focus and emphasis of research.
In this thesis, the multi-time elements are analyzed and studied, then the time model in production procedure is constructed, in which the unify definitions of the setup time, routing time and waiting time are given. Based on this, the JSP modeling with multi-time and the optimism object of minmax makespan is conceived and theoretically analyzed, and the GA algorithm is contrived to solve this problem. The test results show that the average improvement is 6.5% for setup time,9.1% for the routing time,6.9% for both setup time and routing for the performance to classical JSP, where the average improvement is more 2.6% for routing time than for setup time, the more 3.3% for sequence dependent setup time than for sequence independent setup time.
Flexible job shop is extendibility of classical job shop, which involves in machine assigned and the sequence of operation, and the Flexible Job-shop Scheduling Problem (FJSP) is more complicated. Specially, the multi-time is more impact to FJSP, for the uncertainty of the setup time and routing time. On the base of the time model, the code presentation of GA algorithm for flexible job shop is discussed, and the GA algorithm with A/B code based the job coding operation and integer coding machine is devised to solve the FJSP, and the FJSP modeling with multi-time and the optimism object of minmax makespan is conceived and theoretically analyzed. The test results show that the average improvement is 17.4% for setup time,33.6% for the routing time,22.6% for both setup time and routing for the performance to FJSP, where the average improvement is more 16.2% for routing time than for setup time, the more 0.23% for sequence dependent setup time than for sequence independent setup time.
The press shop is the one typical application of job shop in practical production, and the Press shop Scheduling Problem (PSP) usually is simplified as JSP or FJSP. The researches of PSP are not meeting the practical application for the setup time and routing time in production procedure are not considered. On the basis of above researches, according to the production character of the automobile press shop, especially, to overcome the problems of PSP as JSP or FJSP, for example, the setup time and routing time are hard to obtain, the PSP modeling with multi-time and the optimism object of minmax makespan is conceived and theoretically, the PSP based Operation Constraints and Parallel Machine Model (OCPMM) is conceived and the new hybrid GA algorithm is given to solve this problem. Result shows that the PSP based on OCPMM model has high application value for the parameters are less, less uncertainty, more easily obtained and more feasible.
Based on the above research findings, the scheduling system of press shop is designed and developed for the MES system covering the automilbe four shops. This system is applied in practical production in press shop of Anhui Jianghuai Automile Co. Ltd, and is well-tried.
引文
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