基于智能对象的混流装配线敏捷生产管理技术研究
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摘要
为应对日益激烈、瞬息万变的全球化市场竞争,企业纷纷应用敏捷制造(Agile Manufacturing,AM)的理念和技术不断强化制造过程的敏捷性,以准确、快速地响应动态多变的市场需求。因此,制造过程敏捷性成为制造企业和先进制造研究领域不断追求的目标。生产资源(如人、设备、物料)的优化组织与管理、以及状态信息及时准确获取是达成此目标的关键。论文针对离散制造业生产管理对敏捷性的需求,引入射频识别(Radio frequency identification,RFID)技术与物联网思想和技术,旨在通过创新新的生产组织与管理模式,来突破现行生产管理发展的瓶颈。
论文以离散制造业广泛采用的混流装配线为研究背景、混流装配线生产管理为研究对象,将RFID技术与物联网思想引入制造车间,提出和建立了制造系统的智能对象,进而研究基于智能对象的敏捷生产管理模型;并基于此模型,围绕敏捷生产管理的实时制造数据采集与处理、生产过程控制和物料配送优化等关键核心技术问题,开展深入研究,形成基于智能对象的敏捷生产管理系列成果。主要研究成果包括:
①研究了基于智能对象的混流装配线敏捷生产管理模型。丰富的实时制造信息是实现敏捷生产管理的核心,物流与信息流不同步是自动获取实时制造信息的瓶颈。为此,本文将RFID技术应用于制造车间,赋予传统的车间生产对象以实时信息载体,使其转变为具有实时信息自动反馈与交互能力的智能对象,达成物流与信息流同步;通过引入物联网思想,研究了基于智能对象的泛在制造信息反馈与共享体系,支持丰富的实时泛在制造信息环境下的车间管理。在此基础上,针对改善生产组织敏捷性的需求,研究一种基于智能对象的混流装配线敏捷生产管理模型,建立了模型的框架结构、网络支撑体系和集成运行模式。该模型的特点表现为一方面通过智能对象技术支持信息系统、制造物理环境和人的无缝集成,另一方面通过集成接口支持联盟企业制造车间之间、客户与企业之间的透明化协同制造,从而提升对制造事件响应的敏捷性。
②可靠数据是实现敏捷生产管理的关键,由于无线通信特点和制造车间复杂应用环境影响,导致智能对象的RFID原始数据存在不可靠问题,因此,本文深入研究了制造环境下的RFID实时数据处理技术。首先,为便于数据处理,将RFID数据流用事件表示,建立了包含基本事件和复杂事件的RFID事件模型;其次,分析并总结了复杂制造环境下RFID应用可靠性,给出了一种RFID系统应用可靠性的评价指标,提出了从改进设备、部署方案优化、数据处理与优化三个层面改善RFID应用可靠性的技术框架;在此基础上,从数据处理与优化层面,建立了一种改善RFID系统应用可靠性的分层数据处理模型,该模型通过清洗与纠正RFID原始数据流中的不可靠数据,从而为后端敏捷生产管理应用提供可靠的实时应用数据,该模型已在企业车间制造系统成功应用并得到验证。
③低效的混流装配线生产过程控制是敏捷生产管理的瓶颈,为此,以智能对象技术构建的透明化制造车间为基础,研究了新的混流装配线生产过程控制方法。在对混流装配过程形式化描述的基础上,面向生产管理,给出一种基于智能对象的生产过程可视化方法,以实现管理层对生产过程的透明化监控,从而提升对生产过程事件响应的敏捷性;此外,针对手工装配随意性大带来的质量控制问题,通过对工序级生产任务的数字化,并结合智能对象技术,提出一种面向车间装配作业的混流装配过程质量控制方法,以加强装配过程精细化控制,提升产品的装配质量。
④混流装配线高效的物料配送是实现敏捷生产管理的核心。针对现有物料配送方法因缺乏实时制造信息支撑,难以敏捷响应混流装配频繁的状态调整与作业计划变更的问题,在应用智能对象技术实现物流与信息流同步的基础上,研究了一种新的集成实时生产进程的混流装配线敏捷物料推拉配送模型。该模型引入主动服务思想,由智能对象主动驱动物料配送中心按需供给线旁物料,解决混流装配物料错送、漏送、缺料和堆积等问题。此外,针对该模型对工位级配送BOM的需求,提出了以工位为中心的基于装配工艺的物料配送BOM构建方法。
上述研究成果和所设计的一套相应的敏捷生产管理系统已成功应用于某企业摩托车混流装配线,在提升制造过程敏捷性、改善制造过程稳定性和提高企业应变能力等方面发挥了关键作用,验证了本文的研究结论。
Confronted with fierce competition and constantly changing of globalizing market, more and more enterprises have been employing agile manufacturing (AM) technology to continually strengthen manufacturing process’s agility and improve thus accurate and immediate responding ability to dynamic market requirement. Therefore, manufacturing process’s agility is the pursuing goal of manufacturing enterprise and advanced manufacturing (AM) research. Optimizing organization and automatically acquiring real-time state information of production resources (such as people, equipments, materials) are the key to achieve this goal. To meet the agility requirements of production management in discrete manufacturing, RFID (Radio frequency identification) and the thoughts of IOT (the Internet of Things) are employed in the dissertation. The aim is to establish innovative production management and organization mode, in order to break through the development bottleneck of current production management.
The dissertation takes mixed-model assembly line (MMAL), which is widely adopted in discrete manufacturing, as research background, production management of MMAL as research object, RFID and the thoughts of IOT are brought into workshop. Smart object of manufacturing system is presented and created. Then smart object-based agile production management model is studied. On this basis, the key technical problems of the model is further studied, such as real-time manufacturing data acquiring and processing, production process control and material feeding optimizing. And a series of research results of smart object-based agile production management are formed. The main content is as follows:
①A smart object-based agile production management model for MMAL is studied. Abundant real-time manufacturing information is the key to realize agile production management. The asynchronous of material flow and information flow is the bottleneck of automatically acquiring real-time manufacturing information. Therefore, it is proposed to adopt RFID technology to identify and track workshop production objects, and those objects become smart objects with real-time information feedback and interactive function. Then, taking reference from the thoughts of IOT, a smart object-based ubiquitous manufacturing information feedback and sharing architecture is constructed, and it supports workshop production management with abundant real-time manufacturing information.
Then, an agile production management model for MMAL which can satisfy the agility requirements for manufacturing process is presented, and its frame, network support system and integration operation mode are established. On one hand, the model can realize the seamless integration of information system, manufacturing environment and people with the support of smart object technology. On the other hand, it supports transparent cooperative manufacture of different workshops of enterprises in virtual enterprise, or between clients and enterprises. So, the agility of responding to manufacturing event can be improved.
②Reliable data is essential for realizing agile production management. To process RFID unreliable data that is caused by wireless communication or complex manufacturing environment, RFID real-time data processing technology in manufacturing environment is researched. Firstly, RFID data flow is transformed into event to process data conveniently, and a RFID event model is established, including RFID basic events and complex events. Then, RFID application reliability in complex manufacturing environment is analyzed and summarized, and a set of indexes for evaluating RFID application reliability are suggested. The technique system of improving RFID application reliability from improving equipment, optimizing RFID deployment scheme and processing data is put forward. Finally, from the aspect of RFID data process and optimization, a layered data processing model is set up to improve RFID application reliability. By cleaning and correcting unreliable data, the model can provide reliable real-time data for back-end agile production management application. The successful application of the model in a manufacturing system proves its feasibility.
③Ineffective production process control of MMAL is the bottleneck of agile production management. Therefore, on the basis of transparent workshop which is constructed by smart object technology, new production process controlling technology of MMAL is studied. Firstly, the product assembly process of MMAL is formally described. Then, a new assembly process visualized method, which is management layer-oriented and smart object-based, is presented to realize transparent monitoring to production process, and agility of responses to production event is improved. Moreover, to solve the problem of ineffective product quality control of manual assembly, with the support of smart object technology and procedure-level digital production task, a new workstation-oriented assembly process quality control method is proposed to strengthen accurate control of production process and improve product quality.
④Effective material feeding is the core of realizing agile production management. Traditionally material feeding method, which lacks of real-time production information, is hard to agilely respond to frequent state and plan change in MMAL. To solve the problem, on the basis of the synchronization of material flow and information flow which is realized by smart object technology, a new agile material push and pull feeding model (AMP2FM) is put forward, which integrates real-time production progress information. Following the principle of positive service, the smart object automatically orders material supply center to deliver necessary material to assembly line. The problems of wrong or miss feeding, lack of material and material accumulation, etc. are solved. Moreover, to satisfy the BOM digitalized requirement of workstation material delivery, a workstation-centered material feeding BOM construction method is proposed.
The study mentioned above and the designed corresponding agile production management system has been successfully applied to a manufacturing enterprise’s motorcycle MMAL. It has contributed a lot to improve manufacturing process agility, enhance manufacturing process stability and improve enterprise’s response ability, and the dissertation’s research result is testified.
论文以离散制造业广泛采用的混流装配线为研究背景、混流装配线生产管理为研究对象,将RFID技术与物联网思想引入制造车间,提出和建立了制造系统的智能对象,进而研究基于智能对象的敏捷生产管理模型;并基于此模型,围绕敏捷生产管理的实时制造数据采集与处理、生产过程控制和物料配送优化等关键核心技术问题,开展深入研究,形成基于智能对象的敏捷生产管理系列成果。主要研究成果包括:
①研究了基于智能对象的混流装配线敏捷生产管理模型。丰富的实时制造信息是实现敏捷生产管理的核心,物流与信息流不同步是自动获取实时制造信息的瓶颈。为此,本文将RFID技术应用于制造车间,赋予传统的车间生产对象以实时信息载体,使其转变为具有实时信息自动反馈与交互能力的智能对象,达成物流与信息流同步;通过引入物联网思想,研究了基于智能对象的泛在制造信息反馈与共享体系,支持丰富的实时泛在制造信息环境下的车间管理。在此基础上,针对改善生产组织敏捷性的需求,研究一种基于智能对象的混流装配线敏捷生产管理模型,建立了模型的框架结构、网络支撑体系和集成运行模式。该模型的特点表现为一方面通过智能对象技术支持信息系统、制造物理环境和人的无缝集成,另一方面通过集成接口支持联盟企业制造车间之间、客户与企业之间的透明化协同制造,从而提升对制造事件响应的敏捷性。
②可靠数据是实现敏捷生产管理的关键,由于无线通信特点和制造车间复杂应用环境影响,导致智能对象的RFID原始数据存在不可靠问题,因此,本文深入研究了制造环境下的RFID实时数据处理技术。首先,为便于数据处理,将RFID数据流用事件表示,建立了包含基本事件和复杂事件的RFID事件模型;其次,分析并总结了复杂制造环境下RFID应用可靠性,给出了一种RFID系统应用可靠性的评价指标,提出了从改进设备、部署方案优化、数据处理与优化三个层面改善RFID应用可靠性的技术框架;在此基础上,从数据处理与优化层面,建立了一种改善RFID系统应用可靠性的分层数据处理模型,该模型通过清洗与纠正RFID原始数据流中的不可靠数据,从而为后端敏捷生产管理应用提供可靠的实时应用数据,该模型已在企业车间制造系统成功应用并得到验证。
③低效的混流装配线生产过程控制是敏捷生产管理的瓶颈,为此,以智能对象技术构建的透明化制造车间为基础,研究了新的混流装配线生产过程控制方法。在对混流装配过程形式化描述的基础上,面向生产管理,给出一种基于智能对象的生产过程可视化方法,以实现管理层对生产过程的透明化监控,从而提升对生产过程事件响应的敏捷性;此外,针对手工装配随意性大带来的质量控制问题,通过对工序级生产任务的数字化,并结合智能对象技术,提出一种面向车间装配作业的混流装配过程质量控制方法,以加强装配过程精细化控制,提升产品的装配质量。
④混流装配线高效的物料配送是实现敏捷生产管理的核心。针对现有物料配送方法因缺乏实时制造信息支撑,难以敏捷响应混流装配频繁的状态调整与作业计划变更的问题,在应用智能对象技术实现物流与信息流同步的基础上,研究了一种新的集成实时生产进程的混流装配线敏捷物料推拉配送模型。该模型引入主动服务思想,由智能对象主动驱动物料配送中心按需供给线旁物料,解决混流装配物料错送、漏送、缺料和堆积等问题。此外,针对该模型对工位级配送BOM的需求,提出了以工位为中心的基于装配工艺的物料配送BOM构建方法。
上述研究成果和所设计的一套相应的敏捷生产管理系统已成功应用于某企业摩托车混流装配线,在提升制造过程敏捷性、改善制造过程稳定性和提高企业应变能力等方面发挥了关键作用,验证了本文的研究结论。
Confronted with fierce competition and constantly changing of globalizing market, more and more enterprises have been employing agile manufacturing (AM) technology to continually strengthen manufacturing process’s agility and improve thus accurate and immediate responding ability to dynamic market requirement. Therefore, manufacturing process’s agility is the pursuing goal of manufacturing enterprise and advanced manufacturing (AM) research. Optimizing organization and automatically acquiring real-time state information of production resources (such as people, equipments, materials) are the key to achieve this goal. To meet the agility requirements of production management in discrete manufacturing, RFID (Radio frequency identification) and the thoughts of IOT (the Internet of Things) are employed in the dissertation. The aim is to establish innovative production management and organization mode, in order to break through the development bottleneck of current production management.
The dissertation takes mixed-model assembly line (MMAL), which is widely adopted in discrete manufacturing, as research background, production management of MMAL as research object, RFID and the thoughts of IOT are brought into workshop. Smart object of manufacturing system is presented and created. Then smart object-based agile production management model is studied. On this basis, the key technical problems of the model is further studied, such as real-time manufacturing data acquiring and processing, production process control and material feeding optimizing. And a series of research results of smart object-based agile production management are formed. The main content is as follows:
①A smart object-based agile production management model for MMAL is studied. Abundant real-time manufacturing information is the key to realize agile production management. The asynchronous of material flow and information flow is the bottleneck of automatically acquiring real-time manufacturing information. Therefore, it is proposed to adopt RFID technology to identify and track workshop production objects, and those objects become smart objects with real-time information feedback and interactive function. Then, taking reference from the thoughts of IOT, a smart object-based ubiquitous manufacturing information feedback and sharing architecture is constructed, and it supports workshop production management with abundant real-time manufacturing information.
Then, an agile production management model for MMAL which can satisfy the agility requirements for manufacturing process is presented, and its frame, network support system and integration operation mode are established. On one hand, the model can realize the seamless integration of information system, manufacturing environment and people with the support of smart object technology. On the other hand, it supports transparent cooperative manufacture of different workshops of enterprises in virtual enterprise, or between clients and enterprises. So, the agility of responding to manufacturing event can be improved.
②Reliable data is essential for realizing agile production management. To process RFID unreliable data that is caused by wireless communication or complex manufacturing environment, RFID real-time data processing technology in manufacturing environment is researched. Firstly, RFID data flow is transformed into event to process data conveniently, and a RFID event model is established, including RFID basic events and complex events. Then, RFID application reliability in complex manufacturing environment is analyzed and summarized, and a set of indexes for evaluating RFID application reliability are suggested. The technique system of improving RFID application reliability from improving equipment, optimizing RFID deployment scheme and processing data is put forward. Finally, from the aspect of RFID data process and optimization, a layered data processing model is set up to improve RFID application reliability. By cleaning and correcting unreliable data, the model can provide reliable real-time data for back-end agile production management application. The successful application of the model in a manufacturing system proves its feasibility.
③Ineffective production process control of MMAL is the bottleneck of agile production management. Therefore, on the basis of transparent workshop which is constructed by smart object technology, new production process controlling technology of MMAL is studied. Firstly, the product assembly process of MMAL is formally described. Then, a new assembly process visualized method, which is management layer-oriented and smart object-based, is presented to realize transparent monitoring to production process, and agility of responses to production event is improved. Moreover, to solve the problem of ineffective product quality control of manual assembly, with the support of smart object technology and procedure-level digital production task, a new workstation-oriented assembly process quality control method is proposed to strengthen accurate control of production process and improve product quality.
④Effective material feeding is the core of realizing agile production management. Traditionally material feeding method, which lacks of real-time production information, is hard to agilely respond to frequent state and plan change in MMAL. To solve the problem, on the basis of the synchronization of material flow and information flow which is realized by smart object technology, a new agile material push and pull feeding model (AMP2FM) is put forward, which integrates real-time production progress information. Following the principle of positive service, the smart object automatically orders material supply center to deliver necessary material to assembly line. The problems of wrong or miss feeding, lack of material and material accumulation, etc. are solved. Moreover, to satisfy the BOM digitalized requirement of workstation material delivery, a workstation-centered material feeding BOM construction method is proposed.
The study mentioned above and the designed corresponding agile production management system has been successfully applied to a manufacturing enterprise’s motorcycle MMAL. It has contributed a lot to improve manufacturing process agility, enhance manufacturing process stability and improve enterprise’s response ability, and the dissertation’s research result is testified.
引文
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