面向单元化制造的车间制造执行系统研究及应用
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摘要
激烈的市场竞争以及多品种、小批量和快速交货的生产要求给制造企业带来了巨大的压力,企业纷纷开始寻求先进的生产方式以提高自身的竞争能力。单元化制造作为一种先进的生产组织方式逐渐被越来越多的制造企业所接受。制造执行系统作为一种连接上层生产计划与底层工业控制之间的信息系统,能够有效地改善制造过程的管理,降低生产成本,提高生产效率,也得到了越来越多制造企业的关注。目前,国内外在制造执行系统共性技术方面已经开展了大量的研究工作,但对于单元化制造环境下制造执行系统的研究仍比较少。本文重点对单元化制造环境下制造执行系统的体系结构和制造单元优化重组问题进行研究。
论文首先介绍了单元化制造环境下车间制造系统的特点、资源组织模式以及生产计划与控制模式,接着对单元化制造环境下车间制造系统的生产管理活动进行了详细的分析,在项目组前期研究的基础上,提出了一种面向单元化制造的车间制造执行系统的框架结构,然后建立了系统的功能结构,并分析了系统的主要业务流程。
制造单元是单元化制造系统生产组织的基本单位,单元重组是实施单元化制造首先要解决的问题之一。论文首先在分析零件工艺相似性的基础上设计了一种零件工艺相似性的计算方法,然后提出了一种基于模糊聚类的启发式零件分组方法;接着建立了以零件在设备上总加工成本最小化为目标的设备优化分组的数学规划模型,在此基础上形成了一种两阶段制造单元优化重组方法,并结合实例对该方法进行了验证。
上述研究成果已经在课题组开发的车间制造执行系统中得到了应用,取得了较好的应用效果。
Increasingly fierce market competition and production requirements with many product kinds, small batches and rapid delivery of goods have brought great pressure to manufacturing enterprises. Enterprises are beginning to seek advanced production mode to enhance self competitive power. As an advanced production and organization mode, cellular manufacturing technology is gradually accepted by more and more manufacturing enterprises. Manufacturing execution system is an information system connecting upper production planning and lower industrial control, which can effectively improve manufacturing process management, reduce production cost and increase production efficiency. So MES also catches more and more manufacturing enterprises’attention. At present a lot of research work about generic technology of manufacturing execution system has been carrying out at home and abroad. However, there nearly still have no researches on MES under cellular manufacturing environment. This paper will mainly study the MES architecture under cellular manufacturing environment and the manufacturing cells optimal reconfiguration problem.
This paper firstly introduces the characteristic, resource organizing mode, production planning and control mode of workshop manufacturing system, and then analyzes the production management activities of workshop manufacturing system under cellular manufacturing environment in detail. On the basis of our project group’s early research, a workshop manufacturing execution system structure model for cellular manufacturing is put forward. Then the function structure of MES is established and the main business process is analyzed.
Manufacturing cells are the basic unit of production organization in cellular manufacturing system. And manufacturing cells reconfiguration is one of the problems that should be solved first to carry out cellular manufacturing mode. Paper designs a calculation method for parts process similarity based on the analysis of parts process similarity at first. Then a heuristic part grouping method based on fuzzy clustering analysis is proposed. And a mathematical programming model for equipment optimal group is set up aimed to minimize the total cost of parts processing on the equipment. On the basis of these steps, a two-stage manufacturing cell optimal reconfiguration method is formed, which is verified by a concrete example.
The research results mentioned above has been adopted into workshop manufacturing execution system developed by our project teem and obtained good application effects.
论文首先介绍了单元化制造环境下车间制造系统的特点、资源组织模式以及生产计划与控制模式,接着对单元化制造环境下车间制造系统的生产管理活动进行了详细的分析,在项目组前期研究的基础上,提出了一种面向单元化制造的车间制造执行系统的框架结构,然后建立了系统的功能结构,并分析了系统的主要业务流程。
制造单元是单元化制造系统生产组织的基本单位,单元重组是实施单元化制造首先要解决的问题之一。论文首先在分析零件工艺相似性的基础上设计了一种零件工艺相似性的计算方法,然后提出了一种基于模糊聚类的启发式零件分组方法;接着建立了以零件在设备上总加工成本最小化为目标的设备优化分组的数学规划模型,在此基础上形成了一种两阶段制造单元优化重组方法,并结合实例对该方法进行了验证。
上述研究成果已经在课题组开发的车间制造执行系统中得到了应用,取得了较好的应用效果。
Increasingly fierce market competition and production requirements with many product kinds, small batches and rapid delivery of goods have brought great pressure to manufacturing enterprises. Enterprises are beginning to seek advanced production mode to enhance self competitive power. As an advanced production and organization mode, cellular manufacturing technology is gradually accepted by more and more manufacturing enterprises. Manufacturing execution system is an information system connecting upper production planning and lower industrial control, which can effectively improve manufacturing process management, reduce production cost and increase production efficiency. So MES also catches more and more manufacturing enterprises’attention. At present a lot of research work about generic technology of manufacturing execution system has been carrying out at home and abroad. However, there nearly still have no researches on MES under cellular manufacturing environment. This paper will mainly study the MES architecture under cellular manufacturing environment and the manufacturing cells optimal reconfiguration problem.
This paper firstly introduces the characteristic, resource organizing mode, production planning and control mode of workshop manufacturing system, and then analyzes the production management activities of workshop manufacturing system under cellular manufacturing environment in detail. On the basis of our project group’s early research, a workshop manufacturing execution system structure model for cellular manufacturing is put forward. Then the function structure of MES is established and the main business process is analyzed.
Manufacturing cells are the basic unit of production organization in cellular manufacturing system. And manufacturing cells reconfiguration is one of the problems that should be solved first to carry out cellular manufacturing mode. Paper designs a calculation method for parts process similarity based on the analysis of parts process similarity at first. Then a heuristic part grouping method based on fuzzy clustering analysis is proposed. And a mathematical programming model for equipment optimal group is set up aimed to minimize the total cost of parts processing on the equipment. On the basis of these steps, a two-stage manufacturing cell optimal reconfiguration method is formed, which is verified by a concrete example.
The research results mentioned above has been adopted into workshop manufacturing execution system developed by our project teem and obtained good application effects.
引文
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[4]刘诏书,李刚炎.制造执行系统(MES)标准的综述[J].自动化博览,2006(6):32-35.
[5]杨建军.单元制造的设计模式研究[D].上海:上海交通大学,2007.
[6] Schaller J. Designing and redesigning cellular manufacturing systems to handle demand changes [J]. Computers & Industrial Engineering, 2007, 53(3):478-490.
[7] Defersha F M. An integrated approach to the design of cellular manufacturing systems for dynamic production requirements[D]. Quebec: Concordia University, 2006.
[8]吴晓丹,王云峰,朱昭贤等.单元制造系统理论与方法研究综述[J].河北工业大学学报,1999,28(3):1-5.
[9] Richarde B. A design methodology for configuration of manufacturing cells[J].Computers and Industrial Engineering,1998,34(1):63-75.
[10]张为民,陈炳森,石来德.单元化制造的构造单元研究[J].同济大学学报,1999,27(4):440-444.
[11]于洋,查建中,牟建斌.单元化制造技术及其实施方法[J].制造业自动化,2001,23(3):4-6.
[12]王成恩,朱剑英,尉忠信.一种基于工艺特征的制造单元划分方法[J].组合机床与自动化加工技术,1993(1):21-24.
[13] Balakrishnan J, Jog P D. Manufacturing cell formation using similarity coefficients and a parallel genetic TSP algorithm: formulation and comparison[J]. Mathematical and computer modeling,1995,21(12):61-73.
[14] Oliveira S, Ribeiro J F F, Seok S C. A spectral clustering algorithm for manufacturing cell formation [J]. Computers & Industrial Engineering, 2009, 57(3):1008-1014..
[15] Defersha F M., Chen M. A comprehensive mathematical model for the design of cellular manufacturing systems[J]. International Journal of Production Economics, 2006, 103(2): 767-783.
[16]孟朝辉.制造单元设计中心半边图与拆分重组算法[J].计算机工程,2005,31(23):151-153.
[17]王爱民,丁国智,宁汝新.制造单元快速构建技术研究[J].北京理工大学学报,2006,26 (10):850-854.
[18] Harhalakis G, Nagi R, Proth J M. An efficient heuristic in manufacturing cell formation forgroup technology applications[J]. International Journal of Production Research, 1990, 28(1):185-198.
[19] Elmaraghy H A, Gu P. Feature based expert parts assignment in cellular manufacturing[J]. Journal of Manufacturing Systems, 1989, 8(2):139-152.
[20]李杰,王云峰,朱昭贤等.基于模糊技术的制造单元构建方法[J].计算机集成制造系统,2004,10(12):1561-1566.
[21]刘世平,魏迎军,饶运清等.基于模拟退火算法的敏捷化制造单元重构方法[J].华中科技大学学报(自然科学版), 2003, 31(11):58-60.
[22]李岩,吴智铭.基于GA和SA的制造单元成组方法[J].控制与决策,2000,15(6):654-657.
[23]孙艳丰,王众托.遗传算法在优化问题中的应用研究进展[J].控制与决策, 1996,11(4):425~431.
[24]付宜利,石旭东,何霆等.基于遗传算法的制造单元重组技术研究[J].计算机工程与设计,2002,23(4):1-4.
[25] Joines J A, Culbreth C T, King R E. Manufacturing cell design: An integer programming model employing genetic algorithms[J].IIE Transactions,1996, 28(1):69-85.
[26]李清.制造执行系统[M].北京:中国电力出版社,2007.
[27] MESA International. Controls Definition & MES to Controls Data Flow Possibilities[R]. MESA International White Paper 3, 1997.
[28] MESA International. MES explained: a high level vision[R]. MESA International White Paper 6, 1997.
[29] IEC 62264.1-2003, Enterprise-Control System Integration Part1: Models and Terminology[S].
[30] IEC 62264.2-2004, Enterprise-Control System Integration Part2: Object Model Attributes[S].
[31] IEC 62264.3-2007, Enterprise-Control System Integration Part3: Activity Models of Manufacturing Operations Management[S].
[32]肖力墉,苏宏业,苗宇等.制造执行系统功能体系结构研究[A]. 2009中国过程系统工程年会暨中国mes年会论文集[C],2009
[33] Yu-Hui Tao, Tzung-Pei Hong,Sheng-I Sun. An XML implementation process model for enterprise applications[J]. Computers in Industry.2004, 55(2):100-105.
[34] Object Management Group. Manufacturing Domain Task Force RFI-3 Manufacturing Executions Systems[R]. OMG Document mfg/97-11-01, 1997.
[35] Production System Modeling Technical Committee Japan FA Open Systems Promotion Group. Specifications of the OpenMES Framework [R]. Manufacturing Science & Technology Center, 2000.
[36]李德芳.面向行业应用的可配置MES平台及产品[R].国家高技术研究发展计划课题申请书,2007
[37]宋海生,王家海,张曙.网络联盟企业中基于web的制造执行系统[J].制造业自动化,2001, 23(2):20-23.
[38]胡春,李平,宋执环等.制造执行系统体系结构中功能模型的研究[J].信息与控制.2002, 31(6):561-566.
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