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卷烟分拣系统优化研究与应用
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摘要
自我国加入WTO以来,烟草行业竞争日趋激烈。面对国际烟草巨头挑战,高效的物流服务是制胜关键之一。如何高效经济地完成卷烟分拣任务,既是国家烟草专卖局的要求,也是卷烟分拣系统优化研究的目标。卷烟分拣系统是光机电一体化的作业系统,具有自动化程度高、处理速度快等优点,是分拣系统的发展趋势。卷烟分拣系统的优化研究既是对多任务组合优化问题的研究,也是对多作业设备系统综合优化问题的研究,在理论和应用方面具有挑战性。
     针对卷烟分拣系统优化问题,在综述国内外研究成果的基础上,论文分析了卷烟分拣系统结构,对件烟补货、条烟拣选、打包装车等3个关键作业环节展开了优化研究。主要研究内容及创新点如下所述。
     首先,深入分析了卷烟分拣系统,提出了卷烟分拣系统优化研究框架。确定了卷烟分拣系统的边界和内涵,建立了卷烟分拣系统优化的关键指标集合,提出了“系统解耦-子系统优化”的求解思路,归纳了卷烟分拣系统解耦的充分必要条件。分析了件烟补货、条烟拣选、烟包装车等三个关键作业环节,讨论了关键环节的完备性。
     其次,针对件烟补货作业环节进行优化研究。分析了补货子系统和上位子系统的状态集合和状态转移条件,提出了状态归并规则,建立了考虑停机补货时间的随机时间Petri网模型(STPN)。针对该模型提出了分时补货方法。该方法结合缺货即补货方法和安全线补货方法的优点,将补货任务设置为条件优先的作业任务,当上位子系统处于空闲时执行作业任务。该方法可缩短停机时间且降低余烟回库率。依据该方法构造了分时补货电路,提出了电路结构和工作原理。将电路封装在基于无源型RFID的件烟补货子系统中。该子系统的特点是可应对冷门品种与热门品种并存的高强度补货任务。
     再次,针对条烟拣选作业环节进行优化研究。在考虑机组负载的条件下,以订单拣选总作业时间最短为一级优化目标,以分拣机组作业费用最小为二级优化目标,提出了分拣机组负载均衡度计算公式,建立了考虑机组负载均衡度的多机多任务排序模型。针对该模型提出了订单凑配方法,在统计订单分布概率函数的基础上,将订单排成最短处理时间序列(SPT),将单个订单分解为并行处理时间最短的拣选任务集合。该方法通过平衡分拣机组负载以提高分拣效率。依据该方法设计了订单凑配电路,提出了电路的结构和工作原理,并封装在基于无源型RFID的条烟拣选子系统中。该子系统的特点是可应对小批量大额订单和大批量小额订单并存的分拣任务。
     再次,针对烟包装车作业环节进行优化研究。在考虑烟包滞留时间的条件下,以烟包总滞留时间最小为一级优化目标,以烟包装车作业成本最小为二级优化目标,建立了考虑烟包滞留时间的多车多任务排序模型。针对该模型提出了双层排序方法,该方法将烟包按最小等待时间(EDD)排序,将车队按最短处理时间(SPT)排序,以车厢最大利用率(SW)为装车序列,改善了烟包滞留时间等指标。依据该方法设计了有源RFID车厢,封装在基于有源型RFID的烟包装车子系统中。该子系统的特点是可应对紧急任务和普通任务并存的装车作业。
     最后,卷烟分拣系统优化方案应用于湖南省白沙物流公司的卷烟配送中心。优化方案实施两年以来显著增强卷烟分拣系统各项指标。单套系统分拣速度达到16500条/小时,超过国际同类系统分拣速度80%以上。生产用工下降至7.58人/万大箱,明显提高生产效率。单件卷烟分拣成本下降至1.96元。
Cigarette is a short life cycle, large, fast moving consumer good. And the sorting system optimization problem is an important problem in logistic system."We should complete cigarettes sorting task efficient and economical!" This is the earnest hope of the State Tobacco Monopoly Bureau, and also the important issues of the cigarette sorting system optimization. The optimization study of sorting system which based on the current situation of China is still in the exploratory stage. There are many problems should be solved in theory and applications.
     Based on the above background, this paper gave a summary of research work at home and abroad. We studied the sorting system optimization problem. The works involved cigarette sorting system function modeling, function optimization, function modules and application. The main work and innovations are described below.
     We established the summary function model of the cigarette sorting system which based on function modeling method, and proposed three key function model of cigarette sorting system. We deep analyzed a company's cigarette sorting system, depicted the existing operating flow of a company's cigarette sorting system, and proposed the set of key indicators of system optimization. On this basis, we proposed optimization ideas of cigarettes sorting system, analyzed prerequisites and optimization steps of system decoupling, and put forward two functional models of cigarettes sorting system:the summary function model and key function model. Through system decoupling and specification describes, we can clearly define the border and content of problem optimization, grasp the primary and secondary contradictions of problem optimization, laid the foundation for model analysis and strategic design of the problem optimization.
     We established the smoke replenishment parts Petri net model with downtime and constructed smoke replenishment parts function module. In considering the conditions of downtime, we analyzed the state collection and state transition conditions of the replenishment module and the upper module. According to the state collection and state transition conditions, we proposed state merging rules, by mapping the state collection and state transition conditions which be merged, we obtained the smoke replenishment parts Petri net model. On the basis of the Petri net model, using the message trigger mechanism, we proposed the news interlocking type trigger strategy. This strategy can reduce the sorting machine downtime while reducing the rate of remaining cigarettes back to the library. We implement the strategy by circuit and package it into the smoke replenishment parts function module. The characteristics of this module that is it can respond unpopular varieties and popular varieties coexisted high-strength replenishment tasks.
     We established cigarette selection task scheduling model considered the unit load and constructed cigarette selection function module. In considering the unit under load, we put minimizing the total operating time of order picking as the first optimization goal and put minimizing sorting unit operating costs as the second optimization goal, proposed sorting unit load balancing formula, established multi-machine and multi-task scheduling model which considered the degree of load balancing unit. To solve this model, we analyzed the probability distribution of the order, according to the probability distribution; we decomposed order picking tasks and constructed a sorter collection to minimize single order processing time, and proposed order strategy. This strategy can effectively balance sorting unit load and improve the efficiency of sorting. We implement the strategy by circuit and package it into the cigarette selection function module. The characteristics of this module that is it can respond to large orders for small quantities and large quantities of small orders coexisted sorting task.
     We considered the residence time of cigarette packets and the functional module of cigarette packaging loading. We established a cigarette packet loading model for this critical function of cigarette packaging, in considering the retention time, by taking the total residence time to a minimum level as senior optimal target and minimizing the cost of tobacco packaging as second optimal target, proposed the time/cost conversion coefficient. To solve this model, we construct multi-level buffer queue, designed the ordering rule of shortest waiting time (EDD)and the shortest processing time among the packets queue (SPT), designed the maximum utilization (SW)inside the carriage and the shortest processing time in the transpiration(SPT), what constituted the double adapter strategy of cigarette packets-motorcade. Features of the module are available to respond to loading operations of urgent tasks and common task.
     We tested the integrated application in company Bai Sha. The sorting system function program is used in Baisha Company of Hunan Province. The program improved the main indexes of sorting system. The speed of single line is16500tiao/per hour, which is80%more than other program. The cost of produce is down to 7.58people per10,000boxes, which improves the performance of produce. And the sorting cost is down to1.96yuan.
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