基于WLC的中小MTO企业订单投放及排程方法研究
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摘要
改革开放三十余年,我国的中小型制造企业成长迅速,成为国民经济和社会发展的重要力量；但近年来瞬息万变的全球竞争背景和金融风暴带来的急剧变化导致我国中小制造企业自身存在的问题日益显露。中小企业主要以订货生产方式(Make to order,MTO)为主,随着顾客需求的个性化和多样化日益增强,企业竞争越来越激烈,中小企业在经营中首先需要面对的是不确定性和动态性不断增强的环境风险。传统的生产计划与控制策略,包括MRP、TOC、JIT/Kanban等均不能很好的契合我国中小MTO企业所面对的随机性和动态性环境特点。鉴于此类应用背景,西方学者提出基于负荷控制(Workload control, WLC)的生产计划与排程方法,为中小企业的订单投放和排程问题提供了理论依据和实践应用成果,但仍存在诸多不足之处,包括：①既有研究多假设MTO生产环境为理论意义上的纯作业车间；②既有研究对急单插单的关注度不够；③既有研究多假设每个工位具有单一产能；④既有基于WLC的订单投放及排程方法仅使用局部派工规则指导已投放订单在生产车间各设备上的加工顺序。
为此,本文针对中小MTO企业订单投放和排程的优化设计要求,结合既有理论研究成果和企业生产实践的需要,提炼出需进一步分析和解决的若干问题,然后从问题特点出发,提出解决问题的启发式方法及优化算法,并通过仿真实验验证了所提出方法的有效性,为我国中小企业实施基于WLC的订单投放及排程逻辑架构提供理论方法指导。
论文的研究内容包括：
(1)针对产品工艺存在主流向的生产情境,分析了传统基于纯作业车间假设的订单投放方法所存在的问题和可能的改进途径,提出了两种新的投放方法,结合主流向强度系数对上下游工位的负荷阈值做出了补充调整并同时兼顾急单的及时投放。仿真实验显示了所提出方法的良好绩效表现和不同的环境适应性。
(2)结合既有理论研究成果及企业生产实践的需要定义了包含交货期紧急度因子、拖期惩罚因子和客户权重因子的急单识别系数,在此基础上提出了两种新的急单投放方法和一种车间排程指导规则。仿真实验结果表明,所提出的急单优先投放并优先分配产能的方法在急单比例偏低的情境下可以取得很好的控制效果,但当急单比例较高时须将负荷控制阈值调至中等或稍高的水平才能发挥较好的控制作用。
(3)针对加工时间不对等的柔性产能分配问题进行研究,提出了新的柔性设备选择方法；结果显示在随机动态性较强的生产情境下,系统的历史状态对决策的影响不大,而系统的当前状态及新到订单的工艺特点却能给系统绩效带来显著影响。研究同时结合订单工艺存在主流向的生产情境对柔性产能负荷阈值调节问题进行了研究,结论显示当柔性产能位于首道工序时,对其进行阈值调节会改进绩效,当柔性产能位于末道工序时则不需对其做针对性的负荷阈值调整。
(4)针对静态单目标柔性工作车间调度问题FJSP进行分析求解,提出了基于混合遗传算法的求解方案,利用混沌序列的随机性和遍历性特点,在遗传进化的过程中增加基于混沌序列的邻域搜索功能,以提高遗传算法的执行效率。在此基础上对动态柔性作业车间调度问题DFJSP进行分析研究,构建了基于nakespan、工作总拖期的双目标稳定重排和滚动重排架构,并分析了用以处理静态问题的混沌遗传算法所需做出的修改和调整。仿真实验结果显示,滚动重排的整体绩效要好过稳定重排,这说明在随机动态的生产环境下,不必拘泥于既有的预排程计划,应根据动态环境做出快速调整和优化。
(5)设计并实现了基于负荷控制的动态订单投放/排程架构,提出两种启发式排程方法,即关注投放时间和加工前后顺序的FRFA方法、关注平均工序剩余时间空隙及加工时间的APS&PT方法,并结合第(4)项研究内容所提出的全局优化动态排程方法进行集成实验,结果显示在系统趋向于拥挤的状态下,全局优化排程方法相对于启发式方法具有明显的绩效优势,企业可根据自身环境特点,考虑是否投资开发优化排程模块。
After more than 30 years'reform and opening-up to the outside world, China's small and medium-sized manufacturing enterprises developed rapidly and become one of the key factors of national economic and social employment. However, in recent years the rapidly changing global competition background and financial storm brought a sharp change of Chinese SMEs to make all the existing problems becoming obvious. Increased demand for customized products has led to a large growth in the number of MTO companies, leading to greater competition amongst these companies and the increasing environmental risks of uncertainty and dynamic. The traditional production plan and control strategy, including MRP, TOC, JIT/Kanban are not adapt to the Chinese SMEs faced the uncertainty of the MTO's dynamic environment characteristics. Workload control(WLC), one of the production planning and scheduling methods put forward by western scholars, by controlling and balancing machines' workload, can effectively reduce the work-in-process inventory, improve the performance of the delivery order, and well satisfy the non-repetitive and highly customized products during the dynamic and uncertain production environment.The framework Based on WLC control provides theoretical basis and practical application results for the order release and scheduling problem of small and medium enterprises, but still has several disadvantages such as follows:①Most researches are based on such assumptions that the production routing with a MTO context acts as pure job shop characteristics, however this is unlikely to be the case in reality.②Existing research did not pay much attention of rush orders, but the release and scheduling strategy of rush orders is one of the key problems under MTO production situation.③Most researches assume that each station has a single capacity, but in the actual production scene, the processing center tends to have multiple devices or cross-function machines, constitute the optional flexible production capacity.④Most order release and scheduling strategy based on WLC architecture using only local dispatching rules to assign the priority of orders in order pool and work floor, which can't reach global optimal, also can't guarantee high priority order must be completed on time.
In this dissertation, practice problems which are urgently need to be analyzed and solved related to order release and scheduling are extracted from china's MTO SMEs, then heuristic rules and optimization algorithms are put forward to give solutions to such problems, simulation experiments were carried out to test the feasibility and validity of the proposed methods, and this will provide theory method guidance for the implementation of production planning and control logic architectures of small and medium-sized enterprises in China based on work load control.
The main content of the dissertation is as follows:
(1) two new order release methods were proposed to better implement order's accurate release into shop floor under directed-products-routing environment, and the overall performance of the proposed two methods have different environment applicability, MTO enterprises can select appropriate order release method according to their own circumstance, so as to realize reasonable WIP control and on-time delivery.
(2) Recognition coefficient of rush orders includes of due-date emergency degree factor, tardiness punish factor and important degree factor of customers are analyzed and defined, then two new release methods of rush orders and one dispatching rule is proposed, simulation experiments were carried out to test the effectiveness applicability of the proposed methods.
(3) Flexible capacity distribution problems of different processing time are studied and discussed, The result shows that under the uncertain dynamic production situation, the history of the system state is not a key factor for decision-making, but the current state of the system and the feature of new orders will bring significant influence on the performance of the system. Threshold adjustment strategies of flexible capacities combining with the existing of products' mainstream routing are discussed, and the performance of two dispatching rules includes of FIFO and SPT are compared.
(4) A genetic algorithm combined with local search is proposed to solve the FJSP with Makespan criterion. During the local search process, Logistic chaotic sequence is adopted to explore better neighborhood solutions around the best individual of the current generation. Then bi-objective dynamic flexible job-shop scheduling problem is constructed, two rescheduling strategies include of stable rescheduling and rolling rescheduling are proposed to minimize the makespan and tardiness objectives. Representative flexible job shop scheduling benchmark problems are solved in order to test the feasibility and validity of the proposed algorithm, the experiment result shows that in stochastic dynamic production environment, decision makers should not have to be limited to the original plan, scheduling should be quickly adjusted and optimized with the dynamic environment.
(5) Order release & scheduling experimental architecture is designed and realized based on work load control, two new heuristic scheduling methods, include of FRFA(First ready first arrange) and APS&PT(average process slack & processing time) are proposed to compared with the rescheduling algorithm presented in above, the experiment result shows that the global optimization scheduling algorithm presents obvious advantages when the system tends to be crowded than the heuristic methods, especially when tardiness performance is involved, enterprise should consider whether to invest in the development of optimal scheduling module in light of its own environment characteristics.
为此,本文针对中小MTO企业订单投放和排程的优化设计要求,结合既有理论研究成果和企业生产实践的需要,提炼出需进一步分析和解决的若干问题,然后从问题特点出发,提出解决问题的启发式方法及优化算法,并通过仿真实验验证了所提出方法的有效性,为我国中小企业实施基于WLC的订单投放及排程逻辑架构提供理论方法指导。
论文的研究内容包括：
(1)针对产品工艺存在主流向的生产情境,分析了传统基于纯作业车间假设的订单投放方法所存在的问题和可能的改进途径,提出了两种新的投放方法,结合主流向强度系数对上下游工位的负荷阈值做出了补充调整并同时兼顾急单的及时投放。仿真实验显示了所提出方法的良好绩效表现和不同的环境适应性。
(2)结合既有理论研究成果及企业生产实践的需要定义了包含交货期紧急度因子、拖期惩罚因子和客户权重因子的急单识别系数,在此基础上提出了两种新的急单投放方法和一种车间排程指导规则。仿真实验结果表明,所提出的急单优先投放并优先分配产能的方法在急单比例偏低的情境下可以取得很好的控制效果,但当急单比例较高时须将负荷控制阈值调至中等或稍高的水平才能发挥较好的控制作用。
(3)针对加工时间不对等的柔性产能分配问题进行研究,提出了新的柔性设备选择方法；结果显示在随机动态性较强的生产情境下,系统的历史状态对决策的影响不大,而系统的当前状态及新到订单的工艺特点却能给系统绩效带来显著影响。研究同时结合订单工艺存在主流向的生产情境对柔性产能负荷阈值调节问题进行了研究,结论显示当柔性产能位于首道工序时,对其进行阈值调节会改进绩效,当柔性产能位于末道工序时则不需对其做针对性的负荷阈值调整。
(4)针对静态单目标柔性工作车间调度问题FJSP进行分析求解,提出了基于混合遗传算法的求解方案,利用混沌序列的随机性和遍历性特点,在遗传进化的过程中增加基于混沌序列的邻域搜索功能,以提高遗传算法的执行效率。在此基础上对动态柔性作业车间调度问题DFJSP进行分析研究,构建了基于nakespan、工作总拖期的双目标稳定重排和滚动重排架构,并分析了用以处理静态问题的混沌遗传算法所需做出的修改和调整。仿真实验结果显示,滚动重排的整体绩效要好过稳定重排,这说明在随机动态的生产环境下,不必拘泥于既有的预排程计划,应根据动态环境做出快速调整和优化。
(5)设计并实现了基于负荷控制的动态订单投放/排程架构,提出两种启发式排程方法,即关注投放时间和加工前后顺序的FRFA方法、关注平均工序剩余时间空隙及加工时间的APS&PT方法,并结合第(4)项研究内容所提出的全局优化动态排程方法进行集成实验,结果显示在系统趋向于拥挤的状态下,全局优化排程方法相对于启发式方法具有明显的绩效优势,企业可根据自身环境特点,考虑是否投资开发优化排程模块。
After more than 30 years'reform and opening-up to the outside world, China's small and medium-sized manufacturing enterprises developed rapidly and become one of the key factors of national economic and social employment. However, in recent years the rapidly changing global competition background and financial storm brought a sharp change of Chinese SMEs to make all the existing problems becoming obvious. Increased demand for customized products has led to a large growth in the number of MTO companies, leading to greater competition amongst these companies and the increasing environmental risks of uncertainty and dynamic. The traditional production plan and control strategy, including MRP, TOC, JIT/Kanban are not adapt to the Chinese SMEs faced the uncertainty of the MTO's dynamic environment characteristics. Workload control(WLC), one of the production planning and scheduling methods put forward by western scholars, by controlling and balancing machines' workload, can effectively reduce the work-in-process inventory, improve the performance of the delivery order, and well satisfy the non-repetitive and highly customized products during the dynamic and uncertain production environment.The framework Based on WLC control provides theoretical basis and practical application results for the order release and scheduling problem of small and medium enterprises, but still has several disadvantages such as follows:①Most researches are based on such assumptions that the production routing with a MTO context acts as pure job shop characteristics, however this is unlikely to be the case in reality.②Existing research did not pay much attention of rush orders, but the release and scheduling strategy of rush orders is one of the key problems under MTO production situation.③Most researches assume that each station has a single capacity, but in the actual production scene, the processing center tends to have multiple devices or cross-function machines, constitute the optional flexible production capacity.④Most order release and scheduling strategy based on WLC architecture using only local dispatching rules to assign the priority of orders in order pool and work floor, which can't reach global optimal, also can't guarantee high priority order must be completed on time.
In this dissertation, practice problems which are urgently need to be analyzed and solved related to order release and scheduling are extracted from china's MTO SMEs, then heuristic rules and optimization algorithms are put forward to give solutions to such problems, simulation experiments were carried out to test the feasibility and validity of the proposed methods, and this will provide theory method guidance for the implementation of production planning and control logic architectures of small and medium-sized enterprises in China based on work load control.
The main content of the dissertation is as follows:
(1) two new order release methods were proposed to better implement order's accurate release into shop floor under directed-products-routing environment, and the overall performance of the proposed two methods have different environment applicability, MTO enterprises can select appropriate order release method according to their own circumstance, so as to realize reasonable WIP control and on-time delivery.
(2) Recognition coefficient of rush orders includes of due-date emergency degree factor, tardiness punish factor and important degree factor of customers are analyzed and defined, then two new release methods of rush orders and one dispatching rule is proposed, simulation experiments were carried out to test the effectiveness applicability of the proposed methods.
(3) Flexible capacity distribution problems of different processing time are studied and discussed, The result shows that under the uncertain dynamic production situation, the history of the system state is not a key factor for decision-making, but the current state of the system and the feature of new orders will bring significant influence on the performance of the system. Threshold adjustment strategies of flexible capacities combining with the existing of products' mainstream routing are discussed, and the performance of two dispatching rules includes of FIFO and SPT are compared.
(4) A genetic algorithm combined with local search is proposed to solve the FJSP with Makespan criterion. During the local search process, Logistic chaotic sequence is adopted to explore better neighborhood solutions around the best individual of the current generation. Then bi-objective dynamic flexible job-shop scheduling problem is constructed, two rescheduling strategies include of stable rescheduling and rolling rescheduling are proposed to minimize the makespan and tardiness objectives. Representative flexible job shop scheduling benchmark problems are solved in order to test the feasibility and validity of the proposed algorithm, the experiment result shows that in stochastic dynamic production environment, decision makers should not have to be limited to the original plan, scheduling should be quickly adjusted and optimized with the dynamic environment.
(5) Order release & scheduling experimental architecture is designed and realized based on work load control, two new heuristic scheduling methods, include of FRFA(First ready first arrange) and APS&PT(average process slack & processing time) are proposed to compared with the rescheduling algorithm presented in above, the experiment result shows that the global optimization scheduling algorithm presents obvious advantages when the system tends to be crowded than the heuristic methods, especially when tardiness performance is involved, enterprise should consider whether to invest in the development of optimal scheduling module in light of its own environment characteristics.
引文
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