基于精益生产理论的卷烟机械制造企业物流系统优化及仿真研究
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摘要
伴随中国生产力和生产水平的日益提升,原有的劳动力优势和区域优势已经渐渐的失去主导能力,烟机制造企业生存发展的能力和竞争优势越来越多的取决于内部管理的科学性与合理性。在企业的生产过程中引入精益思想可以极大地提升制造企业的竞争力,充分发挥“第三利润源泉”的作用。如何成功的在烟机制造企业中实施精益物流,迎接日益激烈的市场竞争,满足愈加个性化的顾客需求,缩短产品的生命周期已成为亟待解决的重要课题。本论文结合了当今对于精益物流领域进行研究的最新成果,从现代烟机企业的物流活动出发,运用精益思想的管理理论,辅以数学模型及物流仿真软件,对烟机企业生产成本的降低和物流运作效率的提高等一系列方面进行了研究,主要取得了以下研究成果：
1)在对相关理论及资料的调研和分析的基础上,研究了精益物流基础理论,分析了精益物流的概念、目标、内涵及特征,总结了精益物流的主要方法工具。在此基础上,建立了烟机企业精益生产物流系统,设计了其功能模型,并结合系统运行过程进行了相应的系统优化研究。
2)研究了基于群决策理论的供应商评价与选择方法,提出了一种基于证据推理的信息集结方法来解决不完全信息下供应商评价指标权重求解问题；针对不完全互补判断矩阵提出了满意一致性的概念和一种判断矩阵一致性的标准；提出了一种新的多时点供应商评价群决策方法,以某烟机厂真空泵供应商评价为例,分析了该评价方法的应用步骤和有效性。
3)构建了生产物流平衡的方法模型,较详细的论述了该方法模型的基本思想、实施步骤以及各要素之间的互动关系,重点研究了缓冲设置、批量确定以及提前期确定等问题。应用微粒群算法来优化转运批量和生产周期,通过严密的数学推导,得到瓶颈前后的生产批量、转运批量的确定方法,并根据某烟机公司的历史数据,验证了模型的正确性。
4)探讨了精益生产下的订单处理模式,分析了订单处理过程和影响订单周期的因素,并就订单与物流系统的协调问题做了剖析,提出了具体的策略；分析了精益生产下的销售库存管理模式,建立了VMI库存管理模式,从市场预测和为销售商确定补货订单两方面做出了分析。建立了基于模糊数学理论的卷烟机械配送模型,并进行了实例分析。
5)针对某烟机制造企业车间的加工生产线生产能力不均衡而导致生产率较低的问题,通过运用F1exsim仿真建模技术建立生产线仿真模型及生产线平衡优化方法分析,提出了该作业环节物流优化设计方案。通过仿真优化解决了生产线中存在的瓶颈问题,确立了最佳生产线改进方案,有效的提高了生产设备利用率和生产线生产效率。
Along with the rising of domestic productive forces and the production level, the original labor and regional advantages have been gradually losing their dominant superiorities, thus the development capacity and competitive edge of the tobacco machine manufacture enterprise will more depends on the scientific and reasonable inner-management. During the production of a enterprise, the ideas of lean production can greatly upgrade the enterprises'competitiveness, and make full use of "the third profits source". Faced with the increasingly tough market competition, how to put the lean logistics into practice, to meet more personalized customer demand and shorten production cycle have been urgent issues to be solved in a tobacco machine manufacturing enterprises. Combined with the latest research achievement of lean logistics, and with an enterprise1logistics activities as the reaseach project, this thesis has applied the lean thinking management theory, mathematical model, and logistics simulation software to solve the problems that how to reduce production cost and improve logistics operation effeciency, and completes the following tasks:
1)According to the related theory and data based on investigation and analysis,this thesis has studied the basic lean logistics theory, and analyzed the lean logistics concept, goal, connotation and characteristics, summarized the main methods of lean logistics tools, on this basis, a tobacco machine enterprise lean production logistics system was established and its function model has been designed, finally the system optimization has been done along with system running
2)The supplier evaluation and selection method were studied for putting forward a method of information integration based on evidence reasoning to calculate supplier evaluation index-weight under incomplete information contions. The concept of the satisfied consistency and the standard of judgment matrix were brought for incomplete complementary judgment matrix. A new more time point supplier evaluation mean also has been put forward. Taking the evaluation of a tobacco machine factory vacuum pump supplier as an example, this paper studied application steps and effectiveness of the evaluation mean.
3) Set up a model to balance production logistics, discussed in detail of this modle including the basic idea, implementation steps, and interaction between the various elements of this model. Moreover, it also reaseached the issues on buffer settings, batch determination, advanced period. Applied particle swarm algorithm to optimize transit batch and production cycle, and through rigorous mathematical derivation got method for determining of production volume and transhipment volume before and after the bottleneck, and then based on historical data of a hood company, verified the superiority of the model.
4) Investigated the order processing mode under lean production, analyzed order processing, and the factors that affect the order cycle, and analyzed the coordination problem between orders and logistics system, then made specific strategies. Analyzed sales inventory management mode under lean production, Established VMI inventory management model, made analysis from market forecasting and determine replenishment orders for vendors. The cigarette machinery distribution model is established based on fuzzy mathematics theory, and the example analysis on it is carried out.
5) Through the application of Flexsim simulation modeling technology to establish production line simulation model and assembly line balancing optimization method analysis, the design of optimizing logistics on the the operating aspects is aiming at the lower productivity produced by imbalance on the the production capacity of the production line for the manufacturing enterprise workshops. By the simulation optimization, we solved the existing problem of the production line, and established the optimum production line improvement scheme, which improves the production equipment utilization effectively, as well as production efficiency of the production line.
1)在对相关理论及资料的调研和分析的基础上,研究了精益物流基础理论,分析了精益物流的概念、目标、内涵及特征,总结了精益物流的主要方法工具。在此基础上,建立了烟机企业精益生产物流系统,设计了其功能模型,并结合系统运行过程进行了相应的系统优化研究。
2)研究了基于群决策理论的供应商评价与选择方法,提出了一种基于证据推理的信息集结方法来解决不完全信息下供应商评价指标权重求解问题；针对不完全互补判断矩阵提出了满意一致性的概念和一种判断矩阵一致性的标准；提出了一种新的多时点供应商评价群决策方法,以某烟机厂真空泵供应商评价为例,分析了该评价方法的应用步骤和有效性。
3)构建了生产物流平衡的方法模型,较详细的论述了该方法模型的基本思想、实施步骤以及各要素之间的互动关系,重点研究了缓冲设置、批量确定以及提前期确定等问题。应用微粒群算法来优化转运批量和生产周期,通过严密的数学推导,得到瓶颈前后的生产批量、转运批量的确定方法,并根据某烟机公司的历史数据,验证了模型的正确性。
4)探讨了精益生产下的订单处理模式,分析了订单处理过程和影响订单周期的因素,并就订单与物流系统的协调问题做了剖析,提出了具体的策略；分析了精益生产下的销售库存管理模式,建立了VMI库存管理模式,从市场预测和为销售商确定补货订单两方面做出了分析。建立了基于模糊数学理论的卷烟机械配送模型,并进行了实例分析。
5)针对某烟机制造企业车间的加工生产线生产能力不均衡而导致生产率较低的问题,通过运用F1exsim仿真建模技术建立生产线仿真模型及生产线平衡优化方法分析,提出了该作业环节物流优化设计方案。通过仿真优化解决了生产线中存在的瓶颈问题,确立了最佳生产线改进方案,有效的提高了生产设备利用率和生产线生产效率。
Along with the rising of domestic productive forces and the production level, the original labor and regional advantages have been gradually losing their dominant superiorities, thus the development capacity and competitive edge of the tobacco machine manufacture enterprise will more depends on the scientific and reasonable inner-management. During the production of a enterprise, the ideas of lean production can greatly upgrade the enterprises'competitiveness, and make full use of "the third profits source". Faced with the increasingly tough market competition, how to put the lean logistics into practice, to meet more personalized customer demand and shorten production cycle have been urgent issues to be solved in a tobacco machine manufacturing enterprises. Combined with the latest research achievement of lean logistics, and with an enterprise1logistics activities as the reaseach project, this thesis has applied the lean thinking management theory, mathematical model, and logistics simulation software to solve the problems that how to reduce production cost and improve logistics operation effeciency, and completes the following tasks:
1)According to the related theory and data based on investigation and analysis,this thesis has studied the basic lean logistics theory, and analyzed the lean logistics concept, goal, connotation and characteristics, summarized the main methods of lean logistics tools, on this basis, a tobacco machine enterprise lean production logistics system was established and its function model has been designed, finally the system optimization has been done along with system running
2)The supplier evaluation and selection method were studied for putting forward a method of information integration based on evidence reasoning to calculate supplier evaluation index-weight under incomplete information contions. The concept of the satisfied consistency and the standard of judgment matrix were brought for incomplete complementary judgment matrix. A new more time point supplier evaluation mean also has been put forward. Taking the evaluation of a tobacco machine factory vacuum pump supplier as an example, this paper studied application steps and effectiveness of the evaluation mean.
3) Set up a model to balance production logistics, discussed in detail of this modle including the basic idea, implementation steps, and interaction between the various elements of this model. Moreover, it also reaseached the issues on buffer settings, batch determination, advanced period. Applied particle swarm algorithm to optimize transit batch and production cycle, and through rigorous mathematical derivation got method for determining of production volume and transhipment volume before and after the bottleneck, and then based on historical data of a hood company, verified the superiority of the model.
4) Investigated the order processing mode under lean production, analyzed order processing, and the factors that affect the order cycle, and analyzed the coordination problem between orders and logistics system, then made specific strategies. Analyzed sales inventory management mode under lean production, Established VMI inventory management model, made analysis from market forecasting and determine replenishment orders for vendors. The cigarette machinery distribution model is established based on fuzzy mathematics theory, and the example analysis on it is carried out.
5) Through the application of Flexsim simulation modeling technology to establish production line simulation model and assembly line balancing optimization method analysis, the design of optimizing logistics on the the operating aspects is aiming at the lower productivity produced by imbalance on the the production capacity of the production line for the manufacturing enterprise workshops. By the simulation optimization, we solved the existing problem of the production line, and established the optimum production line improvement scheme, which improves the production equipment utilization effectively, as well as production efficiency of the production line.
引文
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