摘要
随着企业信息化的应用发展,以准时制(Just in Time, JIT)和MRPⅡ为代表的生产管理模式被广泛用于大批量少品种的生产环境下,并收到了良好的经济效益。但是目前针对多品种小批量生产管理模式的研究大都停留在理论阶段,工程应用效果均不太好。多品种小批量环境下,零部件种类繁多,产品生产周期长,物流、信息流复杂多变,生产过程多样化,波动较大,均衡生产问题一直没有得到很好地解决,严重影响了生产过程的准时化和平稳性,并且在实际生产过程中,由于生产计划和计划执行的不一致,导致装配的成套率低。
论文在对多品种小批量制造企业调研分析的基础上,结合生产管理方式的特点,提出了基于均衡生产的生产计划模式。该计划模式针对产品制造BOM(Bill of Material)链的不同特点及成套规律,对生产网络进行区间划分,建立了整体离散,局部连续的实时控制模型。
论文首先介绍了生产管理控制技术的发展演变以及均衡生产的思想、研究现状,分析了均衡生产的意义。在对多品种小批量环境下机加车间现行计划方法调研分析的基础上,提出了一种基于均衡生产的计划模式,该模式涵盖了生产线项目的分类结构和计划排配算法等。并在此基础上,通过对均衡生产的流程分析,建立了计划实施过程的控制模型,并详细给出了生产控制的运作流程、监控结构和算法实现等。完成了精益生产管理系统的整体架构和部分功能模块设计,提出了生产运作流程和系统功能的实现方案,主要研制了计划管理和进度管理两大系统模块。最后给出了系统的运行实例,对研究工作和所取得的成果进行了总结,并对下一步的研究提出了建议和设想。
论文的研究成果已在XX公司得到了实施应用,取得了较好的应用效果。
With the development and application of enterprise information, production management model represented by JIT and MRPⅡwas widely applied in mass-batch and single-varieties environment, and achieved good economic benefits. However, in multi-varieties and small-batch environment, this mode still rests on the theory stage, and needs a long way to apply practice. In view of long production cycle and complex material, information flow, mass components and production fluctuation in multi-varieties and small-batch environment, balanced production problem has never been a good solution. The complete assembly rate is low owing to the differences between production plan and plan complementation.
Combined with the characteristics of traditional production management mode, a mode of production plan is proposed in this essay, based on the investigation and analysis of manufacturing enterprise in multi-varieties and small-batch environment. According to different characteristics of BOM chain and complete regular pattern, a real-time control mechanism, which is overall discrete, partly continuous, is established by interval division for production network.
In the beginning of this essay, the development of production control technology, theory and significance of balanced production is introduced, and then a plan mode based on balanced production including a detail description of planning algorithm and classification structure of production chain is proposed, etc. According to process analysis of balance production, a production control method in the process of plan implementation is proposed in this essay. Combined with all above theories, this essay accomplished the whole framework and module design of lean production management system, and developed plan management and process management modules based on production process and function implementations. In the end, the conclusions and summaries of the research work and the results achieved are made, and suggestions and plans for the future work are proposed.
The research in this essay has been implemented in the manufacturing workshops of XX Corporation, and proves this method is feasible and effective.
引文
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