【作者】 李黎；

【导师】 成晔；

【作者基本信息】 清华大学 ， 管理科学与工程， 2004， 硕士

【摘要】 电缆生产企业普遍存在产品品种规格多,生产工序分离间断,生产周期长及半成品流向不定的特点。电缆生产车间任务调度问题解决的好坏将直接影响车间运行的效率。随着生产过程信息量的迅速膨胀、生产系统复杂性和多样性的增加,基于传统的人工信息传递、数据采集与统计手段已经不能满足车间生产调度的要求,因而对电缆生产车间信息化管理的研究与实践具有重要的理论价值与应用前景。本文针对电缆生产特点,提出了以制造执行系统(MES)为核心的三层结构-企业资源计划(ERP)/制造执行系统(MES)/过程控制系统(PCS)的电缆生产信息化的实施方案,加强了制造计划的可执行性,可以对生产车间数据信息自动采集和分析,对整个车间的生产过程进行监控,实现产品质量的在线控制。使建立与按需生产、准时定长制造相适应的生产监控调度系统成为可能。根据最优生产技术(OPT)的解决车间调度问题的思想, 在转换瓶颈启发式算法(SBH)的基础上,提出了一种基于瓶颈分析的启发式调度算法,用于解决制造执行系统中的动态实时调度问题。在该算法中,给出了瓶颈的定义方法, 针对串联子系统和装配子系统详细阐述了基于瓶颈分析的调度机理。建立了服务器端实时数据库与统计数据库;对瘦客户机/服务器体系结构的通信机制进行了系统分析;设计并开发了车间生产监控调度系统,实现了对电缆车间生产调度、过程监控与质量控制的信息集成。车间生产监控调度系统的主要功能有:从计划层获取日生产计划;对生产车间资源的管理;生产车间作业调度;车间生产过程监控;车间生产过程信息在线统计;主调度终端与各工序终端之间进行消息传递和数据库共享。建立了车间监控调度核心算法的仿真模型,对车间生产问题进行了分析,对调度算法进行了验证和优化。建立了车间监控调度原型系统运行的仿真环境,对生产监控调度系统的运行性能进行测试;对数据库执行海量存储、多线程动态读写等操作的性能进行测试。验证与测试的结果表明,基于该调度算法的车间监控调度原型系统在动态性和实时性等方面能够满足电缆生产车间调度的要求,具有重要的工程应用价值和社会经济效益前景。更多还原

【Abstract】 A great variety of product specifications, separate and discontinuous manufacturing procedures, long production cycle and uncertainty of semi-finished articles flow are the typical characteristics of cable manufacturer. As one of the most critical factors, the solution of job scheduling problem will affect the running efficiency of shop floor. With the rapid accumulation of production information and the increasing complexity and diversity of manufacturing system, the conventional way of information transfer, data acquisition and statistic can not fulfill the requirement of shop floor scheduling, therefore, it is essential to research into and practise the information management of cable manufacturing.Aiming at the characteristics of cable manufacturing, A three-hierarchy architecture information system composed of ERP(Enterprise Resource Planning)、MES(Manufacturing Execution System) and PCS(Process Control System) is proposed, in which MES is responsible for the central manufacturing information management as the interface between ERP and PCS. This architecture provides solutions for the problems in production scheduling, process control and quality control in cable manufacturing and leads to the objectives of custom-oriented, length-determined and deadline-met manufacturing.In order to solve the problem of real-time and dynamic scheduling in MES, a heuristic algorithm, based on bottleneck analysis, is proposed. This algorithm derives from the idea of OPT(Optimized Production Technology) and SBH(Shifting Bottleneck Heuristic). In this algorithm, the methods of bottleneck definition are presented; the bottleneck analysis based scheduling mechanism is expounded with the serial line sub system and the assembly line sub system. And the scheduling algorithm is applied and evaluated in the cable manufacturing system. <WP=4>A real-time database and a statistic database are established on server; the communication mechanism of Thin Client/Server system architecture is analyzed systematically. A monitoring and scheduling system for cable manufacturing shop floor is designed and developed for the information integration of job scheduling, process monitoring and quality control. The main functions of the system include: acquisition of daily production plan, management of shop floor manufacturing resources; job scheduling; process monitoring; on-line statistic of production information; information transfer and database sharing among scheduling terminal and process terminals.A simulation model for the monitoring and scheduling system is established, in order to analyze the existing shop floor problems, validate and optimize the scheduling algorithm. An emulation environment for the monitoring and scheduling prototype system is established, in order to test the running performances of the monitoring and scheduling system and the database capabilities of mass storage and multi-route dynamic input and output. The simulating and the emulating results demonstrate that the scheduling algorithm can fulfill the requirements of the cable manufacturing job scheduling against feasibility, dynamics and real-time performance. It has considerable and promising future of social and economic benefit.更多还原