基于APS研究的注塑生产排程改善

Improvement of Injection Molding Production Schedule based on APS Research

以CSG公司注塑车间人工粗估产能的计划排程方式为研究对象,分析发现目前计划排程结果误差大,不能达到预期的执行效果。分析发现因物料进货时程、实际产能、实际库存等影响因素均由人工掌控及运算,与实际偏差较大,导致生产车间常以加班或外包等来满足交期。继而通过分析目前ERP系统的局限性,提出引入APS高级计划排程系统,结合MES实时采集生产现场数据功能,运用TOC约束理论及运筹学方法,根据机台产能、齐套物料、工艺路线、生产提前期等关键因素,自动计算生产资源调度可行解,快速实现较为精准的计划排程,达到车间高效生产、急单快速响应、库存精益控制、交期完美保障的效果。同时为企业生产管理工作提供可靠的人工决策依据与科学管理决策。

Taking the planning and scheduling method of manual rough estimation of production capacity in the injection molding workshop of CSG company as the research object,it was found that the current planning and scheduling results have large errors and could not achieve the expected implementation effect.It was found that the influencing factors such as material purchase schedule,actual production capacity and actual inventory were controlled and calculated manually,which deviated greatly from the actual situation,resulting in the production workshop often working overtime or outsourcing to meet the delivery date.Then,by analyzing the limitations of the current ERP system,it was proposed to introduce APS advanced planning and scheduling system,combined with the function of MES to collect production site data in real time,and use TOC constraint theory and operational research methods to automatically calculate the feasible solution of production resource scheduling according to key factors such as machine capacity,complete set of materials,process route and production lead time,so as to quickly realize more accurate planning and scheduling,achieve the effect of efficient production in the workshop,rapid response to urgent orders,lean inventory control and perfect guarantee of delivery time.It provides reliable manual decision-making basis and scientific management decision-making for enterprise production management.