小批量多返工生产系统瞬态性能分析和优化

Transient performance analysis and optimization of multi-rework production systems with small-lot order

随着智能制造和绿色制造战略的提出,实际生产对小批量定制化加工的需求日益增加,同时为了进一步提高生产制造的加工效率和产品质量,返工生产线在企业中的应用也日益频繁.基于小批量生产背景,针对应用随机故障机器和有限缓冲区的多返工生产系统,进行瞬态性能分析,并对多返工系统进行生产调度.为定量分析该生产系统的瞬态性能,通过马尔科夫分析方法建立系统的数学模型,提出一种动态的分解和聚合算法来预测系统的生产率、消耗率、在制品库存等瞬态性能指标,并基于仿真对比实验验证所提出算法的精确性和有效性.此外,针对返工生产系统在劳动力有限的情景下,采用优化算法对各机器效率进行合理分配来优化系统的生产性能.最后,根据劳动力分配实验结果总结分配策略,为该系统的生产运行提供决策支持.

With the introduction of smart manufacturing and green manufacturing strategies,the demand for small batch customized production is increasing in actual production.Moreover,rework production lines are being used more frequently in actual production in order to further improve the processing efficiency and product quality.Based on the context of small batch production,the transient performance of a multi-rework system with unreliable machines and finite buffers is analysed.Meanwhile,the production scheduling of the multi-rework system is carried out.To quantitatively analyse the transient performance of this production system,a mathematical model of the system is established using the Markov analysis method.Besides,a dynamic decomposition and aggregation algorithm is proposed to predict the transient performance indicators such as productivity,consumption rate and work-in-process inventory of the system,and the accuracy and effectiveness of the proposed algorithm are verified based on simulation comparison experiments.In addition,a genetic algorithm is used to optimize the production performance of the system for a labour-constrained scenario with a reasonable allocation of the efficiency of each machine.Finally,the allocation strategy concluded from the experimental results of labour allocation provides decision support for the production operation of the system.