基于生产线产能优化的生产计划编制方法研究

上海交通大学硕士学位论文基于生产线产能优化的生产计划编制方法研究姓名：管秀娟申请学位级别：硕士专业：@指导教师：孙小明20050101I…ABSTRACTIIAPRODUCTIONPLANNINGDESIGNBASEDONLINECAPACITYUTILIZATIONABSTRACTNowadays,theproductionplanningisofgreatimportanceinproductionmanagement,anditisthekeyruleinacorporation’soperation.Ithasadirectrelationshipwiththeefficiencyofproductioninputandoutput.Themanufacturingcorporationgainsbenefitfromtheproductsneededinmarket.Oncethepriceisfixed,theprofitisuptotheproducts’cost,thelowercost,thehigherprofit.Sothereductionofproducts’manufacturingcostismostimportantforimprovingthecorporation'scompetitioninmarket.Thisthesisisbasedon“TheDesignoftheTurbochargersMachiningWorkshopProject”.Inordertodesignausefulproductionplanningfortheworkshop,thefollowingresearchhasbeendone:everyline’scapacityanalysis,capacityoptimizationbasedonthecapacitydistributionofthesharedmachinesandtheproductionplanningdesignmethod.Thisproductionplanningneedstomeetmarketdemandandfulfilldifferentmanagementgoal,suchasthemachineutilizationbalance,themaximizationofproductvalueorproductnumberetc.Themethodisverifiedtobepracticalthroughanexample.Thefocusofthisthesisisthecapacitydistributionanalysisofthesharedmachines.ThemaincontributionofthisthesisprovidesaproductionplanningdesignmethodfortheTurbochargersMachiningWorkshop.Theproductionplanningcanhelpthecorporationreducetheproductionmanagementcostandimprovethecorporation’scompetition.Soitisausefulexplorationontheeffectivecapacityutilizationforthemanufacturingcorporation.KEYWORDS:ProductionLine,CapacityUtilizationProductionPlanningMarketdemandProductionManagementCost2005221200522120052211[1][2]1.12MRPIIManufacturingResourcesPlanningERPEnterpriseResourcePlanningJIT,Just-In-Time80B[3]1.1.1[4]1.1.2MRPMRP()(3)()()()[5]MRPMRP(MasterProductionScheduleMPS)MRPMRP(BillOfMaterialBOM)MRP(MPS)(BOM)[6]1.1.3MRP60MRP[5]MRPMRPMRPMRP[5]MRP(CRP)[5]MRPMRPMRP[5]1.1.4MRPIIMRP[5]4MRPIIMRPIIMRPII[5]1.1.5ERP90ITGartnerGroupincERPEnterpriseResourcePlanning[6]ERPERPERP[6]ERP1ERP52ERPLPLeanProductionAMAgileManufacturing“”SESimultaneousEngineering3ERPERPERPT1.21.2.16[7,8]ORAI[9]1.2.21/MRP-II(ManufacturingResourcePlanning)JIT(Just-In-Time)Push/Pull[10,11,12]BakerScudder/[13]/[13]MRP-II/[14]/7[14]2.[15]AdvancedManufacturingShopfloor,AMSAPSAMS[16]AMSNPJobShopGTMB(H)MBTS1-1[17]1-1GTMB(H)[17]Fig.1-1FlowChartofGTMB(H)ArithmeticGTMB(H)AMSMBGATSYN8[18]1.31.4129341.5²²²²²²²1.610112.1[19][2][20]12[20]13[20]Fig.2-1ThreelevelsofProductionPlan2.2,2.2.1[21]14[22][23][24]15[25]2.2.2[26][27]²²²²²²²²²²16²2.3[28]2-1172.4[29][22]18%100×=euCCCU(2-1)UCCuCeratedcapacityRCM×U×UC(2-2)RCMUUC191Ki230ttkii=(2-3)Kiitiit023202.4.11iedtFM=(2-4)MdFeti/SMd/S22132.4.2[30]125Fe=F0h=F0(1-q)=F0-d(2-5)FeF0hqd2223[31]2.4.3lmr2-6mlr=(2-6)70%232.5243-1C…St(…)C1C2C1C2SCC1C2StFig.3-1MarketingDemand25S3-1()∑==NnntCNCS10(3-1)C(tn)NC032(){}NNtCCSNTNnnTT,0,10∈∀≥∑=(3-2)NTSS3.16203030611212113-226Fig.3-2MachiningProcessFlowofLine1and2OP1OP2OP3OP4OP51YCMTC26YCMTC26MX45VAHASSVF-OEL3902L390V26YCMV96AHASSVF-OEL390OP4HASSVF-OE12OP5L39012423OP1:OP2:OP4:OP3:OP5:273103-3Fig.3-3MachiningProcessFlowofLine3OP1OP2OP33MX45VAYCMH500AL270EL270E56344113-4OP1:OP2:OP3:28Fig.3-4MachiningProcessFlowofLine4OP1OP2OP3OP4OP54L390V26HASSVFOEYCM-H500AL390OP5L39012445OP1:OP3:OP4:OP5:OP2:295103-5Fig.3-5MachiningProcessFlowofLine5OP1OP25OP1HASSVF-OEYCM-V96A5OP2TNS60L270EL270E36566103-6OP1:OP2:30Fig.3-6MachiningProcessFlowofLine6OP1OP2OP36MH-40AYCMV106AL270EL270E353.2OP2:OP3:OP1:313-7YCM-TC26-1YCM-TC26-2YCM-H500AMH-40AHASSVF-0EYCM-V96AMX-45VATNS60V-26L390L270ECell1Cell1Cell1Cell1Cell1Cell2Cell2Cell2Cell2Cell2Cell3Cell3Cell3Cell3Cell4Cell4Cell4Cell4Cell4Cell4Cell5Cell5Cell6Cell6Cell6HASSVF-0EYCM-H500AMX-45VAL390V-26L390YCM-V96AHASSVF-0EYCM-V106ACell5Cell5Cell2Cell1Cell6Cell5Cell5Fig.3-7MachiningWorkshopLayout12HASSVFOE124L390356L270E3.33-132OP1OP2OP3OP4OP5125288203304036040150301502252882033040360401503015031203901039010165430300202701027010240157556018040120653751032010653.41236.54250EXCEL1YCMTC261YCMTC26YCMTC262528831325YCMTC26MdFe/ti3600/31311.5011.56.5=74.7574()3-233YCMTC26(Cell1-1)11.50parts74parts25.00Sec288.00Sec313.00SecCell1-113-312345Cell1746658123130Cell2746658123130Cell34558133Cell470808393260Cell59797146146Cell661703123.53-3Max(Mi)=Min(Mij)∀MiMijij3-33-434158MX45VA(Cell1-3)258YCMV96A(Cell2-3)345MX-45VA(Cell3-1)470L390(Cell4-1)5195HASSVF-OE(Cell5-1)YCM-V96A(Cell5-1)661MH-40A(Cell6-1)3-4%100)(××=TTMMaxUijiij∀ijUij)(iMMaxiijTijTni11%100)(11111××=TTMMaxU%10036005.600.31358×××Cell1-1Cell1-2Cell1-3Cell1-4Cell1-577.58%86.75%99.15%47.09%44.62%13-835Fig.3-8MachineUtilization3-814523.6364.1(1)124HASSVF-OECell14Cell24124-1Uj∑=NiijU1UjjUijjiN4-1HASSVF-OEU4U14U2447.09%+47.09%94.18%100%3712HASSVF-OECell15Cell25Cell45124U5U15U25U45124L390L390L390112581L39044.62%2L39044.62%4L39010.77%(100%-44.62%-44.62%)L390444-2Pi(Mmax)j×Uij∀(Mmax)jjUijjiP4(Mmax)5×U4526010.7728()241P137()142P237()(2)35635655L270E36TNS60Cell521005L270E35654-138HASSVF-OE(Cell5-1)YCM-V96A(Cell5-1)15.00parts15.00parts97.50parts97.50parts60.00Sec60.00Sec180.00Sec180.00Sec240.00Sec