面向柔性定制的并行不等效客车混装线生产计划主从联合优化

doi:10.3901/JME.2020.22.024

摘要/Abstract

摘要： 针对客车制造过程中多条异构混装线之间加工能力、作业时间不等效的特征，提出面向柔性定制的并行不等效客车混装线生产计划模型。分析订单分解和投产排序的耦合关联机理；以产品紧急度、匹配度以及产线负荷为目标，建立以订单分解为主、投产排序为从的主从联合优化模型。针对模型特征提出一种结合Pareto前沿解的双层交互式遗传算法。为了提高遗传算法的性能，引入自适应调整方法对交叉概率和变异概率进行改进，并采用小生境技术保证种群多样性。利用客车混装线中的案例对提出的模型进行了验证，并与多阶段遗传算法以及企业的实际方案进行了比较。所提出的使用双层交互式遗传算法的模型可以真实地代表企业的实际情况，并最大限度地提高混装线的效率。

关键词: 订单分解, 投产排序, 柔性定制, 主从联合优化, 不等效

Abstract: Due to the non-equivalent processing capacity and working time among multiple heterogeneous mixed-model assembly lines (MMALS) in the bus manufacturing process, a parallel non-equivalent production planning model for flexible customization is proposed. By analyzing the interactions between the order decomposition and production sequencing, a leader-follower joint optimization model that takes the order decomposition as the leader and production sequencing as the follower is proposed, in order to optimize the product urgency, matching degree and production line load. A bi-level interactive genetic algorithm with Pareto front-line solution is developed to solve the model. To improve the performance of the genetic algorithm, an adaptive adjustment method is introduced to guarantee the crossover and mutation probabilities and niche technology to ensure the diversity of population. The proposed model is verified using cases in MMALS of buses and compared with other two methods, namely, the multistage genetic algorithm and the actual scheme of the enterprise. The proposed model that uses the bi-level interactive genetic algorithm can represent the actual situation of the enterprise and maximize the efficiency of MMALS.

Key words: order decomposition, production sequencing, flexible customization, leader-follower joint optimization, non-equivalence

中图分类号:

TH165
TP301

张炜, 王少杰, 甘雅文, 侯亮, 徐昌华. 面向柔性定制的并行不等效客车混装线生产计划主从联合优化[J]. 机械工程学报, 2020, 56(22): 24-37.

ZHANG Wei, WANG Shaojie, GAN Yawen, HOU Liang, XU Changhua. Flexible Customization Oriented Leader-follower Joint Optimization of Production Planning for Parallel and Non-equivalence Bus Mixed-model Assembly Lines[J]. Journal of Mechanical Engineering, 2020, 56(22): 24-37.

参考文献

[1] 张泽群,唐敦兵,金永乔,等. 信息物联驱动下的离散车间自组织生产调度技术[J]. 机械工程学报,2018,54(16):34-44. ZHANG Zequn,TANG Dunbing,JIN Yongqiao,et al. Self-organizing production technology for discrete workshop scheduling driven by internet of things[J]. Journal of Mechanical Engineering,2018,54(16):34-44.
[2] 谢卫红,王永健,成晓超. IT能力对竞争优势的影响机制:以制造柔性为中介[J]. 工业工程,2012,15(2):59-65. XIE Weihong,WANG Yongjian,CHENG Xiaochao. Influencing mechanism analysis of it capability on competitiveness:The mediating effect of manufacturing flexibility[J]. Industrial Engineering Journal,2012,15(2):59-65.
[3] HOU L,JIAO R J. Data-informed inverse design by product usage information:A review,framework and outlook[J]. Journal of Intelligent Manufacturing,2020,31(3):529-552.
[4] 李启锐,彭志平,崔得龙. 单件小批量生产模式下MRP的柔性化改进[J]. 江苏科技大学学报,2016,30(4):355-361. LI Qirui,PENG Zhiping,CUI Delong. Flexible improvement of MRP in jobbing work circumstance[J]. Journal of Jiangsu University of Science and Technology,2016,30(4):355-361.
[5] 郑力,江平宇,乔立红,等. 制造系统研究的挑战和前沿[J]. 机械工程学报,2010,46(21):128-140. ZHENG Li,JIANG Pingyu,QIAO Lihong,et al. Challenges and frontiers of manufacturing systems[J]. Journal of Mechanical Engineering,2010,46(21):128-140.
[6] 熊先青,袁莹莹,牛怡婷,等. 大规模定制家具ERP系统的构建及其关键技术[J]. 林业工程学报,2019,4(4):162-168. XIONG Xianqing,YUAN Yingying,NIU Yiting,et al. Research on key technologies of ERP system for mass customization furniture production[J]. Journal of Forestry Engineering,2019,4(4):162-168.
[7] WUNSCH D,BRATUKHIN A. Multilevel order decomposition in distributed production[C/CD]//Emerging Technologies and Factory Automation,2007. ETFA. IEEE Conference on. IEEE,2007.
[8] 王静,潘开灵,刘翱,等. 云制造平台下订单可分解的协同生产计划模型及求解[J]. 上海交通大学学报,2018,52(12):117-124. WANG Jing,PAN Kailing,LIU Ao,et al. The model and solution for collaborative production planning with order splitting in cloud manufacturing platform[J]. Journal of Shanghai Jiao Tong University,2018,52(12):117-124.
[9] 陈旻,陆志强. 基于订单总拖期的仓储作业调度建模与优化[J]. 上海交通大学学报,2009,12(1):1916-1922. CHEN Min,LU Zhiqiang. Modeling and optimization on operation scheduling with total tardiness objective for a storage system[J]. Journal of Shanghai Jiao Tong University,2009,12(1):1916-1922.
[10] 郑华林,刘飞,熊峰,等. 一种新型的单件小批量生产车间调度方法[J]. 重庆大学学报,2001,24(1):20-23. ZHENG Hualin,LIU Fei,XIONG Feng,et al. A study on the job-shop scheduling problem[J]. Journal of Chongqing University,2001,24(1):20-23.
[11] 张洁,张朋,刘国宝. 基于两阶段蚁群算法的带非等效并行机的作业车间调度[J]. 机械工程学报,2013,49(6):140-148. ZHANG Jie,ZHANG Peng,LIU Guobao. Two-stage ant colony algorithm based job shop scheduling with unrelated parallel machines[J]. Journal of Mechanical Engineering,2013,49(6):140-148.
[12] DAR-EL E,CUCUY S. Optimal mixed-model sequencing for balanced assembly lines[J]. Omega,1977,5(3):333-342.
[13] 范林胜,邓建新,陈一辉,等. 基于仿真的某发动机混合生产线的均衡改进[J]. 组合机床与自动化加工技术,2016(8):118-123. FAN Linsheng,DENG Jianxin,CHEN Yihui,et al. Based on simulation in a balanced improvement of engine hybrid production line[J]. Modular Machine Tool & Automatic Manufacturing Technique,2016(8):118-123.
[14] FLIEDNER M,BOYSEN N. Solving the car sequencing problem via Branch & Bound[J]. European Journal of Operational Research,2008,191(3):1023-1042.
[15] 甘雅文,侯亮,徐昌华,等. 考虑产品切换的客车混流装配线排序问题[J]. 计算机集成制造系统,2019,25(7):1685-1694. GAN Yawen,HOU Liang,XU Changhua,et al. Sequencing for bus mixed-model assembly line with consideration of product switching[J]. Computer Integrated Manufacturing Systems,2019,25(7):1685-1694.
[16] 谢志强,常宁宁,杨静. 基于交货期紧迫度的综合调度算法[J]. 机械工程学报,2011,47(22):181-190. XIE Zhiqiang,CHANG Ningning,YANG Jing. Integrated scheduling algorithm based on delivery dates urgency degree[J]. Journal of Mechanical Engineering,2011,47(22):181-190.
[17] 王艳红,于宁,蔡明,等. 动态制造系统生产计划与调度协同优化[J]. 中国机械工程,2018,29(22):125-129. WANG Yanhong,YU Ning,CAI Ming,et al. Collaborative optimization of dynamic manufacturing production planning and scheduling[J]. China Mechanical Engineering,2018,29(22):125-129.
[18] CHANG P T,LIN K P. Ant colony optimization system for a multi-quantitative and qualitative objective job-shop parallel machine scheduling problem[J]. International Journal of Production Research,2009,46(20):5719-5759.
[19] AZIZOGLU M. Scheduling jobs on unrelated parallel machines to minimize regular total cost functions[J]. IIE Transactions,2002,31(2):153-159.
[20] 戴隆州,吴永明,李少波,等. 多目标粒子群算法在混装线再平衡中的应用[J]. 计算机应用研究,2018,35(1):145-149. DAI Longzhou,WU Yongming,LI Shaobo,et al. Multi-objective particle swarm algorithm in mixed-model assembly line rebalancing[J]. Application Research of Computers,2018,35(1):145-149.
[21] HUANG M,GUO Q,LIU J,et al. Mixed model assembly line scheduling approach to order picking problem in online supermarkets[J]. Sustainability,2018,10(11):1-16.
[22] KUCUKKOC I,ZHANG D Z. Mixed-model parallel two-sided assembly line balancing problem:A flexible agent-based ant colony optimization approach[J]. Computers & Industrial Engineering,2016,97(16):58-72.
[23] ZHOU F,JIAO R J,LEI B. Bilevel game-theoretic optimization for product adoption maximization incorporating social network effects[J]. IEEE Transactions on Systems,Man,and Cybernetics:Systems,2015,46(8):1047-1060.
[24] 刘炜琪,刘琼,张超勇,等. 基于混合粒子群算法求解多目标混流装配线排序[J]. 计算机集成制造系统,2011,17(12):2590-2598. LIU Weiqi,LIU Qiong,ZHANG Chaoyong,et al. Hybrid particle swarm optimization for multi-objective sequencing problem in mixed model assembly lines[J]. Computer Intergrated Manufacturing Systems,2011,17(12):2590-2598.
[25] JOAQUÍN B,CANO A. Solving mixed model sequencing problem in assembly lines with serial workstations with work overload minimisation and interruption rules[J]. European Journal of Operational Research,2011,210(3):495-513.
[26] AITZAI A,BENMEDJDOUB B,BOUDHAR M. A branch and bound and parallel genetic algorithm for the job shop scheduling problem with blocking[J]. International Journal of Operational Research,2012,14(3):343-365.
[27] 郑永前,王永生,于胜男. 实时负荷条件下混流装配线平衡方法研究[J]. 现代制造工程,2010(12):66-72. ZHENG Yongqian,WANG Yongsheng,YU Shengnan. Mixed-model assembly line balancing based on realtime load[J]. Modern Manufacturing Engineering,2010(12):66-72.
[28] 姜静,谭博学,姜琳. 基于改进自适应遗传算法的仿真研究[J]. 山东理工大学学报,2008,22(6):10-13. JIANG Jing,TAN Boxue,JIANG Lin. Simulation analysis based on improved self-adaptive genetic algorithm[J]. Journal of Shandong University of Technology,2008,22(6):10-13.
[29] 李玲玉,郭亚军,易平涛. 无量纲化方法的选取原则[J]. 系统管理学报,2016,25(6):1040-1045. LI Lingyu,GUO Yajun,YI Pingtao. Analyzing the principles for choosing dimensionless methods[J]. Journal of Systems & Management,2016,25(6):1040-1045.
[30] 王炳刚. 混流加工/装配系统集成优化研究[J]. 机械工程学报,2010,46(17):118-126. WANG Binggang. Research on integrated optimization for mixed-model fabrication/assembly systems[J]. Journal of Mechanical Engineering,2010,46(17):118-126.