CN103955766B - Prevention and maintenance associated scheduling optimization method of large-batch customization production system - Google Patents
Prevention and maintenance associated scheduling optimization method of large-batch customization production system Download PDFInfo
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Abstract
The invention discloses a prevention and maintenance associated scheduling optimization method of a large-batch customization production system. The method includes the steps that prevention and maintenance time interval output by an equipment layer is obtained in real time according to a random production plan issued by a market orientation order; delay of balance scheduling is adopted in advance for a system layer, a production conversion opportunity is dynamically used, and cost balance prioritization is carried out in real time; the prevention and maintenance work lead cost balance and work delay cost balance are calculated and compared, so that a maintenance dual-pendulum optimization decision is made; the combination prevention and maintenance result of the system layer is fed back to the equipment layer, a maintenance decision of a next cycle is planned, and a real-time, effective, economical and feasible associated optimization decision-making plan is dynamically and circularly provided. According to the prevention and maintenance associated scheduling optimization method of the large-batch customization production system, through balance maximization of the overall system maintenance cost, prominent economic benefits are brought to the large-batch customization production system of modern manufacturing enterprises.
Description
Technical field
The present invention relates to the planing method of the production schedule and maintenance measures technical field, specifically a kind of mass customization life
The method of the preventive maintenance cooperative scheduling optimization of product system.
Background technology
As market competition is increasingly fierce, in current manufacturing change development, mass customization is advanced as one kind
Production model is used widely.Customized mass production system is by different type multiple devices according to the product of diversified batch
Technological process and configure establishment, support enterprise to adapt to new market and social demand.For this kind of production system carry out production with
The research of Coordination Decision is safeguarded, the preventive maintenance dynamic dispatching optimization method that stochastic production drives is proposed, can ensure that batch is raw
The quality stability of product, improves the healthy reliability of individual device, reduces the maintenance totle drilling cost of production system.
The chance maintenance strategy that traditional many preventive maintenance of equipment optimizing schedulings are driven using upkeep operation mostly.Existing skill
In art, often through the time at equal intervals, just line period preventive maintenance is entered in unification to fixed cycle system entirety maintaining method, ignores life
Produce the respective fade characteristics of devices in system.The preventive maintenance demand of mass customization should mutually be cooperateed with stochastic production planning,
If there is the stability that product quality can be more affected during production batch in preventive maintenance.Liu is in international high level paper
“Three m-failure group maintenance models for M/M/N unreliable queuing
service systems”(《Computers&Industrial Engineering》62nd phase volume 4 in 2012,1011-
Page 1024) in the equipment fault number of units that proposes in system reach the strategy that predetermined value then drives into group maintenance.Scarf is in the world
High-level paper " Hybrid block replacement and inspection policies for a multi-
component system with heterogeneous component lives”(《European Journal of
Operational Research》Volume 2,384-394 page of 206th phase in 2010) in propose a kind of modified batch replacement
Optimized Operation strategy.But above two method have ignored the production model feature of mass customization and the equipment of series-parallel system
Health characteristic, it is impossible to be applied to the actual maintenance plateform system towards mass customization.
Additionally, planning as a whole in system layer in the planing method for integrate the production schedule and maintenance measures, Mellouli is directed to two
Identical device, in international high level paper " Identical parallel-machine scheduling under
availability constraints to minimize the sum of completion times”(《European
Journal of Operational Research》Volume 3,1150-1165 page of 197th phase in 2009) in propose according to most
Regular improved heuristic maintenance schedule method of short process time.But the maintenance scheme that the method is generated is only oriented to active/standby devices system
System, faces number of devices increase and causes amount of calculation to be difficult to effective decision-making when exponentially increasing again, it is impossible to overcome and combine stochastic production
Caused decision-making complexity rises after plan, it is difficult to be applied to the Customized mass production system being made up of different type multiple devices
The actual maintenance optimizing scheduling of system.
The content of the invention
The present invention ignores Mass Customization Production Mode feature and causes for traditional many preventive maintenance of equipment optimizing schedulings
Frequent shutdown, and the deficiency of the production schedule and maintenance optimization shortage Coordination Decision, there is provided a kind of Customized mass production system
The method of the preventive maintenance cooperative scheduling optimization of system.
A kind of method of the preventive maintenance cooperative scheduling optimization of the Customized mass production system provided according to the present invention, bag
Include following steps：
The first step：From the beginning of first maintenance period i=1, individual device in production system is obtained in real time from mechanical floor
Preventive maintenance time interval, and assess jth platform equipment Mj, j=1,2 ..., J, original planning prevention time point；
Second step：The first random Batch orders of market orientation are obtained, from the beginning of first production cycle u=0, inspection is
It is no to there is equipment MjScheduled for carrying out preventive maintenance operation during the production batch；
3rd step：Preventive maintenance operation, all of preventive maintenance operation is not arranged all should before first production cycle
Delayed to after the completion of first production batch, for next production cycle u+1, updated system layer production switch instant and each
The planning prevention time point of platform equipment；
4th step：Maintenance time is checked, i.e., whenever the completion of production batch, the production cycle of a new batch order
TBu+1When being given, individual device is criticized with the presence or absence of the original preventive maintenance time point of mechanical floor in new production in inspection system
Secondary period；
5th step：Cost surplus preferentially, originally between production batch safeguarded, then divided by the arbitrary equipment even in system
The cost impact that the double pendulum scheduling decision of analysis preventive maintenance brings, calculates respectively preventive maintenance operation anticipated cost surplus and operation
Cost surplus is delayed, cost balance result obtained by Dynamic comparison in advance or delays the preventive maintenance operation of equipment；
6th step：Time updates and feedback, i.e., for next production cycle u+1, in the scheduling of system layer interaction optimizing
Update production batch BuProduction conversion opportunity afterwards, and the planning prevention for updating individual device is obtained according to mechanical floor program results
Maintenance time point；
7th step：Assign with follow-up random Batch orders dynamic circulation, going back to the 4th step carries out maintenance time inspection,
In the 5th step by cost surplus preferentially, short Interval Decision Making system layer safeguards double pendulum Optimized Operation, and in the 6th step mechanical floor
Update and feedback with the real-time retention time in the information exchange of system layer, so realize that circulation is progressive, fabricating U life
Produce in the lifetime of system of batch, reduce adjusting the system maintenance totle drilling cost of cooperative scheduling optimization scheme.
Preferably, in the first step, the original preventive maintenance time interval of individual device is the maintenance by mechanical floor
Plan model is calculated and obtained, and is increased with the equipment enlistment age and is gradually successively decreased.Maintenance system foreground shows software for LABVIEW, backstage
Planning software used is MATLAB.
Preferably, in the second step, production conversion opportunity of the random Batch orders between batch is just obtained in real time, at random
The production cycle length of Batch orders is according to changes in market demand.
Preferably, in the 5th step, cost surplus preferentially APB (Advance-postpone balancing, prolong in advance
Balancing afterwards) numerical value deducts operation and delays cost surplus SPC, SCA, SPC this two for preventive maintenance operation anticipated cost surplus SCA
Transfer each self-contained shutdown conversion cost surplus item of cost surplus, light maintenance operating cost surplus item, preventive maintenance operating cost knot
Remainder.Cost surplus calculating analysis preferentially software used is MATLAB.
Preferably, in the 6th step, the reality for safeguarding plan model foundation system layer optimizing scheduling decision-making of mechanical floor
Maintenance period feeds back, and plans new preventive maintenance time interval.Maintenance system foreground shows software for LABVIEW, maintenance measures
The software used with result transmission is MATLAB.
Preferably, in the 7th step, system maintenance totle drilling cost by produce conversion cost rate, preventive maintenance operating cost,
Light maintenance operating cost is constituted.The software that the calculating analysis of system maintenance totle drilling cost is used is MATLAB, and system layer optimizing scheduling is tied
The software that fruit shows is LABVIEW.
Because the production conversion opportunity in Mass Customization Production Mode can cause potential combination to safeguard chance, therefore this
The output of bright package layer preventive maintenance time interval and market orientation the random order production schedule, using production conversion
Opportunity safeguards chance as combination, and by real-time cost surplus effective maintenance of Customized mass production system is preferentially realized
Reduce with cost, even if number of devices increase, order are continually, still ensure that the response of many plant maintenance method for optimizing scheduling
Agility.
The present invention compared to existing technology, with following technical characterstic：
The system layer preventive maintenance cooperative scheduling optimization scheme that the present invention is generated, can consider the life of mass customization
The equipment health characteristic of pattern feature and series-parallel system is produced, traditional maintaining-managing system is improved and is ignored mass customization life
Producing pattern feature causes frequent shutdown and the production schedule-maintenance optimization to lack the deficiency of Coordination Decision.Simultaneously as the production schedule
Optimize with the real-time collaborative of preventive maintenance, it is ensured that the surplus of system overall maintenance cost is maximized, contribute to modern manufacturing enterprise
Industry formulates the preventive maintenance operation of economical rationality, with important engineering practical value.
Specifically, the technological means that the present invention is adopted includes：
Institute's extracting method of the present invention incorporates the production schedule and safeguards information requirement of both planning, interaction transmission production letter
The short range optimization decision-making mode of dynamic circulation is supported in breath data oam flow inter-area traffic interarea, practice, adopts proposed life
The cost impact that the chance strategy for driving is brought with the double pendulum scheduling decision of preventive maintenance in planning system layer is produced, in analysis system
The maintenance of individual device shifts to an earlier date and the respective cost surplus of maintenance delays, implements to produce in batches with this and the collaboration of preventive maintenance is excellent
Change scheduling, realize that the cost surplus of each production cycle is maximized using the collaboration Optimal Decision-making of dynamic circulation, reach batch raw
Product system overall maintenance cost is significantly reduced.
Technical problem solved by the invention is as follows：
(1) the order volume randomness technical problem of batch production：Customized mass production is directly led by market demand,
Discrete, independence and randomness is presented between each batch order, in order to improve the response agility of maintenance optimization strategy, the present invention
Institute's extracting method follows " short range optimization principle ", solves ordering for the competitive environment medium quantity batch processing that production feature constantly shortens
Single amount randomness technical problem.
(2) the double pendulum scheduling decision technical problem of preventive maintenance：The present invention incorporates what the production of production schedule proposition drove
Chance strategy, the maintenance of individual device in analysis system shifts to an earlier date and the respective cost surplus of maintenance delays, by proposing into
This surplus preferentially technology, chance is safeguarded by the use of production conversion opportunity as combination, and conventional maintenance operation single pendulum dispatching method is drilled
It has been melted into double pendulum method for optimizing scheduling.
(3) the dimension calamity complexity technical problem of Coordination Decision：The present invention analyses in depth the system layer production schedule and safeguards
The synergy of planning, constrains by decision-making of the production schedule, and to safeguard Optimized Approaches are planned to, and is changed using the production of between-lot
On opportunity, carry out cost surplus preferentially in real time, realize to dynamic circulation system layer Coordination Decision, solve traditional mode of production and safeguard association
With the dimension calamity complexity technical problem of decision-making.
More specifically, the technique effect that the present invention is obtained is as follows：
The method of the preventive maintenance cooperative scheduling optimization of Customized mass production system proposed by the present invention, by real-time
Cost surplus preferentially significantly reduces the system maintenance totle drilling cost of batch production systems, and efficiently solves the dimension of Coordination Decision
A calamity complexity difficult problem.Even if production equipment quantity increase, Batch orders continually in the case of, still can effectively instruct
Manufacturing enterprise implements the preventive maintenance operation of batch production systems, it is ensured that the response agility of collaboration optimisation strategy.
Description of the drawings
The detailed description by reading non-limiting example made with reference to the following drawings, the further feature of the present invention,
Objects and advantages will become more apparent upon：
Fig. 1 is driving mechanism flow process of the production schedule to maintenance schedule in the system layer of maintenance platform system；
The preventive maintenance cooperative scheduling optimization flow process that Fig. 2 drives for the system layer production of maintenance platform system.
Specific embodiment
With reference to specific embodiment, the present invention is described in detail.Following examples will be helpful to the technology of this area
Personnel further understand the present invention, but the invention is not limited in any way.It should be pointed out that the ordinary skill to this area
For personnel, without departing from the inventive concept of the premise, some deformations and improvement can also be made.These belong to the present invention
Protection domain.
The Customized mass production system for being constituted with seven equipment connection in series-parallel of certain hydraulic transmission manufacturing enterprise below
As a example by be specifically described, but protection scope of the present invention is not limited to following embodiments.
Specifically include following step：
The first step：From the beginning of first maintenance period i=1, individual device in production system is obtained in real time from mechanical floor
Preventive maintenance time interval, and assessment equipment MjOriginal planning prevention time point.During the original preventive maintenance of individual device
Between interval be to calculate to obtain by the maintenance plan model of mechanical floor, increase with the equipment enlistment age and gradually successively decrease.Before maintenance system
Platform shows that software is LABVIEW, and planning software used in backstage is MATLAB.
Second step：Obtain first random Batch orders (the production batch B of market orientation1Production cycle TB1).From first
Individual production cycle u=0 starts (tb0=0), check for equipment Mj(j=1,2 ..., J) scheduled in the production batch
Period carries out preventive maintenance operation.Random production conversion opportunity of the Batch orders between batch is just obtained in real time, its production cycle
Length is according to changes in market demand.
3rd step：Preventive maintenance operation, all of preventive maintenance operation is not arranged all should before first production cycle
Delayed to after first production batch completion.For next production cycle u=u+1, system layer production switch instant is updated
Planning with individual device prevents time point.
4th step：Maintenance time is checked, i.e., whenever the completion of production batch, the production cycle of a new batch order
TBu+1When being given, individual device is criticized with the presence or absence of the original preventive maintenance time point of mechanical floor in new production in inspection system
Secondary period.The production schedule is as shown in Figure 1 to the driving mechanism flow process of maintenance schedule in the system layer of maintenance platform system.
5th step：Cost surplus preferentially, originally between production batch safeguarded, then divided by the arbitrary equipment even in system
The cost impact that the double pendulum scheduling decision of analysis preventive maintenance brings, calculates respectively preventive maintenance operation anticipated cost surplus and operation
Cost surplus is delayed, cost balance result obtained by Dynamic comparison in advance or delays the preventive maintenance operation of equipment.Cost surplus
The software used by calculating analysis preferentially is MATLAB.Preferentially APB numerical value is preventive maintenance operation anticipated cost knot to cost surplus
Remaining (SCA) deducts preventive maintenance operation and delays cost surplus (SPCj(u+1)), transfer each self-contained shutdown of cost surplus for this two and turn
Change this surplus item, light maintenance operating cost surplus item, preventive maintenance operating cost surplus item into.Make cdjRepresent that cost is shut down in production
Rate, csjRepresent production conversion cost rate, TpijThe preventive maintenance activity duration is represented,Represent the preventive maintenance that mechanical floor is cooked up
Time interval, tbuRepresent the production switch instant of system layer, tijThe original planning preventive maintenance time point of expression equipment, CpijTable
Show the cost of preventive maintenance operation, CfijRepresent the cost of light maintenance operation：
APBj(u+1)=SCAj(u+1)-SPCj(u+1)
Wherein, SCAj(u+1)For preventive maintenance operation anticipated cost surplus, SPCj(u+1)Cost is delayed for preventive maintenance operation
Surplus, APBj(u+1)To delay balance numerical value in advance,dRepresent and shut down conversion cost surplus item,fRepresent light maintenance operating cost knot
Remainder,pRepresent preventive maintenance cost surplus item, λij(t) be equipment failure rate function, tbu+1When changing for system layer production
Carve；
6th step：Time updates and feedback, i.e., for next production cycle u=u+1, in the scheduling of system layer interaction optimizing
Middle renewal production batch BuProduction conversion opportunity afterwards, and it is pre- according to the planning of mechanical floor program results acquisition renewal individual device
Anti- maintenance time point.Maintenance system foreground shows that software is LABVIEW, and maintenance measures and result transmission software used is
MATLAB.The actual maintenance periodic feedback for safeguarding plan model foundation system layer optimizing scheduling decision-making of mechanical floor, plans new
Preventive maintenance time is spaced.Preventive maintenance cooperative scheduling optimization flow process such as Fig. 2 that the system layer production of maintenance platform system drives
It is shown.
7th step：Assign with follow-up random Batch orders dynamic circulation, going back to the 4th step carries out maintenance time inspection；
In the 5th step by cost surplus preferentially, short Interval Decision Making system layer safeguards double pendulum Optimized Operation；And the 6th step mechanical floor-
The real-time retention time updates and feedback in the information exchange of system layer；So realize that circulation is progressive, is fabricating U production
In the lifetime of system of batch, reduce adjusting the system maintenance totle drilling cost of cooperative scheduling optimization scheme.System maintenance totle drilling cost is by giving birth to
Produce conversion cost rate, preventive maintenance operating cost, light maintenance operating cost composition.Used by the calculating analysis of system maintenance totle drilling cost
Software is MATLAB, and the software that system layer optimizing scheduling result shows is LABVIEW.
Preferentially result is as shown in table 1 for the cost surplus of system layer series production batch.
System layer series production batch B1 of table 1, B2 ..., the cost surplus of B10 preferentially result
The double pendulum prioritization scheme of system layer preventive maintenance cooperative scheduling is as shown in table 2.
The double pendulum prioritization scheme of the system layer preventive maintenance cooperative scheduling of table 2
Wherein, TpumaxMost long operation duration in safeguard combination of sets, Y represents putting maintenance into practice operation ,-represent and treat next
Cycle result Shared Decision Making.
The specific embodiment of the present invention is described above.It is to be appreciated that the invention is not limited in above-mentioned
Particular implementation, those skilled in the art can within the scope of the claims make various modifications or modification, this not shadow
Ring the flesh and blood of the present invention.
Claims (6)
1. a kind of method of the preventive maintenance cooperative scheduling optimization of Customized mass production system, it is characterised in that including following
Step：
The first step：From the beginning of first maintenance period i=1, the pre- of individual device in production system is obtained in real time from mechanical floor
Anti- maintenance time interval, and assess jth platform equipment Mj, j=1,2 ..., J, original planning prevention time point；
Second step：The first random Batch orders of market orientation are obtained, from the beginning of first production cycle u=0, is checked whether and is deposited
In equipment MjScheduled for carrying out preventive maintenance operation during the production batch；
3rd step：Do not arrange preventive maintenance operation, all of preventive maintenance operation all should to be prolonged before first production cycle
Afterwards to after first production batch completion, for next production cycle u+1, update system layer production switch instant and Ge Tai sets
Standby planning prevention time point；
4th step：Maintenance time is checked, i.e., whenever the completion of production batch, the production cycle TB of a new batch orderu+1
When being given, individual device whether there is the original preventive maintenance time point of mechanical floor in the new production batch phase in inspection system
Between；
5th step：Cost surplus preferentially, originally between production batch safeguarded by the arbitrary equipment even in system, then analyze pre-
The cost impact that the double pendulum scheduling decision of anti-maintenance brings, calculates preventive maintenance operation anticipated cost surplus and operation is delayed respectively
Cost surplus, cost balance result obtained by Dynamic comparison in advance or delays the preventive maintenance operation of equipment；
6th step：Time updates and feedback, i.e., for next production cycle u+1, update in the scheduling of system layer interaction optimizing
Production batch BuProduction conversion opportunity afterwards, and the planning preventive maintenance for updating individual device is obtained according to mechanical floor program results
Time point；
7th step：Assign with follow-up random Batch orders dynamic circulation, going back to the 4th step carries out maintenance time inspection, the
In five steps by cost surplus preferentially, short Interval Decision Making system layer safeguards double pendulum Optimized Operation, and the 6th step mechanical floor be
In real time the retention time updates and feedback in the information exchange of system layer, so realizes that circulation is progressive, is fabricating U production batch
In secondary lifetime of system, reduce adjusting the system maintenance totle drilling cost of cooperative scheduling optimization scheme.
2. the method for the preventive maintenance cooperative scheduling optimization of Customized mass production system according to claim 1, it is special
Levy and be, in the first step, the original preventive maintenance time interval of individual device is the maintenance plan model by mechanical floor
Calculate and obtain, increase with the equipment enlistment age and gradually successively decrease.
3. the method for the preventive maintenance cooperative scheduling optimization of Customized mass production system according to claim 1, it is special
Levy and be, in the second step, production conversion opportunity of the random Batch orders between batch is just obtained in real time, random Batch orders
Production cycle length according to changes in market demand.
4. the method for the preventive maintenance cooperative scheduling optimization of Customized mass production system according to claim 1, it is special
Levy and be, in the 5th step, preferentially APB numerical value deducts prevention to cost surplus for preventive maintenance operation anticipated cost surplus SCA
Upkeep operation delays cost surplus SPC, SCA, SPC this two transfer each self-contained shutdown conversion cost surplus item of cost surplus,
Light maintenance operating cost surplus item, preventive maintenance operating cost surplus item.
5. the method for the preventive maintenance cooperative scheduling optimization of Customized mass production system according to claim 1, it is special
Levy and be, in the 6th step, the actual maintenance cycle for safeguarding plan model foundation system layer optimizing scheduling decision-making of mechanical floor
Feedback, plans new preventive maintenance time interval.
6. the method for the preventive maintenance cooperative scheduling optimization of Customized mass production system according to claim 1, it is special
Levy and be, in the 7th step, system maintenance totle drilling cost is by producing conversion cost rate, preventive maintenance operating cost, light maintenance operation
Cost is constituted.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN104680315B (en) * | 2015-02-12 | 2018-01-02 | 上海交通大学 | Ports handling machine intelligence preventative maintenance system and method based on bounding theory |
| CN104680251B (en) * | 2015-02-12 | 2017-11-28 | 上海交通大学 | Consider the harbour facilities intelligence preventative maintenance system and method for external environment influence |
| US20190050773A1 (en) * | 2016-02-12 | 2019-02-14 | Honda Motor Co., Ltd. | Production facility investment planning assistance system and commodity production system |
| CN106094757B (en) * | 2016-07-15 | 2018-12-21 | 郑州航空工业管理学院 | A kind of dynamic flexible solving job shop scheduling problem control method based on data-driven |
| CN110084401B (en) * | 2019-03-21 | 2021-04-23 | 中车工业研究院有限公司 | Scheduling optimization method and device based on reserved maintenance time |
| CN110865617B (en) * | 2019-11-14 | 2022-11-04 | 东华大学 | Equipment opportunity maintenance and production scheduling integrated optimization method under time-varying working condition |
| CN113408750A (en) * | 2021-05-18 | 2021-09-17 | 同济大学 | Opportunity maintenance method of serial production system based on energy-saving time window |
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| CN103106543A (en) * | 2013-01-29 | 2013-05-15 | 上海交通大学 | Method of dynamic interaction preventive maintenance planning of equipment level and system level of production system |
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| CN103106543A (en) * | 2013-01-29 | 2013-05-15 | 上海交通大学 | Method of dynamic interaction preventive maintenance planning of equipment level and system level of production system |
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| 《Hybrid block replacement and inspection policies for a multi-component system with heterogeneous component lives》;Philip A.Scarf等;《European Journal of Operational Research》;20101231;第2卷(第206期);正文第384-394页 * |
| 《Identical parallel-machine scheduling under availability constraints to minimize the sum of completion times》;Racem Mellouli等;《European Journal of Operational Research》;20091231;第3卷(第197期);正文第1150-1165页 * |
| 《Three m-failure group maintenance models for M/M/N unreliable queuing service systems》;Gia-Shie Liu;《Computers & Industrial Engineering》;20121231;第4卷(第62期);正文第1011-1024页 * |
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