CN105045236B - A kind of production line balance dispatching method and system - Google Patents
A kind of production line balance dispatching method and system Download PDFInfo
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Abstract
The invention discloses a kind of production line balance dispatching method and system, including scheduling, tracking, feedback and adjusting stage；The scheduling stage refers to obtain production streamline site configuration and production process information, formation original allocation suggestion；Tracking phase obtains production line balance data in real time, and the working ability of each website on streamline is weighed based on dependency analysis；Feedback stage refers to based on the above-mentioned analysis to website working ability, delivery amount as defined in interior complete can be expected according to current production allocative decision in defined delivery by predicting, website processing tasks are coordinated using the method for feedback control, generation production adjustment suggestion, feedback control streamline resource and site configuration；The production that adjusting stage refers to be obtained according to feedback stage, which adjusts, to be suggested, the circulation of adjustment production line material and the distribution of process website.The present invention can the planning of science activities production schedule, scheduling manufacturing resources configuration ensure process inside and process between balance.
Description
Technical Field
The invention relates to a method and a system for scheduling production of a production line, which are used for coordinating the scheduling and the configuration of resources on the production line and belong to the technical field of intelligent control of the production line.
Background
The production process of the clothes and home textile enterprises, especially the clothes enterprises, which are typical labor-intensive industries, has the following characteristics: (1) Organizing production activities around the customer order, with the specification, quantity, delivery date, etc. of the product determined according to the customer order, thus presenting an order priority issue; (2) The styles are various, and the processing and the manufacturing are carried out according to a certain process flow; (3) One or more processes can be completed by the same production equipment, but some special processes can only be produced by specific production equipment; (4) The operation of workers can not be separated in the production process, the working efficiency of each worker is different, the number of the working procedures is different from the working hours required by each working procedure, and the production balance is difficult to guarantee.
The individuation and diversification of consumer demands lead to the fact that customer orders are more and more characterized by multiple varieties, small batch and short delivery period. Under the market environment, the characteristics of clothes and home textile production enable how to schedule and organize the production of each order to shorten the production period of products and maximize the production profit to become the key points of attention of manufacturing enterprises, and the simultaneous online production of multiple tasks becomes an effective measure for coping with diversified and urgent orders. In the prior art, in order to avoid production conflicts, process insides and imbalance among processes possibly caused by multi-task production, a single-task production mode is usually adopted, namely, production of another batch of products is put into production after a batch of product production tasks are completed or are about to be completed, the production conflict problem is solved to a certain extent, but the balance problem of the processes is still not properly solved, the whole production time is prolonged, part of equipment is possibly in an idle state, the production efficiency is low, and the production flexibility of enterprises cannot be improved.
Disclosure of Invention
The invention aims to: aiming at the problems and the defects in mixed flow production of clothing and home textile manufacturing enterprises, the invention provides a flow line production scheduling method and a flow line production scheduling system.
The technical scheme is as follows: a flow line production scheduling method comprises four stages of scheduling, tracking, feedback and adjustment.
The scheduling stage is to acquire the station configuration of the product production line and the information of the product production process to form an initial distribution suggestion; the process information must include information that can feed back the complexity of the process, such as process length information; the processing time of the procedures is an important index for generating an initial distribution suggestion, and the number of required work stations must be judged according to the specific processing time of each procedure when the initial distribution suggestion is generated so as to ensure the balance among the procedures. The longer the processing time of the working procedure is, i.e. the more complicated the working procedure is, more stations should be allocated theoretically to avoid the situation of no material processing in the subsequent working procedure.
The tracking stage is to acquire production data of the production line in real time through the Internet of things technologies such as identification labels and sensors, track the processing condition of products being processed on the production line and the processing condition of each worker, and analyze and measure the processing capacity of each station on the production line based on the dependency relationship. The dependency relationship mainly refers to a dependency relationship between processes. Between processes which have interdependencies and do not have workpieces in stock, the processing speed of workers at the station of the next process is limited by the processing speed of workers at the station of the previous process, that is, the processing condition of the next process depends on the completion condition of the previous process.
The feedback stage is to predict that the specified delivery amount can be completed within the specified delivery expectation according to the current production allocation scheme based on the analysis of the station processing capacity, and coordinate the station processing task by adopting a feedback control method to generate a production adjustment suggestion. The feedback stage specifically includes: acquiring real-time production data of a tracking stage and task data of a scheduling stage; acquiring historical processing data of workers at the assembly line station; analyzing the data by using an artificial intelligence algorithm to obtain the working procedure processing efficiency of workers, and obtaining the evaluation of the station processing capacity based on historical data; and (3) measuring and calculating the production trend (progress) in the current production configuration mode according to the station processing capacity evaluation, comparing the current actual production condition with the current production trend, finding out deviation, finding out a bottleneck process or a conflict process possibly existing in future production, drafting an adjustment measure, generating a production adjustment suggestion, and feeding back control pipeline resources and station configuration.
The adjusting stage is used for adjusting the material flow of the production line and the distribution of the process stations according to the production adjusting suggestion obtained in the feedback stage. Optionally, the user may suggest a specific allocation scheme for manually adjusting the staff and the site according to the production adjustment generated in the feedback stage, thereby avoiding the production of a production bottleneck process, reducing the degree of dependence on professional skills or experiences of managers such as a group leader, and improving the production accuracy. Optionally, for the assembly line with the automatic material conveying device, the flow of the materials can be intelligently controlled by the scheduling system according to the production adjustment suggestion, the station allocation of the task process can be changed, the generation of bottleneck processes or conflict processes can be avoided, and the production efficiency can be improved.
In addition, the invention also provides a scheme of the pipeline scheduling system. The scheduling system can be used for scientific scheduling and scheduling balance of tasks, tracking the processing condition of the assembly line tasks and performing feedback control, ensuring the production balance inside the processes and among the processes, avoiding the generation of bottleneck processes or conflict processes and improving the flexibility and intelligence of production. The scheduling system may specifically include: the device comprises a data acquisition module, a data storage module, a processing and analyzing module and a scheduling and executing module.
The data acquisition module is used for obtaining assembly line and processing task information, specifically includes: task delivery date, processing quantity, process information, assembly line station configuration information and station worker processing data; and identifying real-time production data uploaded by terminal equipment such as a tag, a reader-writer and a counting sensor.
The processing and analyzing module is connected with the data acquisition module through the data storage module and specifically comprises a preprocessing module, an initial distribution module and a production adjustment module. The initial allocation module utilizes the acquired information to produce an initial allocation suggestion of a processing station of an order product; the production adjusting module measures the processing capacity of each station by using the processing data of assembly line workers, finds conditions possibly causing production bottlenecks through comparative analysis of predicted trends and actual conditions, and dynamically adjusts a production allocation strategy.
The scheduling execution module is connected with the processing analysis module, and executes the production scheduling scheme according to the scheduling mode, and specifically comprises: the method comprises the following steps that (1) manual scheduling is conducted, a scheduling module pushes information such as production distribution suggestions and production adjustment suggestions obtained by a processing module to a mobile terminal, and corresponding managers change a production scheme according to the information; and (3) in the mode (2), intelligently scheduling, wherein the scheduling module controls the automatic material conveying device according to the processing module result, sends the workpiece to a specified station for processing, and executes a production change scheme.
Has the advantages that: compared with the prior art, the assembly line production scheduling method and the scheduling system provided by the invention can support multi-task simultaneous online production according to the balance of actual production guarantee and maximization of efficiency of manufacturing enterprises, and can provide task initial allocation and production adjustment scheduling services. The production capacity of the production line is analyzed and predicted based on the dependency relationship, and the production allocation strategy is timely adjusted by adopting a feedback control method, so that the production conflict and the imbalance of the working procedures are avoided under the condition of expecting delivery of each processing task, the production period of the product is shortened, and the production flexibility and the overall production efficiency are improved.
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FIG. 1 is a schematic flow chart of a production scheduling method according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a production scheduling system according to an embodiment of the present invention;
FIG. 3 is a flow chart of a process of the process analysis module according to an embodiment of the present invention.
Detailed Description
The present invention is further illustrated by the following examples, which are intended to be purely exemplary and are not intended to limit the scope of the invention, as various equivalent modifications of the invention will occur to those skilled in the art upon reading the present disclosure and fall within the scope of the appended claims.
The flow line production scheduling method comprises four stages of scheduling, tracking, feeding back and adjusting. Specifically, with reference to fig. 1, in the scheduling stage, the process information of the product to be processed and the configuration information of the assembly line stations are utilized to generate an initial allocation suggestion of a station task on the basis of the maximum user configuration information such as the number of processes that can be accepted by each station; the tracking stage is used for tracking the processing condition of the product being processed on the production line and the processing condition of each worker in real time by using the technology of the Internet of things, and providing data support for the production adjustment suggestion in the feedback stage; in the feedback stage, a feedback control theory is used for predicting the production trend, finding bottleneck processes which may appear in the future production and locations of the bottleneck processes, and drawing up production adjustment measures; the adjusting stage is a process of executing the changed production scheme and feeding back according to different scheduling modes.
The design and production process of the products of manufacturing enterprises such as clothes, home textiles and the like follow a certain production flow, different products to be processed consist of different process sequences, and the same production equipment at the bottom layer can complete processing tasks of multiple processes. The following describes the pipeline production scheduling system provided by the present invention with reference to fig. 2.
In this embodiment, a clothing hanging production line is taken as an example for explanation, and then the scheduling system of the present invention is a clothing production scheduling system, and is an online production scheduling balancing system for realizing different orders and different styles of products, so as to ensure the balance inside and among the processes and avoid the bottleneck process. This production scheduling system includes: the system comprises a data acquisition module E1, a data storage module E2, a processing and analyzing module E3 and a scheduling execution module E4.
And the data acquisition module E1 is used for acquiring and receiving information.
In particular, the data acquisition module E1 relates to a data acquisition device P101. The data acquisition device P1 is arranged on each station of the production line, and each station is provided with a production device and can be used for finishing the processing tasks of one or more working procedures. The data acquisition device P101 specifically includes:
an identification tag, preferably an RFID identification tag in this embodiment, disposed on the workpiece or the workpiece transport device for uniquely identifying the workpiece, tracking the workpiece;
the reader-writers are arranged at all stations of the production line, preferably RFID readers in the embodiment and used for reading label information, identifying the workpiece and realizing tracking and positioning of the production flow of the workpiece together with the identification labels;
optionally, the system further comprises a counting sensor arranged at each station of the production line and used for counting the processing number of workers at the station;
optionally, the system further comprises an inductive switch arranged in front of the station buffer area, and the inductive switch is used for counting the number of the workpieces to be processed at the station.
Further, the data acquisition module E1 is configured with a communication module P102 and provides an interface for communicating with other information systems, so as to obtain order task information and pipeline configuration information.
And the processing and analyzing module E3 is connected with the data acquisition device E1 through the data storage module E2 and is used for processing data and analyzing the production process to form an intelligent optimization suggestion for the flow line production.
Specifically, the process analysis module E3 includes a preprocessing module P301, an initial allocation module P302, and a production adjustment module P303. The preprocessing module P301 is used for preprocessing the original data acquired by the acquisition module E1 for improving the data quality, and mainly refers to performing vacancy value filling by methods of replacing vacancy values by global variables or extracting data required for filling vacancies from related information, and performing data cleaning operations such as dirty data cleaning by methods of searching numerical value abnormal records by using probability statistics, and the like; the initial allocation module P302 is a pipeline station initial allocation suggestion generated by using the pipeline station configuration information and the process information of the to-be-processed style, and provides a basis for order scheduling, thereby reducing the degree of dependence on experience; the production adjusting module P303 analyzes and predicts the production trend through the dependency relationship, finds the production bottleneck and the leading factors which may exist in the future production by adopting a feedback control method, draws up a generation distribution adjusting strategy and generates a production adjusting suggestion.
And the scheduling execution module E4 is connected with the processing analysis module E3 and is used for executing the obtained intelligent optimization suggestion and ensuring production balance. The scheduling execution module E4 provides 2 scheduling modules, which specifically include: (1) In the manual scheduling mode, the scheduling execution module E4 pushes production optimization information such as production allocation suggestions and production adjustment suggestions obtained by the processing analysis module E3 to the mobile terminal, and a corresponding management terminal equipment owner adjusts allocation of sites and circulation of materials among the sites according to the production field condition and executes a change scheme; the mobile terminal is preferably a handset, a mobile phone or a tablet and the like, and is convenient to carry; (2) And in an intelligent scheduling mode, a scheduling execution module E4 adjusts the circulation of materials by controlling an automatic material transmission device according to the production adjustment suggestion obtained by a processing analysis module E3, and automatically executes a production change scheme.
Further, the processing flow of the processing analysis module E3 is described with reference to fig. 3. After acquiring the procedure information of the style, the processing and analyzing module E3 first needs to perform task determination, that is, determines whether the style generates an initial allocation suggestion (new task) or a production adjustment suggestion (execution task);
further, the processing flow of different tasks in corresponding modules is described with reference to fig. 1.
The new task is processed by the initial allocation module P302, and the scheduling stage in step S1 in the scheduling method is executed, which specifically includes: executing S101, and acquiring process information of the styles to be processed and configuration information of the assembly line stations; executing S102, acquiring user configuration information, namely limitation made on process station allocation, such as maximum number of processing processes that can be accepted by a station, station starting state and the like; and S103, generating a proposal for the initial distribution of the to-be-processed style on the selected pipeline.
The above steps are further explained by taking the production and processing of the men's round-neck shirts as an example. Executing step S101, obtaining the process information of the style to be processed and the configuration information of the selected assembly line station, specifically comprising: the process information of the to-be-processed style is shown in the following table 1, and the process information at least comprises a process name, required processing equipment and processing duration, and is used for selecting stations and determining the number of stations used in the process; the configuration and the enabling conditions of the equipment of each station on the pipeline are shown in the following table 2;
TABLE 1 information table of the working procedure of the product to be processed
| Serial number | Name of procedure | Processing equipment | Length of processing (minutes) |
| 1 | Closing shoulder | Overedger | 2 |
| 2 | Rolling collar | Collar rolling machine | 1 |
| 3 | Rolling collar cloth joint | Lockstitch sewing machine | 1 |
| 4 | Sleeve stitching | Overedger | 2 |
| 5 | Sleeve and rib | Overedger | 2 |
| 6 | Sleeve edge and bottom hem | Edge folding and overedger | 2 |
| 7 | Finished product ironing | Manual operation | 3 |
| 8 | Examination of | Manual operation | 2 |
TABLE 2 pipeline site configuration information Table
| Type of processing equipment | Site numbering | Remarks for note |
| Overedger | Sites #1, #2, #5, #6, #7, #8, #9 | |
| Collar rolling machine | Site #3 | |
| Lockstitch sewing machine | Site #4 | |
| Manual operation platform | Sites #10, #11, #12,#13、#14 | Site #13 not available |
Executing S102, matching the production flow line for the task to be processed, and acquiring user configuration information about the flow line: for example, each station on the pipeline can be used, and each station can bear 3 processes at most; the matching principle comprises the following steps: (1) information of a task procedure to be processed; (2) pipeline station configuration information; (3) the current production task information of the assembly line; the method specifically comprises the following steps: selecting a candidate production line which is consistent with the process flow and the station configuration for the task to be processed according to the information (1) and the information (2); and preferentially selecting the production line with few tasks currently performed, or about to complete the old task, or with similar tasks as the production line of the task according to the information of the current production task of the candidate production line.
Step S103 is executed to generate an initial allocation suggestion table as shown in table 3 according to the production line selected in the foregoing step and the acquired process information of the to-be-processed style. The initial allocation proposal table is formed according to the following steps: (1) product process configuration; (2) site equipment configuration and enabling state; (3) the station can accept the process number configuration. The method specifically comprises the following steps: calculating and analyzing the number of the pipeline stations which can be used in each process and the corresponding serial numbers according to the process information (mainly referring to processing equipment) of the styles to be processed provided in the table 1 and the configuration information of the pipeline stations provided in the table 2; according to the process information (mainly referring to the process complexity, i.e., the process theoretical machining length information) of the to-be-machined style provided in table 1, the station state information configured by the user and the information of the maximum acceptable process quantity provided in step S102, the number of stations used in each process and the corresponding station number are reasonably distributed. On the basis of the suggestion, the user can arrange the personnel and the sites according to the actual situation of the production site of the production line.
TABLE 3 initial Allocation recommendation Table
| Serial number | Name of procedure | Available site numbering |
| 1 | Closing shoulder | 1,2 |
| 2 | Rolling collar | 3 |
| 3 | Rolling collar cloth joint | 4 |
| 4 | Sleeve stitching | 5,6 |
| 5 | Sleeve and rib | 6,7 |
| 6 | Sleeve edge and bottom hem | 8,9 |
| 7 | Finished product ironing | 10,11,12 |
| 8 | Examination of | 14 |
The execution task is processed by the production adjustment module P303, a production adjustment suggestion is generated for a style task that is being produced on the production line, the maximum production efficiency under the conditions of delivery expectation and completion amount of the style task is ensured, and the tracking and feedback stage in the execution scheduling method specifically includes:
and S2, executing a tracking stage, acquiring the real-time production data of the assembly line through the data acquisition module E1, preprocessing the real-time data through the preprocessing module P301, and analyzing the machining capacity of the station based on the dependency relationship and the statistical fluctuation theory, wherein the machining capacity of the station depends on the machining proficiency of the station workers on the types of the workpieces and the working efficiency. The dependency relationship mainly refers to the dependency relationship among the working procedures, and the processing condition of the subsequent working procedure depends on the completion condition of the previous working procedure; the statistical fluctuation means that the working efficiency of workers is statistically fluctuated.
The following model can be established:
i ∈ [1, M ]: the ith workpiece;
j is an element [1, N ]: a j-th step;
k: a kth process site;
t (i, j): the theoretical time consumption for finishing the jth procedure by the ith workpiece is consumed;
ST (i, j, k): starting the machining time of the ith workpiece on the kth station of the jth procedure; when j is larger than 1, the time depends on the finish machining time of the ith workpiece at the corresponding station of the j-1 procedure;
ET (i, j, k): finishing the machining time of the ith workpiece on the kth station of the jth procedure; the time depends on the processing speed of the kth station worker of the jth procedure, and the processing speed of the kth station worker is influenced by the processing speeds of the preorders 1-j-1 procedure workers due to the dependency relationship among the procedures;
PT (i, j, k): the processing time of the ith workpiece on the kth station of the jth procedure;
PC (i): in the production period of the ith workpiece, the process which consumes the longest time in the processing flow directly determines the production period of the workpiece;
count (j): the workpiece inventory allowance of the jth procedure is the number of workpieces which are processed in the jth procedure and are to enter the next procedure;
based on the interdependence relationship between the processes, it can be obtained that:
ST (i, j, k) = ST (i +1, j, k) + 1) = constant when j =1,i ∈ [1, M ];
when j belongs to (1, N, i belongs to [1, M ], defining that k is the kth station of the jth procedure, and k' is the kth station of the procedure related to the jth procedure when calculating the following values and is only used for distinguishing k;
ST(i,j,k)＝ET(i,j-1,k′)+count(j-1)×T(i,j)；
ET(i,j,k)＝ST(i,j,k)+PT(i,j,k)＝ET(i,j-1,k′)+count(j-1)×T(i,j)+PT(i,j,k)；
PT(i,j,k)＝ET(i,j,k)-ST(i,j,k)；
PC(i)＝ET(i,N,k′)-ST(i,1,k)；
to measure the processing capacity of the process station, define: e (k, s, j): the total number of the work pieces belonging to the task s completed by the kth site worker in the jth procedure can be obtained by counting the finishing time record of the work pieces belonging to the task s completed by the kth site worker in the jth procedure;
further, the method can be obtained as follows:
the kth station worker can finish the time consumption of the ith workpiece of the task in the jth procedure;
the processing capacity of the station k for processing the workpiece to which the task s belongs in the jth procedure is finished, namely the output of the task s on the jth procedure finished by a worker at the station k in unit time;
and (3) executing a step S3, namely a feedback stage, predicting the production condition under the current production allocation scheme based on the station processing capacity measurement in the step S2, dynamically adjusting a production allocation strategy by adopting a feedback control theory, coordinating all processing tasks on a production line, and avoiding the generation of bottleneck processes and conflict processes. Specifically, S3 may include the steps of:
executing S301, predicting a production trend under the current production distribution scheme according to the station processing capacity measurement data M (k, S, j) obtained in the step S2 and the statistical information count (j) of the inventory allowance of each process station, namely finding out processes and time points which may generate unbalance along with the change of the inventory of each workpiece along with the processing of each process station, and ensuring the balance among the processes;
defining: k is a proportionality coefficient of workpiece processing between adjacent working procedures; t is the unit time used for calculation; l is the upper limit proportionality coefficient of the output surplus in the working procedure; k (j) is the number of jth process stations;
the following can be obtained:
the processing capacities of the stations of the adjacent working procedures are matched with each other, namely the output of all the stations of the previous working procedure can meet the demand of all the stations of the next working procedure;
the output of the previous procedure is far larger than the demand of the next procedure, the capacity of the previous procedure is excessive, and a task production allocation strategy of a procedure site needs to be adjusted;
output of the previous processIf the quantity cannot meet the demand of the next procedure and the processing of the station of the next procedure is limited by the completion condition of the previous procedure, the task allocation of the station needs to be adjusted between the procedures with the dependency relationship, for example, the processing station can be added for the previous procedure, and the processing station of the next procedure can be reduced;
step S302 is executed, and in order to ensure the balance inside the process, the processing saturation of each station inside the process needs to be calculated, so as to adjust the distribution of tasks inside the process.
Process saturation of site k = (∑ m) i＝1 Theoretical time consumption (i，j) ) k /(∑ i＝1 Actual time consumption (i,j) ) k ；
If the station saturation value is less than 1, the speed of the station worker in the process j lags behind the average level; and if the station saturation value is not less than 1, indicating that the station worker can skillfully complete the processing task of the working procedure j, and if the saturation value is higher, proving that the processing speed of the worker is higher. On the premise of ensuring that the station output of which the station saturation value is not less than 1, the method can distribute processing tasks of other procedures for a worker of the station or share processing tasks of other stations with insufficient output in the same procedure, and ensures the balance in the procedures;
and executing S303, drawing up site production task adjustment measures, and generating a production adjustment suggestion.
The scheduling method and the scheduling system provided by the invention can scientifically plan production plan, schedule production resource allocation to ensure the balance inside and among procedures, and maximize production efficiency under the condition of ensuring expected delivery and completion quantity.
Claims (3)
1. A flow line production scheduling method is characterized by comprising four stages of scheduling production, tracking, feedback and adjustment;
the scheduling stage is to acquire the station configuration of the product production line and the information of the product production process to form an initial distribution suggestion; the process information must include process machining length information that can feed back the complexity of the process machining; the working procedure processing time length is an important index for generating an initial distribution suggestion, and the number of required working stations is determined according to the specific processing time length of each working procedure when the initial distribution suggestion is generated so as to ensure the balance among the working procedures;
the tracking stage is to acquire production data of the production line in real time through the Internet of things technologies such as identification labels and sensors, track the processing condition of products being processed on the production line and the processing condition of each worker, and analyze and measure the processing capacity of each station on the production line based on the dependence relationship; the dependency relationship mainly refers to the dependency relationship among the processes; between the processes which have interdependence relation and do not store workpieces, the processing speed of workers at the station of the next process is limited by the processing speed of workers at the station of the previous process, namely the processing condition of the next process depends on the completion condition of the previous process;
the feedback stage is to predict that the specified delivery amount can be completed within the specified delivery expectation according to the current production allocation scheme based on the analysis of the processing capacity of the station, coordinate the station processing task by adopting a feedback control method, generate a production adjustment suggestion, and feedback-control the assembly line resources and the station configuration;
the adjusting stage is used for adjusting the material flow of the production line and the distribution of the process stations according to the production adjusting suggestion obtained in the feedback stage;
the user can recommend the specific allocation scheme of manual adjustment personnel and sites according to the production adjustment generated in the feedback stage, so that the production bottleneck process is avoided; for the assembly line with the automatic material conveying device, the circulation of materials can be intelligently controlled by a scheduling system according to production adjustment suggestions, the station allocation of task procedures is changed, the generation of bottleneck procedures or conflict procedures is avoided, and the production efficiency is improved;
for the clothing production line scheduling stage of hanging, specifically include: executing S101, and acquiring process information of styles to be processed and assembly line station configuration information; executing S102, obtaining user configuration information, namely the limitation made on the distribution of the process station: the station can bear the number of processing procedures and the starting state of the station at most; executing S103, and generating a site initial distribution suggestion of the styles to be processed on the selected assembly line;
the execution task is processed by a production adjustment module, a production adjustment suggestion is generated aiming at the style task which is produced on the production line, the maximum production efficiency under the conditions of expected delivery and finished quantity of the style task is ensured, a tracking and feedback stage in the scheduling method is executed, and the tracking stage establishes the following model:
i ∈ [1, M ]: the ith workpiece;
j ∈ [1, N ]: the jth step;
k: the kth process site;
t (i, j): the theoretical time consumption for completing the jth procedure by the ith workpiece is consumed;
ST (i, j, k): starting the machining time of the ith workpiece on the kth station of the jth procedure; when j is larger than 1, the time depends on the finish machining time of the ith workpiece at the corresponding station of the j-1 procedure;
ET (i, j, k): finishing the machining time of the ith workpiece on the kth station of the jth procedure; the time depends on the processing speed of the kth station worker of the jth procedure, and the processing speed of the kth station worker is influenced by the processing speeds of the preorders 1-j-1 procedure workers due to the dependency relationship among the procedures;
PT (i, j, k): the machining time of the ith workpiece on the kth station of the jth procedure;
PC (i): in the production period of the ith workpiece, the process which consumes the longest time in the processing flow directly determines the production period of the workpiece;
count (j): the workpiece inventory allowance of the jth procedure is the number of workpieces which are processed in the jth procedure and are to enter the next procedure;
based on the interdependencies among the processes, it is possible to obtain:
ST (i, j, k) = ST (i +1, j, k) + 1) = constant when j =1,i ∈ [1, M ];
when j belongs to (1, N, i belongs to [1, M ], defining that k is the kth station of the jth procedure, and k' is the kth station of the procedure related to the jth procedure when calculating the following values and is only used for distinguishing k;
ST(i,j,k)＝ET(i,j-1,k′)+count(j-1)×T(i,j)；
ET(i,j,k)＝ST(i,j,k)+PT(i,j,k)＝ET(i,j-1,k′)+count(j-1)×T(i,j)+PT(i,j,k)；
PT(i,j,k)＝ET(i,j,k)-ST(i,j,k)；
PC(i)＝ET(i,N,k′)-ST(i,1,k)；
to measure the processing capacity of the process station, define: e (k, s, j): the total number of the work pieces belonging to the task s completed by the kth site worker in the jth procedure can be obtained by counting the finishing time record of the work pieces belonging to the task s completed by the kth site worker in the jth procedure;
further, the method can be obtained as follows:
the kth station worker can finish the time consumption of the ith workpiece of the task in the jth process;
the processing capacity of the station k for processing the workpiece to which the task s belongs in the jth procedure is finished, namely the output of the task s on the jth procedure finished by a worker at the station k in unit time;
a feedback stage, namely predicting the production condition under the current production allocation scheme based on the measurement of the processing capacity of the station in the tracking stage, dynamically adjusting a production allocation strategy by adopting a feedback control theory, coordinating each processing task on a production line and avoiding the generation of bottleneck procedures and conflict procedures; the method comprises the following steps:
executing S301, predicting a production trend under the current production distribution scheme according to the obtained station processing capacity measurement data M (k, S, j) and the statistical information count (j) of the inventory allowance of each process station, namely finding out processes and time points which may generate unbalance along with the processing of each process station and the change of the inventory of each workpiece, and ensuring the balance among the processes;
defining: a is a proportionality coefficient of workpiece processing between adjacent working procedures; t is the unit time used for calculation; l is the proportion coefficient of the excess upper limit produced in the working procedures; k (j) is the number of jth process stations;
the following can be obtained:
the processing capacities of the stations of the adjacent working procedures are matched with each other, namely the output of all the stations of the previous working procedure can meet the demand of all the stations of the next working procedure;
the output of the previous procedure is far larger than the demand of the next procedure, the capacity of the previous procedure is excessive, and a task production allocation strategy of a procedure site needs to be adjusted;
the output of the previous procedure cannot meet the demand of the next procedure, and the processing of the station of the next procedure is limited by the completion condition of the previous procedure, so that the task allocation of the station needs to be adjusted among the procedures with the dependency relationship;
executing S302, wherein in order to ensure the balance in the process, the processing saturation of each station in the process needs to be calculated, so as to adjust the distribution of tasks in the process;
process saturation of site k = (∑ m) i＝1 Theoretical time consumption (i,j) ) k /(∑ i＝1 Actual time consumption (i,j) ) k ；
If the station saturation value is less than 1, the speed of the station worker in the process j lags behind the average level; if the saturation value of the station is not less than 1, the station indicates that a worker can skillfully complete the processing task of the process j, and the higher the saturation value is, the faster the processing speed of the worker is proved to be; on the premise of ensuring that the station output of which the station saturation value is not less than 1, the method can distribute processing tasks of other procedures for a worker of the station or share processing tasks of other stations with insufficient output in the same procedure, and ensures the balance in the procedures;
and executing S303, drawing up site production task adjustment measures, and generating a production adjustment suggestion.
2. A pipeline scheduling system using the pipeline production scheduling method of claim 1, comprising: the system comprises a data acquisition module, a data storage module, a processing and analyzing module and a scheduling execution module;
the data acquisition module is used for acquiring the information of the assembly line and the processing task;
the processing and analyzing module is connected with the data acquisition module through the data storage module and specifically comprises a preprocessing module, an initial distribution module and a production adjustment module; the initial allocation module utilizes the acquired information to produce an initial allocation suggestion of a processing station of an order product; the production adjusting module is used for measuring the processing capacity of each station by using the processing data of assembly line workers, finding conditions possibly causing production bottlenecks through comparative analysis of predicted trends and actual conditions, and dynamically adjusting a production allocation strategy;
for a clothing hanging production line, an online production scheduling balance system for different orders and different styles of products is realized, the balance inside and among processes is ensured, and the bottleneck process is avoided; the data acquisition module is used for acquiring and receiving information; the data acquisition module relates to a data acquisition device; the data acquisition device is arranged on each station of the assembly line, and each station is provided with a piece of production equipment and can be used for completing the processing tasks of one or more working procedures; the data acquisition device specifically includes: the identification tag is arranged on the workpiece or the workpiece conveying device, is an RFID identification tag and is used for uniquely identifying the workpiece and tracking the workpiece; the reader-writers are arranged at all stations of the production line, are RFID readers and are used for reading label information, identifying the workpiece and realizing the tracking and positioning of the production flow of the workpiece together with the identification label; the counting sensor is arranged at each station of the production line and used for counting the processing number of workers at the station; the system also comprises an inductive switch arranged in front of the station buffer area and used for counting the number of the workpieces to be processed at the station; the data acquisition module is provided with a communication module and provides an interface for communicating with other information systems, and is used for acquiring order task information and assembly line configuration information;
the processing and analyzing module is connected with the data acquisition device through the data storage module and is used for processing data, analyzing the production process and forming an intelligent optimization suggestion for assembly line production; the processing and analyzing module E3 comprises a preprocessing module, an initial distribution module and a production adjusting module; the preprocessing module is used for preprocessing the original data acquired by the acquisition module for improving the data quality, and mainly comprises the steps of carrying out vacancy value filling by methods of replacing vacancy values by global variables or extracting data required for filling vacancies from related information, and the like, and carrying out data cleaning operations such as dirty data cleaning by methods of searching numerical value abnormal records and the like by using probability statistics, and the like; the initial distribution module is used for generating an initial distribution suggestion of the assembly line station by utilizing the configuration information of the assembly line station and the process information of the styles to be processed, providing a basis for order scheduling and reducing the dependence degree on experience; the production adjustment module analyzes and predicts the production trend through the dependence relationship, finds the production bottleneck and the leading factor which may exist in the future production by adopting a feedback control method, draws up a generation distribution adjustment strategy and generates a production adjustment suggestion;
the scheduling execution module is connected with the processing analysis module and is used for executing the obtained intelligent optimization suggestion to ensure production balance; the scheduling execution module provides 2 scheduling modules, which specifically include: (1) In the manual scheduling mode, the scheduling execution module pushes production optimization information such as production allocation suggestions and production adjustment suggestions obtained by the processing analysis module to the mobile terminal, and a corresponding management terminal equipment owner adjusts allocation of sites and circulation of materials among the sites according to the production allocation suggestions and the production adjustment suggestions and executes a change scheme by combining production field conditions; the mobile terminal is preferably a handset, a mobile phone or a tablet and the like, and is convenient to carry; (2) And in the intelligent scheduling mode, the scheduling execution module automatically executes a production change scheme by controlling the material automatic transmission device to adjust the circulation of the materials according to the production adjustment suggestion obtained by the processing analysis module.
3. The pipeline scheduling system of claim 2, wherein the information collected by the data collection module specifically includes: task delivery date, processing quantity, process information, assembly line station configuration information and station worker processing data; and identifying real-time production data uploaded by terminal equipment such as a tag, a reader-writer and a counting sensor.
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