CN111898998A - Production line optimization method and device based on buffer area capacity and process beat - Google Patents
Production line optimization method and device based on buffer area capacity and process beat Download PDFInfo
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Abstract
The application discloses a production line optimization method and device based on buffer area capacity and process beat, wherein the production line optimization method comprises the following steps: constructing a production line simulation model; determining a bottleneck process; matching each process beat according to the relation between the production line balance rate and each process beat; and setting buffer areas before and after the bottleneck process to form a process optimization key section, and calculating the optimal capacity value of the capacity of the buffer areas. By constructing a production line simulation model and combining process beat optimization and buffer area capacity optimization, the influence of various conditions influencing the production efficiency on the production line efficiency is eliminated, and the production line efficiency can be effectively improved. In addition, the production efficiency of the production line is improved by improving the flow control method, the existing production line equipment does not need to be greatly modified by hardware, the optimization modification cost is low, and the method has a good application prospect.
Description
Technical Field
The invention belongs to the technical field of automatic production lines, and relates to a production line optimization method and device based on buffer area capacity and process beats.
Background
The industrial automatic production line has important significance in an automatic factory, and a good automatic production line can improve the production efficiency, increase the product benefit and reduce the production cost. The existing automatic production lines still have the problems of low equipment utilization rate, low production efficiency and blockage of production logistics, and the problems restrict the further development of the automatic production of enterprises. Under the increasingly intense market competition environment, the automatic production line has a set of more excellent automatic production lines, can improve the production efficiency and reduce the production cost, and has a better dominant position in the market competition.
The existing automatic production line optimization method generally adopts the following two modes: 1) the automatic production line is optimized by changing decision parameters, increasing the number of devices and comprehensively adjusting the uniform processing time distribution. 2) The sum of idle time and overload time of stations on the production line is controlled to be minimum by changing the production line rhythm, so that the station utilization rate is maximized. The two production line optimization methods improve the production efficiency of the production line, but the influence of equipment faults, personnel operation time change and other reasons on the production line is not considered, and the problems that the production line efficiency is improved to a limited extent after optimization still exist.
Aiming at the problems that the efficiency of the production line is possibly influenced by equipment faults, personnel operation time changes and the like in the production line, a production line optimization method based on the capacity of the buffer area is gradually developed, and the capacity of the buffer area between two levels is calculated according to the relation between the availability of the two levels of serial production lines and the capacity of the buffer area. The existing method for calculating the capacity of the buffer area provides a relation between the availability of the serial production line and the capacity of the buffer area:
wherein A is the availability of the two-stage serial production line; lambda [ alpha ]1，λ2The failure rates of front and rear two devices of the two-stage serial production line are respectively set; mu.s1，μ2Respectively the repair rates of front and rear two devices of the two-stage serial production line; omega1，ω2The productivity of two devices in front of and behind the two-stage serial production line respectively; k is the capacity of the buffer in the two-stage serial production line. However, the above method of calculating the buffer capacity is complicated. Due to the multiple parameters, the calculation accuracy is limited and the calculation amount is large.
Disclosure of Invention
Aiming at the problems in the prior art, the invention aims to provide a buffer area capacity and beat-based optimization method and device for an automatic production line, which combine the advantages of the optimization of the beats of each process and the capacity of the buffer area of the production line, are suitable for the actual working conditions of the automatic production line, and can greatly improve the efficiency of the automatic production line.
In order to achieve the above object, a first aspect of the present invention provides a production line optimization method based on buffer capacity and process tact, comprising the steps of:
1) constructing a production line simulation model, and substituting the production constraint and production parameters of the production line into the simulation model;
2) setting production parameters of simulation operation according to a production plan and a production shift of a production line, operating a simulation model, and determining a bottleneck process according to the balance rate of the production line;
3) matching each process beat according to the relation between the production line balance rate and each process beat;
4) setting buffer zones before and after the bottleneck process to form a process optimization key section, and according to the fault rates lambda of two devices before and after the process optimization key sectioni，λi+1And the productivity omega of two devices before and after the key stage of process optimizationi，ωi+1And determining the functional relationship between the availability A of the procedure optimization key section and the capacity K of the buffer area in the procedure optimization key section, and further obtaining the optimal capacity value of the capacity K of the buffer area in the procedure optimization key section.
Optionally, the production line optimization method further includes substituting the process tempo and the buffer capacity after the optimization in steps 3) and 4) into the simulation model, and modifying the bottleneck process and the buffer capacity of the simulation model according to the simulation result.
Optionally, the building of the production line simulation model includes building a simulation model of a processing device and a logistics system of the production line according to the process flow and the factory layout of the production line.
Optionally, step 3) includes: adjusting the production beat of each device of the production line according to a calculation formula of the balance rate of the production line;
wherein, Sigma TiIs the sum of the beats of each process, n is the total number of work positions, TmaxIs the beat of the bottleneck process.
Optionally, the availability a of the process optimization key segment and the buffer capacity K in the process optimization key segment satisfy the following functional relation:
wherein λ isiOptimizing the failure rate, λ, of upstream equipment in a critical section for a processi+1Optimizing the failure rate, omega, of downstream equipment in the critical section for a processiOptimizing the production rate, omega, of upstream equipment in the critical section for a processi+1The productivity of downstream equipment in the critical section is optimized for the process, and K is the capacity of the buffer in the critical section.
Another aspect of the present invention provides a production line optimizing apparatus based on buffer capacity and tempo, comprising:
the construction module is used for constructing a production line simulation model and substituting the production constraint and the production parameters of the production line into the simulation model;
the bottleneck procedure determining module is used for setting production parameters of simulation operation according to a production plan and a production shift of a production line, operating a simulation model and determining a bottleneck procedure according to the balance rate of the production line;
the process beat optimization module is used for matching each process beat according to the relation between the production line balance rate and each process beat;
a buffer area capacity optimizing module for setting buffer areas before and after the bottleneck process to form a process optimizing key section, and according to the fault rates lambda of two devices before and after the process optimizing key sectioni，λi+1And the productivity omega of two devices before and after the key stage of process optimizationi，ωi+1Determining the functional relationship between the availability A of the procedure optimization key section and the capacity K of the buffer area in the procedure optimization key section,and further obtaining the optimal capacity value of the buffer capacity K in the process optimization key section.
Optionally, the process beat optimizing module includes:
the calculation submodule is used for calculating the balance rate of the production line according to the sum of the process beats, the total number of work digits and the beat of the bottleneck process;
and the beat matching submodule is used for matching the beats of each process according to the comparison result of the balance rate of the production line and the preset value of the balance rate.
Optionally, the buffer capacity optimizing module includes:
a key section construction submodule for setting buffer areas before and after the bottleneck process to form a process optimization key section;
a calculation submodule for optimizing the failure rate lambda of two devices before and after the key section according to the working procedurei，λi+1Productivity omegai，ωi+1And determining the functional relationship between the availability A of the procedure optimization key section and the capacity K of the buffer area in the procedure optimization key section, and further obtaining the optimal capacity value of the capacity K of the buffer area in the procedure optimization key section.
Through the above description, the technical scheme provided by the application can at least realize the following beneficial effects:
by constructing a production line simulation model and combining process beat optimization and buffer area capacity optimization, the influence of various conditions influencing the production efficiency on the production line efficiency is eliminated, and the production line efficiency can be effectively improved. In addition, the production efficiency of the production line is improved by improving the flow control method, the existing production line equipment does not need to be greatly modified by hardware, the optimization modification cost is low, and the method has a good application prospect.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the invention and together with the description, serve to explain the principles of the invention.
FIG. 1 is a schematic flow chart of a process line optimization method based on buffer capacity and tempo provided in an embodiment of the present application;
FIG. 2 is a schematic view of a production line after adding a buffer as provided in one embodiment of the present application;
FIG. 3 is a schematic illustration of a critical section of process optimization in a production line provided in one embodiment of the present application;
FIG. 4 is a graphical illustration of the availability A of the process optimization key segment as a function of buffer capacity K, as provided in one embodiment of the present application;
FIG. 5 is a schematic diagram of a production line optimization apparatus based on buffer capacity and tempo according to an embodiment of the present application;
fig. 6 is a schematic structural diagram of a process beat optimization module provided in an embodiment of the present application;
fig. 7 is a schematic structural diagram of a buffer capacity optimization module provided in an embodiment of the present application.
Detailed Description
Reference will now be made in detail to the exemplary embodiments, examples of which are illustrated in the accompanying drawings. When the following description refers to the accompanying drawings, like numbers in different drawings represent the same or similar elements unless otherwise indicated. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present invention. Rather, they are merely examples of apparatus and methods consistent with certain aspects of the invention, as detailed in the appended claims.
As shown in fig. 1, the method for optimizing a production line based on buffer capacity and process tact of the present invention comprises the following steps:
s11: constructing a production line simulation model, and substituting the production constraint and production parameters of the production line into the simulation model; wherein, the production line Simulation model can be constructed by using software such as Plant Simulation and the like;
s21: setting production parameters of simulation operation according to a production plan and a production shift of a production line, operating a simulation model, and determining a bottleneck process according to the balance rate of the production line;
s31: matching each process beat according to the relation between the production line balance rate and each process beat;
s41: setting buffer zones before and after the bottleneck process to form a process optimization key section, and according to the fault rates lambda of two devices before and after the process optimization key sectioni，λi+1And the productivity omega of two devices before and after the key stage of process optimizationi，ωi+1And determining the functional relationship between the availability A of the procedure optimization key section and the capacity K of the buffer area in the procedure optimization key section, and further obtaining the optimal capacity value of the capacity K of the buffer area in the procedure optimization key section. The buffer areas are arranged before and after the bottleneck process, so that the problems of unsmooth production line logistics and low equipment utilization rate caused by production stagnation of the production line due to equipment failure can be solved, the production line with the added buffer areas is shown in figure 2, wherein Bi represents equipment of each process, and Mi represents the buffer areas. For convenience of research, two process buffer areas before and after the bottleneck process are separated to form a key section for analysis and research, the key section is shown in fig. 3, wherein Bi represents bottleneck process equipment, Mi represents a buffer area arranged at the upstream of the bottleneck process, and Mi +1 represents a buffer area arranged at the downstream of the bottleneck process.
Optionally, the production line optimization method further includes substituting the process tact and the buffer capacity optimized in steps S31 and S41 into the simulation model, modifying the bottleneck process and the buffer capacity of the simulation model according to the simulation result, further optimizing the simulation model, and performing multiple modification and optimization on the simulation model to obtain a simulation model with optimal production efficiency of the production line, thereby providing an optimized process control method for the actual production of the production line.
Optionally, the building of the production line simulation model includes building a simulation model of a processing device and a logistics system of the production line according to the process flow and the factory layout of the production line.
Optionally, step S31 includes: adjusting the production beat of each device of the production line according to a calculation formula of the balance rate of the production line;
wherein, Sigma TiIs the sum of the beats of each process, n is the total number of work positions, TmaxIs the beat of the bottleneck process. The production line balance rate can be calculated through the formula, and then whether the beats of all working procedures in the current state are matched can be determined according to the comparison result of the calculated production line balance rate and the preset balance rate, for example, when the P is more than or equal to 90 percent, the production line balance is excellent and 80 percent<P<When 90% is found to indicate that the line balance is good, the tact of each step in the above two states may not be adjusted. If P is less than or equal to 80 percent, the balance of the production line is poor, and the beat sum sigma T of each procedure needs to be adjustediOr the tempo of the bottleneck process TmaxAnd recalculating the balance rate of the production line until the balance rate of the production line is more than 80%. In order to improve the balance rate of the production line, the sum sigma of the beats of each procedure can be increasediOr reducing the tact of a bottleneck processmaxAnd carrying out matching optimization on the production beat. In this embodiment, the preset value of the balance rate of the production line is set to three states, however, the present invention is not limited to this, and the number of states and the specific value range of the preset value of the balance rate of the production line can be adjusted accordingly according to the needs of the actual production line.
The optimal production beat can be selected for each equipment by optimizing and matching the production beats of each equipment according to the formula, so that the production efficiency of the whole production line is improved.
Optionally, the availability a of the process optimization key segment and the buffer capacity K in the process optimization key segment satisfy the following functional relation:
wherein λ isiOptimizing the failure rate, λ, of upstream equipment in a critical section for a processi+1Optimizing the failure rate, omega, of downstream equipment in the critical section for a processiOptimizing the production rate, omega, of upstream equipment in the critical section for a processi+1Production of downstream equipment in critical section for process optimizationThe rate, K, is the capacity of the buffer in the critical section of process optimization. The availability calculation formula in this embodiment eliminates a parameter of the equipment repair rate that has almost no influence on the production line efficiency, on one hand, saves a large amount of statistical workload for determining the parameter, and on the other hand, reduces the inaccuracy in availability calculation caused by the error in the parameter statistics, thereby causing the inaccuracy in the calculation of the capacity value of the buffer area to cause a larger error. The optimal capacity of the buffer is obtained by using the functional relationship a ═ f (K) between the availability a of the key segment and the capacity K of the buffer, which means that the availability a hardly changes with the change of K after the value of K is a certain value, and the value of K is the optimal capacity value of the buffer. The usability function curve a ═ f (k) is shown in fig. 4.
As shown in fig. 5, the production line optimizing apparatus based on buffer capacity and tempo of the present invention comprises:
the construction module 10 is used for constructing a production line simulation model and substituting the production constraint and the production parameters of the production line into the simulation model;
a bottleneck procedure determining module 20, configured to set production parameters for simulation operation according to a production plan and a production shift of the production line, operate a simulation model, and determine a bottleneck procedure according to a production line balance rate;
a process tempo optimization module 30 for matching each process tempo according to a relationship between the production line balance rate and each process tempo;
a buffer area capacity optimizing module 40, configured to set buffer areas before and after the bottleneck process to form a process optimization key section, and according to the failure rates λ of two devices before and after the process optimization key sectioni，λi+1And the productivity omega of two devices before and after the key stage of process optimizationi，ωi+1And determining the functional relationship between the availability A of the procedure optimization key section and the capacity K of the buffer area in the procedure optimization key section, and further obtaining the optimal capacity value of the capacity K of the buffer area in the procedure optimization key section.
Optionally, the process beat optimizing module 30 includes:
the calculating submodule 301 is used for calculating the balance rate of the production line according to the sum of the process beats, the total number of work digits and the beat of the bottleneck process;
and the beat matching submodule 302 is used for matching the beats of each process according to the comparison result of the balance rate of the production line and the preset value of the balance rate.
The specific manner in which the calculation sub-module 301 calculates the line balance rate and the beat matching sub-module 302 matches the beats of each process has been described in detail in the above embodiment of the line optimization method, and is not described herein again.
Optionally, the buffer capacity optimizing module 40 includes:
a key section construction submodule 401, configured to set buffer areas before and after the bottleneck process to form a process optimization key section;
a calculation submodule 402 for optimizing the failure rate lambda of two devices before and after the key section according to the processi，λi+1Productivity omegai，ωi+1And determining the functional relationship between the availability A of the procedure optimization key section and the capacity K of the buffer area in the procedure optimization key section, and further obtaining the optimal capacity value of the capacity K of the buffer area in the procedure optimization key section.
The specific way of calculating the optimal capacity value of the buffer capacity K by the calculating submodule 402 has been described in detail in the above embodiment of the production line optimization method, and is not described herein again.
Generally, compared with the prior art, the above technical solution conceived by the present invention mainly has the following technical advantages:
1. according to the invention, through an improved scheme of constructing a simulation model, combining with beat matching improvement and arranging buffer areas in front of and behind a blocked node, the factors which influence the production efficiency in a complex way are eliminated, and the purpose of optimizing the production efficiency is achieved.
2. According to the technical scheme, the production efficiency of the automatic production line is improved by improving the process control method, and the method does not need to carry out large hardware modification on the existing equipment, so that the method has the advantage of low modification cost and has a good application prospect.
Further, the buffer capacity calculation formula introduced in the background art has the following problems:
(1) the failure rate, the repair rate and the production rate in the formula are subject to exponential distribution, but in practical application, the statistics of the parameters requires the collection of a large number of samples, and the workload is large.
(2) In the availability calculation process, certain errors exist in the determination of the independent variable fault rate, the repair rate and the productivity, and the availability result with larger errors can be obtained after the multiple error variables are subjected to mathematical operation. However, in the calculation of the set buffer in the present invention, the calculation formula of the availability is as follows:
the availability calculation formula eliminates the parameter of the equipment repair rate, on one hand, a large amount of statistical workload for determining the parameter is saved, and on the other hand, the reduced calculation result has larger availability errors caused by the error of the parameter.
A program product for implementing the above method according to an exemplary embodiment of the present disclosure is described, which may employ a portable compact disc read only memory (CD-ROM) and include program code, and may be run on a terminal device, such as a personal computer. However, the program product of the present disclosure is not limited thereto, and in this document, a readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
The program product may employ any combination of one or more readable media. The readable medium may be a readable signal medium or a readable storage medium. A readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any combination of the foregoing. More specific examples (a non-exhaustive list) of the readable storage medium include: an electrical connection having one or more wires, a portable disk, a hard disk, a Random Access Memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing.
A computer readable signal medium may include a propagated data signal with readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated data signal may take many forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. A readable signal medium may also be any readable medium that is not a readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
Program code embodied on a readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
Program code for carrying out operations for the present disclosure may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, C + + or the like and conventional procedural programming languages, such as the "C" programming language or similar programming languages. The program code may execute entirely on the user's computing device, partly on the user's device, as a stand-alone software package, partly on the user's computing device and partly on a remote computing device, or entirely on the remote computing device or server. In the case of a remote computing device, the remote computing device may be connected to the user computing device through any kind of network, including a Local Area Network (LAN) or a Wide Area Network (WAN), or may be connected to an external computing device (e.g., through the internet using an internet service provider).
Furthermore, the above-described figures are merely schematic illustrations of processes included in methods according to exemplary embodiments of the present disclosure, and are not intended to be limiting. It will be readily understood that the processes shown in the above figures are not intended to indicate or limit the chronological order of the processes. In addition, it is also readily understood that these processes may be performed synchronously or asynchronously, e.g., in multiple modules. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. This application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
It will be understood that the invention is not limited to the precise arrangements described above and shown in the drawings and that various modifications and changes may be made without departing from the scope thereof. The scope of the invention is limited only by the appended claims.
Claims (8)
1. The production line optimization method based on the capacity of the buffer area and the process beat is characterized by comprising the following steps of:
1) constructing a production line simulation model, and substituting the production constraint and production parameters of the production line into the simulation model;
2) setting production parameters of simulation operation according to a production plan and a production shift of a production line, operating a simulation model, and determining a bottleneck process according to the balance rate of the production line;
3) matching each process beat according to the relation between the production line balance rate and each process beat;
4) setting buffer zones before and after the bottleneck process to form a process optimization key section, and according to the fault rates lambda of two devices before and after the process optimization key sectioni，λi+1And the productivity omega of two devices before and after the key stage of process optimizationi，ωi+1And determining the functional relationship between the availability A of the procedure optimization key section and the capacity K of the buffer area in the procedure optimization key section, and further obtaining the optimal capacity value of the capacity K of the buffer area in the procedure optimization key section.
2. The line optimization method of claim 1, further comprising:
and (4) substituting the optimized process rhythm and buffer area capacity of the steps 3) and 4) into the simulation model to optimize and modify the bottleneck process and buffer area capacity of the simulation model.
3. The line optimization method of claim 1, wherein said constructing a line simulation model comprises constructing a simulation model of processing equipment and logistics systems of a production line according to a process flow and a plant layout of said production line.
4. The line optimization method of claim 1, wherein step 3) comprises: adjusting the production beat of each device of the production line according to a calculation formula of the balance rate of the production line;
wherein P is the balance rate of production line, Sigma TiIs the sum of the beats of each process, n is the total number of work positions, TmaxIs the beat of the bottleneck process.
5. The line optimization method according to claim 1, wherein the availability a of the process optimization key and the buffer capacity K in the process optimization key satisfy the following functional relationship:
wherein, A is the availability of a key section of the process optimization, lambdaiOptimizing the failure rate, λ, of upstream equipment in a critical section for a processi+1Optimizing the failure rate, omega, of downstream equipment in the critical section for a processiOptimizing the production rate, omega, of upstream equipment in the critical section for a processi+1The productivity of downstream equipment in the critical section is optimized for the process, and K is the capacity of the buffer in the critical section.
6. Production line optimizing apparatus based on buffer capacity and process beat, its characterized in that includes:
the construction module is used for constructing a production line simulation model and substituting the production constraint and the production parameters of the production line into the simulation model;
the bottleneck procedure determining module is used for setting parameters of simulation operation according to a production plan and a production shift of the production line, operating a simulation model and determining a bottleneck procedure according to the balance rate of the production line;
the process beat optimization module is used for matching each process beat according to the relation between the production line balance rate and each process beat;
a buffer area capacity optimizing module for setting buffer areas before and after the bottleneck process to form a process optimizing key section, and according to the fault rates lambda of two devices before and after the process optimizing key sectioni，λi+1And the productivity omega of two devices before and after the key stage of process optimizationi，ωi+1And determining the functional relationship between the availability A of the procedure optimization key section and the capacity K of the buffer area in the procedure optimization key section, and further obtaining the optimal capacity value of the capacity K of the buffer area in the procedure optimization key section.
7. The line optimizer of claim 6, wherein the beat optimizer module comprises:
the calculation submodule is used for calculating the balance rate of the production line according to the sum of the process beats, the total number of work digits and the beat of the bottleneck process;
and the beat matching submodule is used for matching the beats of each process according to the comparison result of the balance rate of the production line and the preset value of the balance rate.
8. The line optimization device of claim 6, wherein the buffer capacity optimization module comprises:
a key section construction submodule for setting buffer areas before and after the bottleneck process to form a process optimization key section;
a calculation submodule for optimizing the failure rate lambda of two devices before and after the key section according to the working procedurei，λi+1Productivity omegai，ωi+1And determining the functional relationship between the availability A of the procedure optimization key section and the capacity K of the buffer area in the procedure optimization key section, and further obtaining the optimal capacity value of the capacity K of the buffer area in the procedure optimization key section.
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