CN117829823A - Repair assembly line optimization method and system meeting site constraint conditions - Google Patents
Repair assembly line optimization method and system meeting site constraint conditions Download PDFInfo
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Abstract
The invention discloses a repair assembly line optimization method and system meeting site constraint conditions, and belongs to the field of equipment maintenance optimization. The invention completes the average repair time of equipment with the same model in one batch by calculating the optimal process array corresponding to each possible module number of the repair pipeline and the corresponding repair pipeline; and determining an optimal process array corresponding to the shortest average repair time of the equipment with the same model in a batch completed by the repair pipeline, and taking the optimal process array as a repair pipeline optimization result meeting site constraint conditions. The invention not only meets the site constraint condition, but also saves time and rapidly completes the repair line of the repair task, and can rapidly and efficiently assist the repair line in optimizing design.
Description
Technical Field
The invention belongs to the field of equipment maintenance optimization, and particularly relates to a repair assembly line optimization method and system meeting site constraint conditions.
Background
Since repair personnel/facilities on a repair line can be in full-load operation without stopping, repair line modes are typically employed when a large number of equipment is being repaired in a short period of time and it is desired to complete as soon as possible. The repair line will hereinafter be referred to as repair line for short. In practical work, the field area of repair lines is often limited, and the repair lines belong to hard constraints which are not easy to break through.
When the repair process of the equipment is determined, further development of the design is required to convert it specifically into repair lines. For ease of description, the general convention is as follows: the repair processes of the apparatus are described in series and are numbered in a small to large order according to the order of repair, for example, process 2 can only be started after process 1 is completed. The repair line needs to embody the repair process of the equipment of the type and the repair process sequence must not be changed. The repair line consists of a plurality of modules, the modules are connected in series, each module can work simultaneously in a pipeline mode, and the interior of each module consists of a plurality of adjacent repair processes of the equipment. Because of the limited area of the field, repair processes inside the contract module cannot be performed simultaneously and can only be completed one by one. The floor area occupied by the module is equal to the maximum of the floor areas occupied by the processes within the module.
After knowing the repair process and the area occupied by each process, how to divide the process for each module of the repair line, the total area occupied by the repair line can not exceed the actual area of the field, and the repair task can be completed in as short a time as possible. This is a problem commonly encountered when designing repair lines. Currently, this repair process division problem is solved mainly by experience of designers in terms of repair process of the apparatus, repair line management, and the like. This design based on subjective experience of the designer, rather than the ubiquitous approach, makes it difficult to ensure that high quality repair lines are stably designed.
Disclosure of Invention
Aiming at the defects of the prior art, the invention aims to provide a repair pipeline optimization method and a repair pipeline optimization system meeting site constraint conditions, and aims to solve the problem that the existing method is difficult to guarantee stable design of a high-quality repair pipeline.
To achieve the above object, in a first aspect, the present invention provides a repair line optimization method satisfying site constraint conditions, the repair line being composed of a plurality of modules connected in series, each module being composed of a plurality of adjacent repair processes of an apparatus connected in series, different modules being capable of operating simultaneously in a pipelined manner, different repair processes within the same module operating in a numbered order, the method comprising:
acquiring the total area of an actual field which can be used by a repair assembly line, the number of repair processes related to equipment, the area of the field which is required to be occupied by each repair process, and the time average value and root variance of completing each process;
based on the data, calculating an optimal process array corresponding to each possible module number of the repair pipeline and the average repair time for the corresponding repair pipeline to finish a batch of equipment with the same model;
and determining an optimal process array corresponding to the shortest average repair time of the equipment with the same model in a batch completed by the repair pipeline, and taking the optimal process array as a repair pipeline optimization result meeting site constraint conditions.
Preferably, calculating an optimal process array corresponding to the current module number specifically includes:
generating a possible process array corresponding to the current module number in a traversing manner;
excluding possible process arrays that do not meet site constraints;
for each of the remaining possible process arrays, calculating the maximum value and the root variance of the characteristic values of the working intensity of each module of the corresponding repair pipeline, and respectively taking the maximum value and the root variance as a first characteristic value and a second characteristic value of the repair pipeline;
when only one minimum first characteristic value exists, the process array corresponding to the repair pipeline with the minimum first characteristic value is used as an optimal process array corresponding to the current module number, or when a plurality of minimum first characteristic values exist, the process array corresponding to the repair pipeline with the minimum first characteristic value and the second characteristic value simultaneously is used as an optimal process array corresponding to the current module number.
Preferably, the criteria meeting the site constraints are: and taking the maximum value of the field area required to be occupied by each repair process in the module as the field area occupied by the module, superposing the field area occupied by each module as the field area occupied by the whole repair assembly line, and if the field area is not more than the total field area of the practical field which can be used by the repair assembly line, determining that the field constraint condition is met.
Preferably, the operating strength characteristic of each module is the sum of the summations of the time averages of the processes in that module.
Preferably, under the condition of calculating an optimal process array corresponding to the current module number, the average repair time of the repair assembly line for completing one batch of equipment is calculated, and the method specifically comprises the following steps:
calculating the mean value and root variance of all the process time of each module;
according to the mean value and root variance of all the process time of each module, iteratively calculating the mean value and root variance of the repair time when the equipment leaves each module when the repair assembly line finishes repairing the equipment according to the sequence of the equipment in the batch;
when the repair pipeline finishes repairing the whole batch of equipment, the average repair time of the last equipment leaving the last module is taken as the average repair time of the repair pipeline finishing the batch of equipment.
Preferably, the average value of all the process time of each module is the sum of the sums of the time average values of all the processes in the module, and the root variance of all the process time of each module is 1/2 th power of the sum of the squares of the root variances of the time of each process of the module.
Preferably, the repair pipeline completes repair of the first device in the order of the devices in the lot, the device leaves the mean and root variance of the repair time for each module:
wherein,，/>for the current number of modules>And->Repair pipeline modules, respectively>Mean and root variance of all process times to complete it, < >>And->Respectively the current device leaving module->Time-to-repair mean and root variance of (c).
Preferably, the repair line completes the first in the order of the equipment in the batchWhen repairing individual devices, the device leaves the time-to-repair means and root variance of each module:
if it isThen
If it isThen
Wherein,，/>for the number of devices in a batch, +.>，/>For the current number of modules>Andrepair pipeline modules, respectively>Mean and root variance of all process times to complete it, < >>And->Respectively the previous device leaving module>Time-of-repair mean and root variance, +.>And->Respectively the current device leaving module->Time-to-repair mean and root variance of (c).
To achieve the above object, in a second aspect, the present invention provides a repair line optimization system satisfying site constraints, comprising: at least one memory for storing a program; at least one processor for executing the program stored in the memory, the processor being adapted to perform the method according to the first aspect when the program stored in the memory is executed.
To achieve the above object, in a third aspect, the present invention provides a computer-readable storage medium storing a computer program which, when run on a processor, causes the processor to perform the method according to the first aspect.
In general, the above technical solutions conceived by the present invention have the following beneficial effects compared with the prior art:
the invention provides a repair assembly line optimization method and a repair assembly line optimization system meeting site constraint conditions, which are used for calculating an optimal process array corresponding to each possible module number of a repair assembly line and the average repair time of finishing equipment of the same type in a batch by the corresponding repair assembly line; and determining an optimal process array corresponding to the shortest average repair time of the equipment with the same model in a batch completed by the repair pipeline, and taking the optimal process array as a repair pipeline optimization result meeting site constraint conditions. The invention not only meets the site constraint condition, but also saves time and rapidly completes the repair line of the repair task, and can rapidly and efficiently assist the repair line in optimizing design.
Drawings
FIG. 1 is a flow chart of a repair pipeline optimization method meeting site constraints, provided by the invention.
FIG. 2 is a schematic diagram of a repair process and repair line module according to an embodiment of the present invention.
FIG. 3 is a schematic distribution of repair time simulation results for all possible repair lines provided by an embodiment of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
As shown in fig. 1, the present invention provides a repair pipeline optimization method satisfying site constraint conditions, the repair pipeline is composed of a plurality of modules connected in series, each module is composed of a plurality of adjacent repair processes of equipment connected in series, different modules can work simultaneously in a pipeline manner, and different repair processes in the same module work according to a numbering sequence, the method comprises:
acquiring the total area of an actual field which can be used by a repair assembly line, the number of repair processes related to equipment, the area of the field which is required to be occupied by each repair process, and the time average value and root variance of completing each process;
based on the data, calculating an optimal process array corresponding to each possible module number of the repair pipeline and the average repair time for the corresponding repair pipeline to finish a batch of equipment with the same model;
and determining an optimal process array corresponding to the shortest average repair time of the equipment with the same model in a batch completed by the repair pipeline, and taking the optimal process array as a repair pipeline optimization result meeting site constraint conditions.
Preferably, calculating an optimal process array corresponding to the current module number specifically includes:
generating a possible process array corresponding to the current module number in a traversing manner;
excluding possible process arrays that do not meet site constraints;
for each of the remaining possible process arrays, calculating the maximum value and the root variance of the characteristic values of the working intensity of each module of the corresponding repair pipeline, and respectively taking the maximum value and the root variance as a first characteristic value and a second characteristic value of the repair pipeline;
when only one minimum first characteristic value exists, the process array corresponding to the repair pipeline with the minimum first characteristic value is used as an optimal process array corresponding to the current module number, or when a plurality of minimum first characteristic values exist, the process array corresponding to the repair pipeline with the minimum first characteristic value and the second characteristic value simultaneously is used as an optimal process array corresponding to the current module number.
Preferably, the criteria meeting the site constraints are: and taking the maximum value of the field area required to be occupied by each repair process in the module as the field area occupied by the module, superposing the field area occupied by each module as the field area occupied by the whole repair assembly line, and if the field area is not more than the total field area of the practical field which can be used by the repair assembly line, determining that the field constraint condition is met.
Preferably, the operating strength characteristic of each module is the sum of the summations of the time averages of the processes in that module.
Preferably, under the condition of calculating an optimal process array corresponding to the current module number, the average repair time of the repair assembly line for completing one batch of equipment is calculated, and the method specifically comprises the following steps:
calculating the mean value and root variance of all the process time of each module;
according to the mean value and root variance of all the process time of each module, iteratively calculating the mean value and root variance of the repair time when the equipment leaves each module when the repair assembly line finishes repairing the equipment according to the sequence of the equipment in the batch;
when the repair pipeline finishes repairing the whole batch of equipment, the average repair time of the last equipment leaving the last module is taken as the average repair time of the repair pipeline finishing the batch of equipment.
Preferably, the average value of all the process time of each module is the sum of the sums of the time average values of all the processes in the module, and the root variance of all the process time of each module is 1/2 th power of the sum of the squares of the root variances of the time of each process of the module.
Preferably, the repair pipeline completes repair of the first device in the order of the devices in the lot, the device leaves the mean and root variance of the repair time for each module:
wherein,，/>for the current number of modules>And->Repair pipeline modules, respectively>Mean and root variance of all process times to complete it, < >>And->Respectively the current device leaving module->Time-to-repair mean and root variance of (c).
Preferably, the repair line completes the first in the order of the equipment in the batchWhen repairing individual devices, the device leaves the time-to-repair means and root variance of each module:
if it isThen
If it isThen
Wherein,，/>for the number of devices in a batch, +.>，/>For the current number of modules>Andrepair pipeline modules, respectively>Mean and root variance of all process times to complete it, < >>And->Respectively the previous device leaving module>Time-of-repair mean and root variance, +.>And->Respectively the current device leaving module->Time-to-repair mean and root variance of (c).
Example 1
The relationship between repair process and module is represented by a process array (abbreviated as process array) of repair line, the number of elements of the process array is the number of modules, the firstThe individual element is->The last process number responsible inside the individual module. For example, FIG. 2 illustrates a process array [246 ]]Representative repair process versus repair line module. Art array [246 ]]Comprising 3 elements, means that the repair line consists of 3 modules, module 1 being responsible for completing repair process 1 and repair process 2, module 2 being responsible for completing repair process 3 and repair process 4, module 3 being responsible for completing repair process 5 and repair process 6.
The known information of the present embodiment includes: total area of field available for repair lineNumber of repair processes for the apparatus>Process->The requirement of occupying floor area->Complete the process->Time mean>Time root variance->，。
The embodiment provides a design method for optimizing a process array under the condition that site constraint conditions are met, so that the time for repairing a batch of equipment by a repair line is used for judging whether the repair line is good or not. The method comprises the following specific steps:
1) Obtaining the total area of the actual field where the repair line can be usedNumber of repair processes for the apparatus>Process->The requirement of occupying floor area->Complete the process->Time mean>Time root variance->Initializing the number of modules of the repair line。
2) Initializing a first criterionSecond criterion->Wherein->Representing infinity.
3) The number of the traversal generating modules is as followsRepair line process matrix at the time->。
Repair line process matrixColumn number = =>Number of lines = from->The number is selected from +.>Number of combinations, e.g.>=6，/>=3, then the number of rows=10 (the number of combinations of 2 out of 5). Each row of data of the matrix is a process array, matrix +.>Comprises a module number of->All process arrays at that time. The process array generation mode is' from 1 to 1Is selected from->After the number, the number +.>And arranging the numbers from small to large to obtain a process array.
4) From the slaveSelecting an optimal array meeting site constraints +.>。
Initializing an optimal process arrayEmpty array, repair time->Matrix->Line number of (2)。
4.1 Initializing a current process arrayFor matrix->Is>Row vector, calculate the repair line modules +.>Occupied area of the field->：
Wherein,representing the process array->Middle module->The number of the last process it is responsible for.
4.2 Calculating two characteristic values of the repair line.
Firstly, working strength characteristic values of all modules are calculated：
In the method, in the process of the invention,modules are numbered.
Then, willMaximum value of +.>As a first characteristic value of the repair line +.>Will beIs used as the second characteristic value +.>。
4.3 Land area determination)
If the total area of the repair line field isEnter into4.5 Otherwise, enter 4.4).
4.4 By comparing the first characteristic valueAnd the first criterion->Second characteristic value->And a second criterion->Updating the optimal process array->。
If the repair line characteristic valueIf true, enter 4.5);
if the repair line characteristic valueIf true, continue to judge if->If true, updating the optimal process array +_>，/>Re-enter 4.5), otherwise, go directly to 4.5);
if the repair line characteristic valueIf true, updating the optimal process array +_>，/>，Reenter 4.5).
4.5 Updating line sequence number)If->Is true (+)>For matrix->Line vector number of (c) then enter 4.1), otherwise enter 4.6).
4.6 If the process array is optimal4.7) if the equipment is empty, otherwise, calculating the average repair time of the repair line corresponding to the optimal process array to finish one batch of equipment of the same type according to the following steps>。
4.6.1 Calculating the average value of all the process time for each module of the repair line to complete the repair lineRoot variance->。
Wherein,representing an optimal process array->Middle module->The last process number responsible.
4.6.2 For a current device number of 1, arraySaving the mean value of the repair time of the device for each module, its element +.>Array->Preserving the root variance of the time the device completes each module,/->，The method comprises the steps of carrying out a first treatment on the surface of the Initializing next device sequence number->。
4.6.3 Calculating repair line completion apparatusRepair of (1), apparatus->Mean value array leaving repair time of each module +.>Sum root variance array->。
If it isThen
If it isThen
Wherein the element isIs the equipment completion module->Mean value of repair time, element->Is the equipment completion module->Root variance of repair time.
4.6.4 Updating device serial numberIf->（/>Number of devices in one lot), the average value array of the current device is updated +.>Root variance array->After that, into 4.6.3),otherwise, the repair line completes the average repair time of one batch of equipment +.>。
4.7 Handle)Preserving to optimal process matrix->Is>In a row.
5) Increasing the number of modules, updatingIf->Enter 2), otherwise enter 6).
6) In the optimal process matrixIn column 2 data of (2), find the minimum value to be marked +.>Corresponding to row +.>I.e. the number of repair line modules after optimization, the process array of the corresponding row is +.>And (3) a process array optimized for repair lines. />For the optimized repair line to complete the average repair time of a batch of equipment, +.>Has the characteristic of minimum value.
Example 2
In this embodiment, repairing a piece of equipment involves 15 repair processes, and the relevant information is shown in table 1. In the existing 20 square meter field, the number of the equipment in one batch is 100. The method of the invention is applied to design repair lines, optimizes the process array of the repair lines and is used for determining the repair process which is responsible for each module.
TABLE 1 information about repair process
Solution: 1) Initialization of
Inputting relevant data: total area of field available for repair lineNumber of repair processes for the apparatus>Process for preparing a composite materialDemand for floor area->Complete the process->Time mean>Time root variance->Initializing the number of modules of the repair line。
2) Initializing a discriminant numberNumber of discrimination->。
3) The number of the traversal generating modules is as followsRepair line process matrix at the time->。
When (when)When (I)>Is->。
4) From the slaveSelecting an optimal array meeting site constraints +.>. 4.1 to 4.7) is calculated +.>An optimal process array satisfying the site area constraint condition is [815 ]]The corresponding average repair time is 33825.8 minutes, +.>Preserving to optimal process matrix->In line 1 of (2).
5) Increasing the number of modules, updatingIf->Enter 2), otherwise enter 6). After multiple entries 2) to 5), an optimal process matrix is obtained>As shown in table 2. When the number of modules exceeds 9, the area of the field exceeds the constraint and is not considered.
TABLE 2 optimal Process matrix
6) In the optimal process matrixIn column 2 data of (2), find the minimum value to be marked +.>Minute, number of repair line modules optimized at this time +.>Its technological array->Is->。
The repair line optimized in the above example contains 8 modules, which are specifically as follows:
the module 1 completes repair process 1-process 3, and the required site is 4.3 square meters;
the module 2 completes the repair process 4, and the required site is 0.3 square meter;
the module 3 completes the repair process 5, requiring a field of 0.6 square meter;
the module 4 finishes the repair process 6 to the process 9, and the required site is 5.8 square meters;
the module 5 completes the repair process 10, requiring a field of 0.3 square meters;
the module 6 completes the repair process 11-process 12, and the required site is 2.7 square meters;
the module 7 completes the repair process 13-process 14, and the required site is 4.8 square meters;
the module 8 completes the repair process 15 requiring 1.2 square meters of land.
The repair line completed 100 pieces of equipment for an average repair time of 13952.4 minutes (about 232.5 hours). The average total man-hour for repairing 100 pieces of equipment was 63120.0 minutes (about 1052.0 hours). The repair time is 22.1% of the total time, and the optimization effect of the scheme formulated by the method is obvious.
And establishing relevant simulation of the repair line, and simulating the repair effect of one batch of equipment. In the above example, the time average simulation result of completing a batch of equipment by the repair line optimally designed by the method of the invention is 14019.2 minutes, which is very close to 13952.4 minutes of the result of the method of the invention. In the above calculation example, it is theoretically common thatThe number of available repair lines meeting the site constraint condition is 1223, all available repair lines are operated in a simulation mode, the average repair time range for completing 100 pieces of equipment is 233.5-970.3 hours, and the average repair time distribution of the repair lines is shown in fig. 3.
Simulation results show that: the optimal repair line obtained by the method is the same as the optimal repair line obtained by the simulation method. Since the number of repair lines is dependent onIncreased exponential levels, even if a significant number of repair lines can be deleted with site constraints, when +.>The number of feasible repair lines is larger at any time, and the time consumption for calculating the repair time of the feasible repair lines by adopting a mode of traversing simulation (or analytic calculation) is huge, so that an optimal scheme is difficult to obtain. The method of the invention only needs to calculate the +.>The site constraint strip can be obtained after repair timeThe repair line can quickly complete repair tasks in a time-saving manner, and can quickly and efficiently assist in optimizing the design of the repair line.
It will be readily appreciated by those skilled in the art that the foregoing description is merely a preferred embodiment of the invention and is not intended to limit the invention, but any modifications, equivalents, improvements or alternatives falling within the spirit and principles of the invention are intended to be included within the scope of the invention.
Claims (10)
1. The repair pipeline optimization method meeting site constraint conditions is characterized in that the repair pipeline consists of a plurality of modules connected in series, each module consists of a plurality of adjacent repair processes of equipment connected in series, different modules can work at the same time in a pipeline mode, and different repair processes in the same module work according to a serial number sequence, and the method comprises the following steps:
acquiring the total area of an actual field which can be used by a repair assembly line, the number of repair processes related to equipment, the area of the field which is required to be occupied by each repair process, and the time average value and root variance of completing each process;
based on the data, calculating an optimal process array corresponding to each possible module number of the repair pipeline and the average repair time for the corresponding repair pipeline to finish a batch of equipment with the same model;
and determining an optimal process array corresponding to the shortest average repair time of the equipment with the same model in a batch completed by the repair pipeline, and taking the optimal process array as a repair pipeline optimization result meeting site constraint conditions.
2. The method of claim 1, wherein calculating an optimal process array corresponding to the current module number, specifically comprises:
generating a possible process array corresponding to the current module number in a traversing manner;
excluding possible process arrays that do not meet site constraints;
for each of the remaining possible process arrays, calculating the maximum value and the root variance of the characteristic values of the working intensity of each module of the corresponding repair pipeline, and respectively taking the maximum value and the root variance as a first characteristic value and a second characteristic value of the repair pipeline;
when only one minimum first characteristic value exists, the process array corresponding to the repair pipeline with the minimum first characteristic value is used as an optimal process array corresponding to the current module number, or when a plurality of minimum first characteristic values exist, the process array corresponding to the repair pipeline with the minimum first characteristic value and the second characteristic value simultaneously is used as an optimal process array corresponding to the current module number.
3. The method of claim 2, wherein the criteria that satisfy the site constraints are: and taking the maximum value of the field area required to be occupied by each repair process in the module as the field area occupied by the module, superposing the field area occupied by each module as the field area occupied by the whole repair assembly line, and if the field area is not more than the total field area of the practical field which can be used by the repair assembly line, determining that the field constraint condition is met.
4. The method of claim 2 wherein the operating strength characteristic of each module is the sum of the summations of the time averages of each process completed in the module.
5. The method of claim 1, wherein calculating the average repair time for the repair line to complete a batch of equipment in the optimal process array corresponding to the current number of modules, specifically comprises:
calculating the mean value and root variance of all the process time of each module;
according to the mean value and root variance of all the process time of each module, iteratively calculating the mean value and root variance of the repair time when the equipment leaves each module when the repair assembly line finishes repairing the equipment according to the sequence of the equipment in the batch;
when the repair pipeline finishes repairing the whole batch of equipment, the average repair time of the last equipment leaving the last module is taken as the average repair time of the repair pipeline finishing the batch of equipment.
6. The method of claim 5 wherein the average of all process times each module completes is the sum of the sums of the squares of the root of the time each module completes for all process times each module completes is 1/2 th the power of the sum of the squares of the root of the time each process for each module completes.
7. The method of claim 5, wherein the repair pipeline completes repair of the first device in the order of the devices in the lot, the device leaving the means and root variance of repair time for each module:
wherein,，/>for the current number of modules>And->Repair pipeline modules, respectively>Mean and root variance of all process times to complete it, < >>And->Respectively the current device leaving module->Time-to-repair mean and root variance of (c).
8. The method of claim 5, wherein the repair line completes the first in the order of equipment in the lotWhen repairing individual devices, the device leaves the time-to-repair means and root variance of each module:
if it isThen
If it isThen
Wherein,，/>for the number of devices in a batch, +.>，/>For the current number of modules>And->Repair pipeline modules, respectively>Mean and root variance of all process times to complete it, < >>And->Respectively the previous device leaving module>Time-of-repair mean and root variance, +.>And->Respectively the current device leaving module->Time-to-repair mean and root variance of (c).
9. A repair line optimization system that satisfies site constraints, comprising:
at least one memory for storing a program;
at least one processor for accessing a program stored in the memory, the processor being configured to access the method of any of claims 1 to 8 when the program stored in the memory is accessed.
10. A computer readable storage medium, characterized in that the computer readable storage medium stores a computer program which, when run on a processor, causes the processor to enter the method according to any one of claims 1 to 8.
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