Research On Intelligent Control Of Material Flow In Sheet-Metal Blanking Workshop And Storage Management System

With the development of global manufacturing organizations, some automobile body companies outsource blanking process to the professional factories which have decoiling & blanking & stacking production lines. In order to supply kinds of sheet-metal just in time, the blanking factories often have large-scale warehouse of nonstandard coils. So workshop-material-flow and warehouse management became a hot research issue. Traditional Kanban management is generally used, but it has the defaults, such as, manual business process management, information flowing delay after material flowing, high mistakes ratio, stacking and crane job schedule in a state of chaos, very much production waste, and hard to manage the storage.After investigation and study of blanking factories, an Intelligent Control of Material Flow in Sheet-Metal Blanking Workshop and Storage Management System is proposed to solve the difficulties by following advanced manufacturing and management theories. The system can intelligently do multi-process material-flow-job scheduling, calculation and allocation of storage space, storage monitor, and production execution monitor.Crane job is pre-process of blanking. A calculation model for Crane job scheduling problem (CJSP) is proposed. The difference between CJSP and other workshop job scheduling problems was presented. The author improved on traditional disjunctive graph model so as to investigate job schedule feasibility of CJSP, by added bidirectional conjunction arc (when the process needs two or more machines) and single-direction resource bound arc. A RBR (rule based reasoning) based carne job scheduling algorithm (RCJSA) is proposed. It breaks up the whole multi-processes into parts, and reduces the complexity of calculation of CJSP. Many rules and job priority principle for production suitability were defined, in order to solve time sequence conflict and obtain the optimum CJSP solution.Storage space allocation issue is a multi-objective optimization problem. Because of the double principles, fine quality and fast and efficient process principle and safety first principle, there is some conflict between the objectives and rules. To solve these problems, this paper proposed a freight-classification freight-orientation flexible-share storage strategy and many storage space allocation rules. This strategy includes the merits of freight-classification strategy and freight-orientation strategy, but cut off theirs shortcomings, such as storage space quantity designed as the max possible at storage freight quantity. It sets buffer storage space, and uses flexible-share rules and state chart of storage space to get the optimum calculation result. A materialstorage control strategy based on production plan and time window has been presented, which can improve the storage change agility.AJAX was used in J2EE framework to improve the real-time part-refresh ability of storage monitor E-Kanban and wireless moveable task direction E-Kanban. A chaotic encryption algorithm was designed to protect the wireless communication. The system, based on above strategies and methods, has been implemented and putted to use in a large-scale automobile sheet-metal blanking company, which improves automated administration level.