Study And Realization On The Control Policy For Lean Manufacture Systems

It faces enormous change for the management mode of production system in the manufacturing industry with the rapid development of scientific technology, especially of information technology, the formation of competitive buyer's market, individuation tendency of consumer conception, establishment of global market and trade system, thriving of knowledge economics and the rising attention to continual development and environmental protection. Being a typical management method of small-batch and lot-variety production, lean manufacturing meets the practical requirements of market change. Production control, as one typical characteristic and the important component of foundation of lean manufacturing, is a crucial technique to realize production planning and operative management. Therefore, studying production control holds the balance for success in lean manufacturing.This article focuses on the control policy research in lean manufacture systems suitable for Chinese market by absorbing and developing the up-to-the-minute research results. On the basis of studying theory development of control policy of lean manufacture systems, the dissertation further exploits modern control theory and method by using OR (operations research), queuing network, petri net, GA (genetic algorithm), and simulation technology.It is divided into five parts: the development history of control policy of lean manufacture systems, study on the typical control policy, research on the customized Lean Product System(CLPS) control policy, implementation analysis of lean manufacturing which uses CLPS control policy as the essential part, the realization of lean manufacturing software systems based on CLPS control policy. It includes the contents as follows:1. It studies the development history of control policy of lean manufacture systems, and points out that production control policy is one of the important issues in any specific manufacturing model. Furthermore, it studies various control policies in control management for lean manufacture systems, and demonstrates their advantages and disadvantages from different levels by using different theories.2. It analyzes in detail the differences among push, pull and squeeze (TOC) control policies, and concludes that pull is superior to push and squeeze in WIP and cycle time, etc.3. A new-type system, called CLPS control policy, is given based on TOC and MRP theories to solve the beforehand control policy don't perfectly exert the production system's capacity... Petri net and Simulation results indicate that the improved CLPS is the best control policy in consideration of stock cost and customers satisfaction.4. It puts forward that lean manufacture with CLPS control policy is the best choice for Chinese enterprises. Moreover, a new implementation method is given; this method not only can reduce the implementing difficulty but also improve the system's performance.5. Aiming at the current situation that ERP is being used widely, the paper discusses the limitations of ERP. Combining with the theories of lean manufacturing and analyzing the specific inputs of ERP, it points out that better results can be achieved by using the lean theory to rebuild the ERP environment; furthermore, a particular way for reconstruction is given.6. For the imperfect current situation of ERP, as well as the conclusion that lean manufacture with CLPS control policy is the optimal choice for Chinese present enterprises, it puts forward the software realization of lean manufacture with CLPS control policy. Comparing with the existing ERP system, it proves the feasibility and advancement of the CLPS software system.