Research On Flexible Cell Production System And Its Reconfiguration Oriented To Mass Customization

The target of mass customization is how to manufacture the individuation customized product by the cost and speed in mass production. The method of reasonable production organization makes the cost of mass customization product reducing and the response speed improving.However, the existing mode of production organization can not meet the requirements of mass customization of reconfigurable,low investment, high flexibility,short lead times,high production efficiency,and low logistics cost charaxteristics,therefore,a new production mode is urgent need which can make mass customization from the theory to practice.So, for the features of production organization for mass customization features,this paper presents a proposition that is flexible cell production systems and its reconfigurable based on work-cell oriented to mass customization.In this paper, a variety of shortcomings of the existing production mode are analyzed under mass customization environment. At same time the organizational characteristics and the needs of production management for mass customization are analyzed, on this basis it was proposed that the flexible cell production systems based on work-cell and the integration framework are used for mass customization. It was also proposed the cell production reconfiguration and layout system, and clarified three key technologies of the system and in-depth study of work-cell performance of flexible cell production systems in the subsequent two chapters, cell production system reconfiguration for mass customization and the system layout considering the contour distance of work-cell U-shape, specific research as follows:①To solve the problem of determining the operator quantity and capacity for the"chaku-chaku"semi-automatic production cell, the production cell constrained by dual resource was studied. The method for determining the operator quantity and capacity was proposed. Logical model was built based on colored timed Petri net and formalize defines"chaku– chaku"rules. It was confirmed the steady state of production lines from physical and space aspects by simulation system, the system features for the homogeneity staff and heterogeneous staff was studied by the numerical analysis methods. Simultaneously, concrete calculation algorithm for waiting-time for operator was worked out and production capacity was developed. Finally, based on the case and discussion of the simulation results, The case study showed that the algorithm was an effective approach to determining system operator quantity and capacity and very useful for the enterprise.②Aimed at the problem that the difference efficiency for walking-workers affects the output of production line in cell production style, an overtaking mechanism was proposed by using overtaking station and verified the validity through mathematical analysis and simulation method. This paper firstly defined the overtaking mechanism by some principles, and then the logic model for production line with overtaking mechanism was proposed. Calculated formulas for saving time of production line with overtaking mechanism were deduced which compares to ordinary production line. Finally the variation principle of the output and staff utilization and machine utilization with overtaking mechanism was found through simulation method. The conclusions highlight guidelines for practicing managers on the walking-worker production lines with overtaking-stations.③To solve the problem in mass customization that the product must satisfy the individual demands of customer, at the same time the customized product are similar to that of the product in mass production, a thinking is proposed that cellular assembly systems is used for assembly operations in MC. By considering the several key factors including dynamic assembly cell reconfiguration, worker assignment, multi-period production planning, backorder cost, and hiring\firing cost etc, this paper presents an integer mathematical programming model for the design of cellular assembly systems in a dynamic environment in mass customization. Numerical examples are presented to demonstrate the model and its potential benefits.④The facility layout of a cell production system involves the positioning of cells within given boundaries, so as to minimize the total projected travel time between cells. Defining the layout includes specifying the spatial coordinates of each cell, its orientation in either a horizontal or vertical position, and the location of its load/unload point. At the same time, the design of a manufacturing layout is incomplete without consideration of aisle structure for material handling. This paper presents a method to solve the layout and asile structure problems simultaneously by shortest path with earch part load/unload point. In this representation, the shortest path algorithms are utilized as the aisles for a material handling system. Computational tests demonstrate the goodness of the method.Finally,this paper gives the prediction that cellular manufacturing system will integrate cell production system, and points out the development orientation of cell production system.