Research On Material Integrated Management Techniques For Complex Equipment Manufacturing Enterprise

With the aggravation of market competition and the increase of customer product-needed individuation, agile production management mode in complex equipment enterprise has been brought new challenges. The kitting of the materials, which being the base of production management, is the essential guarantee to realize agile production planning efficient operation highly. Therefore, the current problems of the research and application of material kitting management are analyzed during complex equipment production cource. Under the background of development and application in Dalian Locomotive & Roll Stock Works (DLOCO), the dissertation studies Integrated Management System of Production Planning & Material Control (PMCMS) method system and implementation techniques. The major research results include the following:At first, a commonness structure, which is suitable for integrated production management mode of complex equipment, is put forward. And PMCMS model based on this structure is set up.Aiming at the problem of relative production activities, such as material requirements, capacity requirements and plan schedule, etc. taken into account dividedly, which caused by product BOM and BOP not completely integrated, the model of Generic BOM and BOP Based on Production Planning is brought forward. Product structure data and dynamic manufacturing data are united in this model so that dynamic material flows are reflected. By using the generic production structure, the material logical relationship between BOM and BOP are expressed during the kitting process of component assembly. And the consistency between product variables and operation variables is guaranteed by the diversity parameters and their values.Owing to material substitution between different activities involving in material requirements harmony among product BOM, process planning BOM and production planning BOM, the model of material substitution is established based on PGBOMP with multi-constraint and multi-object. And according to material different attributes, an algorithm is designed to select part substitution to ensure resources reasonable configuration and supply & demand relation balance. By carrying out rearrangement on material resources, dynamic management methods and decision-making criterion are provided.By building up an model of components kitting analysis and adjustment, the dynamic monitoring results and real-time parts shortness are reported on components assembling and kitting process of complex equipment. And by analyzing the reasonable allocation of material resources, balanced and ordered production status is guaranteed. According to the difference of material monitoring requirement, the multi-layer material monitoring pattern is found. Dynamic adjusting algorithm of linking local coordination with global coordination for lacking parts is brought forward. And this algorithm provides techniques guarantee for production schedule to reduce cost loss caused by key resources leave unused because of required materials shortness.Combining with production management situation in DLOCO, the structure design and its application of PMCMS are introduced.