Reconfigurable Scheduling Method For Multi Product And Variant Volume Production

Manufacturing enterprises must realize quick response ability facing to sustainedchangeable market requirements under fierce market competition. At this time, thereconfigurable manufacturing system (RMS) theory, which combines efficiency ofproduction unite and flexibility of job shop production, becomes a supporting method toextensible production ability based on manufacturing resource adjustment. So the advent ofRMS is an effective way to handle dynamic changes in production execution progress formanufacturing system. With the production mode of manufacturing enterprises has changedinto multi product type and variant volume (MPTVV), the research about static and phaseadjustment of RMS is hard to meet requirements of the sustained manufacturing systemchanging. Thus, this paper sets the manufacturing system object as sustained and dynamicadjustment facing production execution progress. The adjustment uses the scheduling planas starting point. The theory and application method is researched about combiningscheduling plan into RMS. In order to support sustained and dynamic manufacturingresource optimal distribution, the research is to push the RMS changing into manufacturingexecution level using production plan as representation. Based on this method, the RMSfacing production execution progress is researched and proposed combination of theory andpractice in this paper. And then the practical software is developed based on the proposedRMS and the research result is validated by using the software in practical projects.Main contents of this paper are as follows:(1)Using production mode of MPTVV as research background, the reconfigurablemanufacturing theory facing practical production is analyzed. At same time, the sustainedreconfigurable scheduling method is proposed as the core of new reconfigurablemanufacturing system, and its technology framework, function model and businessprocedure are studied. Based on the function model and business flow of reconfigurablescheduling, three core technologies are proposed, including reconfigurable cell formation,flow and job shop hybrid reconfigurable scheduling and dynamic reconfigurable schedulingdriven by disturbance events.(2)Using production cell as research object in sustained reconfigurable system facing practical execution environment, the progressive cell formation reconfiguration technologyis studied. Problems of similar classification, the balance of manufacturing cell burden,resource sharing and inheritable adjustment are analyzed in cell building andreconfiguration progress. The mathematical mode is built based on manufacturingconstrains and rebuilding objective. The progressive cell formation reconfigurationtechnology using neural network algorithm is researched in order to support the sustainedreconfigurable cell requirement. In order to support the initial cell formation building, thesimilar classification considering logistics cost is researched, at the same time the methodsof reducing the number of crossing cells and balancing cells burden are proposed. Forsolving the sustained formation adjustment problem in execution progress, the inheritablereconfiguration method is proposed.(3) For solving the contradiction between efficiency and flexibility in MPTVV, theflow and job shop hybrid reconfigurable scheduling is researched. Problems of the flowstyle production in manufacturing cell and manufacturing resource sharing in hybridscheduling are analyzed. The reconfigurable scheduling mode of hybrid production style isbuilt, and then the reconfigurable scheduling method based on immune genetic algorithm isproposed. To guarantee the flow style production in cells, the flow production method withbuffer parts is proposed. After analyzing the manufacturing resource sharing method, theresource adjustment method based on immune algorithm of minimum manufacturing cost isbuilt.(4) The dynamic reconfigurable scheduling (DRS) method is researched for solvingquickly disturbance events response. The disturbance events unification, the contradictionbetween efficiency and stability in rescheduling method, the affected response of hybridproduction style and the resource sharing method caused by manufacturing disturbances areanalyzed. And then the DRS mode is built. The DRS method based on the ant algorithm isproposed. For unifying production disturbance events, the modularization handling methodcontaining four basic approaches is studied. For solving contradiction in rescheduling andresource sharing problems, the rescheduling objective considering due day and operationsprocessed machines is developed. Based on disturbance responses with different productionstyles, the tolerance method of disturbance buffer is researched. (5) Based on requirements of manufacturing enterprises, the sustained reconfigurablescheduling software is developed. Through testing in project application, the researchachievement of this paper is validated.