Research On Design System Of Production Line For Mass Customization

The main thought of Mass Customization (MC) is to satisfy variant customer's demands under the same cost and efficiency as of Mass Production. Beside technology of product family design, the flexibility and response ability of the manufacturing system are basic reassurance of MC. Design and reconfiguration of manufacturing system according to MC requirements is a unique research area. Following this line, the thesis discusses the demand of MC to Manufacturing System, such as system modulization, layout patent, and system tranportation. The approach of multi-line production system under MC is also studied. To be concrete, Problems of line balancing and facility layout are then discussed.The research is aimed at the production lines plant in shoe industry. A design system for production lines optimization is developed, under the principle of MC. The system consists of four modules: Production Data Management, Capability Requirement Planning, Line Balancing, and Facility Layout. Production Data Management Module is responsible for the management of basic manufacturing data, including basic process data, typical process flow data, equipment and worker data, etc. Capability Requirement Planning Module is responsible for the planning of manufacturing resources according to estimate of market demands, supplies the company with data for resource planning. Line Balancing Module is responsible for production line balancing based on the detailed orders, in order to improve the use of manufacturing resources. And Facility Layout Module is responsible for facility layout according to the result of line balancing and the manufacturing data. The response ability of manufacturer is improved to a large extent by this system. Thus the basis of Mass Customization is founded.Also, multi-line balancing problem is discussed, and a new variant genetic algorithm called KPGA is proposed. It overcomes the drawbacks of the traditional GAs and adopts the so-called Coss-kindred Selection. The Algorithm is verified to be more efficient than the traditional GA and other variant GAs. It is used to solve the multi-line layout problem discussed above, and satisfactory result is achieved.