Research On Planning And Controlling Based On TOC And MRPⅡ

With the increasing competition in market, frequent changes in orders and shorter delivery time requirements make the manufacturing industry facing seriouse challenges. How to organize the production process effectively and make it going on smoothly has become a key issue for a company to win the competition. Agile Manufacturing mode provides a new concept to resolve this problem and it is of great importance to study the planning and controlling method under this mode.Based on the traditional Manufacturing Resource PlanningⅡ(MRPⅡ), concepts and methods of the Theory of Constraints (TOC) are introduced. The feasibility of integration is analyzed. The planning and controlling framework in Agile Manufacturing system based on MRPⅡand TOC is established; the integration realization approaches and the key technologies are analyzed as well.An improved way of time period dividing is adopted to identify the bottleneck in a manufacture system, which makes up of the defect that some task load might be neglected in the traditional way. The basic principles of time period dividing are proposed, and the identification algorithm based on the improved way is analyzed. Results show that the new way could distinguish the bottleneck of a system in a time bucket accurately.Aiming at the bottleneck scheduling problem under single bottleneck condition, single-goal and multi-goal heuristic optimization scheduling algorithms are used to order the critical tasks on bottleneck, which take the minimum delayed time and number of tasks as objects. The corresponding scheduling algorithm is accomplished as well. Case study proves that optimized result could be obtained through multi-goal heuristic algorithm, and it also has instructive significance to practical production.The scheduling algorithm based on DBR is designed. Combined the two planning theories of'push'and'pull', critical parts and non-critical parts are scheduled.Results of DBR andhybrid self-adaptive genetic algorithm show that the former method could improve the output and the delivery time of tasks could be assured when there is a bottleneck in system.Based on the studies above, the prototype system of planning and controlling system in Agile Manufacturing was developed using JAVA,JSP and SQL SERVER. Running results of the system indicates that the approaches proposed above which can satisfy the requirement in practice are valid and feasible.