Application Research Of Work Load Control In Elevator Cabin Manufacturing

Elevator cabin manufacturing belongs to discrete ordering production model of multispecies and small lots. Elevator cabin has a wide variety of components and parts types, its manufacturing processes change frequent and complicated, Orders arrive very stochastically, it exits some very serious problems, order’s lead time are very long and lots of order’s delivery performance are very poor. Then how to solve these problems? How to take full advantage use of production resources and improve production efficiency? Enterprise administrators are puzzled by problems above. However, selecting and using effective production plan and control (PPC) technology is critical to solve these problems.Several kinds of traditional and maturing production plan and control technologies such as:MRP Ⅱ JIT and OPT can not apply to elevator cabin manufacturing very good, so it is very urgent and significantly to find a PPC technology which is fit for elevator cabin manufacturing model. According to the summary of past related researches, the production management problems of elevator cabin manufacturing can be solved by work load control (WLC) technology. WLC has two basic principles, one is controlling and balancing machine’s work load, the other is controlling and balancing work load of production system through setting order’s date of delivery. It also has three layers control structures. They are order accepting strategy task review and release and dispatching rules of job shop. This article research WLC’s application in elevator cabin manufacturing.First, GM(1,1)is used to predict the quantity of month’s orders accord to the history orders data of a elevator cabin manufacturing company, the predict results is used to guide the company’s production plan.Then, a work load control structure of elevator cabin manufacturing is established according to the features of elevator cabin manufacturing. In the second layer Task review and release (TRR) a0-1integer programming model is established to optimize order’s selecting and releasing. Because of the elevator cabin manufacturing characteristics a simulation model is created by eM-plant, genetic algorithm is used to optimize the sequencing and releasing of selected orders, an example simulation is executed to prove effectiveness of integer and genetic algorithm (IGA) by comparing IGA with integer direct release (DR)Thereafter, elevator cabin simulated optimized manufacturing system is founded based on elevator cabin WLC system. Orders components and parts releasing is optimized by GA module in the simulation system. Sim-talk language is used to realize the control strategies and visualize the system. Optimized algorithm and simulation are integrated by the simulation system.Finally, based on the simulation system, a production plan optimal method based on genetic algorithm and a delivery date prediction method are proposed, a simulation example is executed to verify these effectiveness. Meanwhile, it proposes a rearrangement order inserting method. All these methods can help to assist order enquiry decision-making.