Research On Management Process Design Of Discrete Manufacturing System

In face of the keen market competition, the agile manufacturing strategy is proposed that the agile manufacturing enterprises should have the capability of quick reaction, reconfigurating resources and organizing production to meet customers'individual needs. On the basis of this strategy, the core problem of the agile manufacturing system is brought forward that is how to make product design and manufacturing process design. Then, the concept of management process design is proposed, which perfects the manufacturing process design system.Based on intensive study of literature home and abroad, the multi-hierarchy classification of production system change factors is analyzed. All kinds of methods of manufacturing process design are reviewed. Since the methods have limitations on manufacturing process design, it is necessary to build mathmatical model of manufacturing process. Many kinds of modeling methods of DEDS are analyzed, including Queuing Network, Maximal Algebra and Petri nets. In the end, it is determined to model the manufacturing process by Petri nets. Then, the management process design system based on Toyota Production System is analyzed detailedly.Many kinds of manufacturing process'PN models are built, including inflexible manufacturing process in series, push-type flexible manufacturing process in series and pull-type flexible manufacturing process in series. Furthermore, all kinds of models'Incidence Matrix, three-phase State Equations and Reachable Mark Chart are deduced and Behavioral Performances of the models are analyzed. And Then, series-parallel manufacturing process and parallel-series manufacturing process'PN models are built and Behavioral Performances of the two models are analyzed.In view of the events'occurrence and states'continuous in manufacturing process having relation with time, three kinds of manufacturing process'TTPN models are built, which are inflexible manufacturing process in series, push-type flexible manufacturing process in series and pull-type flexible manufacturing process in series. All models'dynamic parameters are discussed, including production period, productivity, lead time, equipment operating factor and so on. The relation between work-in-process quantity and operation time of push-type flexible manufacturing process in series is discussed, and a method is proposed which could control work-in-process quantity by adjusting the operation time.Reducing complicated manufacturing process SPN model and computering the equivalent performance parameters are realized. Then, how to apply the reduction methods of the manufacturing process'SPN models for assembly lines layout problem is discussed. Demonstration and simulation study are used to estimate available of new methods.This paper compares TPS and MES,and brings forward both of them have the same essence and different methods, which provides a base to expand MES into General Manufacturing Execution System(GMES). In the end, a summary is made and some further researches are pointed out.