Research On Integrated Operation Plan Management Method For Discrete Manufacturing Industry

Discrete manufacturing enterprises have diverse product demand, complex product structure, flexible process route and dynamic production environment. Operation plan management is directly for the organization, coordination and optimization of the shopfloor resources in the manufacturing process. The scientificity and agility of operation plan management method has a direct impact on the productivity and market responding speed of the enterprise. With the development of information technique and the advanced manufacturing mode such as computer integrated manufacturing (CIM), informationization and integration is becoming the new developmental direction of operation plan management. Therefore, with the support of the National Science and Technology Plan(2012BAF12B08) and the Natural Science Foundation (70772086), focusing on the existing problems of operation plan management in discrete manufacturing industry, on the basis of analyzing the operation plan management theories, methods and application status in discrete manufacturing industry at home and abroad, the integrated operation plan management system framework and methods for discrete manufacturing industry are investigated. The management thoughts of system and integration are applied to study the methods simultaneously.Firstly, according to the characteristics of the production process and operation plan management process of the discrete manufacturing enterprises, the system framework of integrated operation plan management for discrete manufacturing industry that is composed of operation planning layer, scheduling layer and activity control layer is proposed to analyze the main content, relationship and difficulties of integrated operation plan management. And under this, a three-layer operation plan management function model based on BPS/MES/PCS structure is built. The information flow of integration and interaction between the systems is analyzed.To deal with the weakness of the hierarchical control mode of production plan, the integration control mode of operation plan and MRP is presented. In consideration of the multiple constraints such as BOM, process route and MRP of the operation planning problem under this integration control model, the network model of manufacturing process is built for the problem. Based on the graph theory, a dynamic critical paths algorithm is designed to solve the problem. The computational results show that the proposed algorithm could get feasible operation plan efficiently as well as shorten the production cycle.For the problem that the process flexibility of discrete manufacturing product has increased the complexity of operation plan scheduling, in combination of the types and characteristics of discrete manufacturing product process flexibility, the traditional FJSP is extended by taking the sequence flexibility into consideration. The extended problem is abstracted as the Flexible Process Job-shop Scheduling Problem (FPJSP). To shorten the production cycle, an integer programming model is proposed for FPJSP. And the hybrid genetic algorithm(HGA) that combines the genetic algorithm and variable neighborhood search(VNS) algorithm is designed. Computational results verify the effectiveness of the proposed HGA for solving FPJSP.Considering that the complicated and volatile production environment have made the traceability of operation plan execution process more difficult, a reference data model is created to describe the relationship between the entities in operation plan execution process tracing. Taking the lot as trace unit, aiming to ensure the traceability of the operation plan execution process, a traceability model based on n-dimensional affine space is proposed. The trace data storage structure and the traceability algorithm based on the traceability model are designed. Computational results show that the proposed model and algorithm could reduce data redundancy and improve the traceability efficiency.Finally, combining the operation plan management methods with actual production requirements and information technology, based on the above-mentioned models and algorithms, the integrated operation plan management prototype system is developed. And the application of integrated operation plan management methods at discrete manufacturing enterprise is discussed to prove feasibility and effectiveness of the proposed methods.