Research On Optimization And Organization Of Make To Order And Manual Operation System

Since the reform and opening up for over 30 years, Chinese small and medium-sized manufacturing enterprises have developed rapidly, becoming the important strength to promote the development of economy rapidly and provide social employment. However, with the impact of the global financial crisis spreading and countries trade protectionism upgrading gradually, the export market that small and medium-sized manufacturing enterprises in our coastal areas lived on atrophy obviously. Serious challenges that many small and medium-sized manufacturing enterprises face today include such negative factors as various, small batch and unpredictable demand, the rapid increase of labor costs, raising prices of raw materials and the rise of RMB exchange rate. How to seek for survival and development in the complex operating environment is the problem that small and medium-sized manufacturing enterprises need to be urgently solved.Make to Order (MTO) is an important operation mode that many small and medium-sized enterprises used to cope with the needs of the complex and changeable environment and reducing the operation risk. Manual Operation System (MOS) has become the production system structure mode and our small and medium-sized manufacturing enterprises mainly used for its less equipment investment and strong adaptability to the change of need. Facing the complex operating environment, studing the theory and methods of MTO/MOS employee organization and optimization and planning scheduling from the aspects of lower cost, increasing flexibility, meeting the demand are of great importance to the survival and development of small and medium-sized manufacturing enterprises. This paper studies MTO/MOS from the following four aspects:(1) Organization mode of MOS. According to the structure and characteristics of MOS, this paper analyzes three kinds of commonly used static organization mode in the production practice, building different plan period output models in all kinds of the organization under different conditions. This paper analyzes the pros and cons of different mode numerically under different conditions with an example. (2) Workers multi-skills configuration. This paper compares CP-cherry picking with SC-skill chaining, and analyzes the optimal allocation of workers'skills by these two modes. The optimization results show that the lesser the task demand fluctuation is, the fewer skills need to be trained by CP-cherry picking, otherwise by SC-skill chaining. The optimization results also find that with the increase of demand fluctuation, the total of skills need to be trained increases slower by SC-skill chaining which is more effective.(3) Workers demand configuration. First, This paper analyzes three influence factors on the number of workers:the volatility of the production, cross-training workers, and work overtime and temporary employment; Secondly, based on the above three factors, with the objective function of minimum total cost, this paper sets up a two-stage optimization model for decision variable with the demand of workers. This paper solves the models composed by two and much operation teams respectively by the integral and nested genetic algorithm and verifys the effectiveness of nested genetic algorithm by the optimized results of the two operation teams. The results show that, with the increased cost of workers, the optimal operation team workers'demand decrease, and the total cost increase; with the efficiency factors lower, the number of workers will increase, and the total cost will also increase.(4) Order task scheduling. This paper studies the static and dynamic scheduling problems of the order task. First based on the fuzzy due date and random processing time, this paper puts forward solving order task scheduling problem by genetic algorithm; Second, taking the well flexibility of artificial operation system into consideration, this paper puts forward a heuristic algorithm IEDD from the scheduling theory method; Finally, with the aid of the GA algorithm and IEDD rules, this paper studies the scheduling problem of MTO/MOS through simulation, and compares with the traditional heuristic algorithm EDD, STR, CR and SPT, which show that the GA algorithm and IEDD method proposed in this paper are more effective.In addition, with the thought of bilateral matching, and considering the cost of production and customer satisfaction, multi-objectively optimizing the order task scheduling problem is studied by GA algorithm.Finally, summarize the whole text, and the future research direction is given. This research is supported by the national natural science funds projects:research on optimization and organization of make to order and manual operation system (70971026).