The Research On Integrated Optimization Of Production Planning And Scheduling Of Multistage Manufacturing System For Complex Products

Complex products are a kind of product which has complicated demand, production technology, manufacturing process, system maintenance, project management and work environment. The process from raw materials to products or semi-finished products for complex products is usually completed in the multistage manufacturing system. The subsystems of multistage manufacturing system may be the work unit, workshops of an enterprise or the enterprises of an enterprise union, which can achieve the machining, assembly and other value adding manufacturing process. In the complex products multistage manufacturing system, the production relationship among subsystems is complex, the production type is various, the processing object is changing constantly and the information communication is frequent. Therefore, its production planning and management is very complicated and integrated optimization of production planning and scheduling of multistage manufacturing system for complex products seems very important.In this dissertation, we focused on integrated optimization of production planning and scheduling study, the product man-hour calculation study and manufacturing resource modeling study. The main study is summarized as follows:(1) To provide the abundant and accurate product man-hour for integrated optimization of production planning and scheduling of the multistage manufacturing system, the product standard time calculation study was presented as the pretreatment study for integrated optimization of production planning and scheduling. After the analysis on the current standard time and man-hour calculation study, the manual standard time calculation based on primitive operation(PO) and the product standard time calculation based on primitive operation and equipment type were presented.(2) To provide the complex manufacturing resource and task information for integrated optimization of production planning and scheduling of the multistage manufacturing system, the manufacturing resource and task integrated modeling study was presented as the pretreatment study for integrated optimization of production planning and scheduling. In order to solve the manufacturing resource description and integration, the Capacity Manufacturing Unit(CMU) and the Manufacturing Resource and Task Integrated Model(MRTIM) based on CMU were proposed.The proposed standard time calculation method can calculate product standard time accurately and rapidly, and the MRTIM can integrate the manufacturing resource, task, man-hour and person configuration in a frame and construct the mapping relationship. They provide a strong support for production planning and scheduling rapidly and accuratedly. On the basis of pretreatments study, the core research content of this dissertation were proposed.(3) The integrated optimization of production planning and scheduling modeling study on complex products multistage manufacturing system. In the traditional serial production planning and scheduling, the production planning and scheduling are dissevered, and the plan cannot respond the changes in the scheduling process, the changes in the scheduling process cannot be fed back to plan. In order to solve this problem, the integrated optimization of production planning and scheduling study was presented. Firstly, the classical subsystems integrated optimization of production planning and scheduling definition and detailed model of the multistage manufacturing subsystem were proposed, such as Flexible Jobshop and Permutation Flowshop; Then the multistage manufacturing system integrated optimization of production planning and scheduling model was presented, which considered the complex production relation among subsystems and the frequent communication between production planning and scheduling. Therefore, the modeling study achieves the simultaneous optimization of production planning and scheduling, and the defect of serial production planning and scheduling is overcome and the integrated optimization of production planning and scheduling for multiproduct is solved.(4) The algorithm study of integrated optimization of production planning and scheduling detailed model for complex products multistage manufacturing system. To solve the multistage manufacturing system integrated optimization of production planning and scheduling model in full space, the Modified Discrete Particle Swarm Optimization(MDPSO) algorithm and the Cultural Algorithm based on MDPSO(CA-MDPSO) were presented. MDPSO algorithm has unique encoding and decoding mode and modified evolutionary approach compared with classical Particle Swarm Optimization(PSO). CA-MDPSO is the combination of MDPSO algorithm, Cultural algorithm and Genetic algorithm and possesses two-level evolution frame. The experiment and comparison with other classical algorithms verifies the validity of the presented algorithms. This section solved the integrated optimization of production planning and scheduling model and improved the new intelligent optimization algorithms and extended their application in integrated optimization of production planning and scheduling domain.(5) The prototype system of complex products multistage manufacturing system integrated optimization of production planning and scheduling based on network was designed, which verified the presented theory and methods inextenso, such as product standard time calculation and search, manufacturing resource and task modeling and resource search and integrated optimization of production planning and scheduling.The research makes some contributions in key techniques of multistage manufacturing system integrated optimization of production planning and scheduling study. From the product basic standard time establishment, the vitrification of manufacturing resource and the implement of integrated optimization of production planning and scheduling, the presented research form an organic whole. The presented key technology not only make a breakthrough in the theory study, but also can effectively enhance the competitiveness of manufacturing enterprises, and improve the enterprise productivity, resource utilization and management capacity with no investment or less investment consequently.