Study On Organization And Decision Of Planning About Manual Operation System Under The Mode Of Make-to-Order

Since our country began to reform and open in1978,the number of small and medium-sized manufacturing enterprises (SMMEs) has been increasing and the size of them has been expanding,there is no doubt that the SMMEs have become the one of the the key forces which promote the national economy rapidly develop and solve the problem of social employment.Under the domestic and international market environment of increasingly fierce competition and complex demands,Make To Order(MTO) has become the main operation mode of the SMMEs that effectively respond to market risk and enhance competitiveness,while the Manual Operation System (MOS) has become the main structure mode of the SMMEs production system that can lower production costs, improve system flexibility and meet the customer demands. However,as the global financial crisis continuing to spread and the international politics having an adverse impact on the economy,the overall situation of China’s export trade is grim,and the needs tends to be more custom,complex and rapidly delivery.Therefore,the enterprises have the great pressure to accelerate product innovation, shorten product cycle and improve the operation management.Technology innovation and rapidly changing market also makes the more intense competition in the same industry,Coupled with the realty of domestic recruitment difficulties, rising labor costs and the rising resource prices and the economical problems of RMB exchange rate going up and currency expansion,the SMMEs in CHINA is facing unprecedented challenges about the survival and development.From the point of the internal operations, due to a number of factors, there are many problems in the SMMEs.As the actual problems of the MTO/MOS in SMMEs are oriented,summarized and refined as theoretical issues,the paper researches and explores the MOS organization and management mode which adapts to the environment of MTO,and the models of plan decision-making concerning order demands and delivery are established. The following research supports SMMEs in theories and methods that can reduce the operating costs,enhance their competitiveness and respond effectively to customer needs. The specific contents are displayed as follows:First,study about the mechanism of self-organization and self-adaptive and the state of evolution in MOS that the frontline employees are viewed as autonomous entities:the concept,features,external environment,elements,internal relations, structure, function and self-organizing characteristic of MOS is analyzed under MTO,and the order requirements, the complex changes of tasks,system performance or goals,state variables of employees,control parameters and random disturbance factors are explored about MTO/MOS.Then,the mechanism of self-organization and self-adaptive bout MTO/MOS is constructed based on the above contents,moreover, the internal relations and interactions about the system goals, employees state, control parameters and random disturbance factors are described based on the mechanism,the model about the state evolution of the employees’ behavior is established as the theory of collaborative dynamics being applied. The unstable state and stable state solution is obtained by the order parameter analysis and solution of the model when the random fluctuation force is zero. The practical significance of the solutions is explained and conditions that the MOS achieves and maintains a desired steady state are given.Second,after the operation mechanism of self-organization and self-adaptive and the discipline of state evolution about MTO/MOS is cleared, the organization mode,which is one of the control parameters that affect the state of the MOS staff,is further studied. When the variety,tasks (that is the planning input) and the delivery of the orders change intricately,according to the mechanism of self-organization and self-adaptive,the dynamic organization mode is analyzed and built.The detail is illustrated as follows:the influencing factors, characteristics and the manifestation styles of the organization mode about MTO/MOS are analyzed,the quantities in the same period about every static operation mode are calculated and compared,and the flow charts about three dynamic organization modes based on new order tasks, imbalance in the schedule and emergency plugging new orders are drawn.The principles and conditions that the MTO/MOS carried out the dynamic organization mode are described.Based on the employee’s initiative and multi-skilled,the mechanism and system about the MOS dynamic organization mode is studied by using the method of Multi-Agent, and the concepts of Coordination Agent,Reconfiguration Agent,Task Agent, Virtual Work Center Agent and Employee Agent are proposed. According to the mechanism of autonomous and coordination,the control architecture chart about the MTO/MOS dynamic organization mode is established based on Multi-Agent. The relations and functions of each Agent are explained on the basis of the above chart.Third,from the above we know that the complexity of the amount of task change is one of the factors influencing the MOS dynamic organization mode,while the task amount is the planning input. As the random rate of qualified products,the quality learning rate and the uncertain rate of efficient rework is considered,the decisions of optimal planning input are made respectively for the single-stage and multi-stage of production.The specifics are displayed as follows:a)After the description of actual problems,the model about planning input yields that only considering the random rate of qualified products is built for the single stage,the model is applied and tested through a numerical example. The sensitivity about the mean and standard deviation of the rate of qualified products, the probability of the initial unqualified product and the learning coefficient is analyzed, some relevant conclusions are drawn,b) It models and makes optimal decisions about the planning input yields for the single production stage while comprehensively considering the rate of qualified products which obeys continuous distribution and the rate of efficient rework which obeys discrete distribution. The validity of the model is tested and the relevant law is obtained by numerical examples. The sensitivity about the mean and standard deviation of the rate of qualified products is analyzed. c)For the multi-stage production system, it models, solves and makes optimal decisions about the problem of planning input quantities and corresponding costs while considering the qualified rate of each stage is constant, subjecting to random discrete distribution and continuous distribution. The theoretical derivation and numerical examples are carried out and some relevant conclusions are drawn.Fourth, for the another important factor that affects the MTO/MOS organization mode——the complex change about the order delivery,the decision of the optimal order date before input and the guaranteed delivery after input and makespan prediction is studied, the details are showed as follow:a)For the time decision of the materials order,the eight kinds of situation are considered that correspond to the types of raw materials one or more,the makespan is determined or random and whether or not to consider rework., the optimal models are established, analyzed,and solved respectively and the models are applied and tested through numerical analysis. b)After materials supplying and the other production preparation,the orders would be arranged to go to production. For the factors affecting the makespan,it is predicted based on statistical analysis,the interval about prediction is modeled and the numerical simulation is taken, the sensitivity analysis about the mean of makespan is carried out and the measures about controlling the makespan influencing factors are proposed. c) The custom demand delivery model is established according to some assumption and the model of guaranteed delivery and price decision is determined,the numerical example is going on at last.The full-text is studied closely around the four core performances(cost, quality, quantity, delivery time) of the MTO/MOS.That is:the first part is the basic theoretical research and plays a general role about the full text. The second part plays a connecting role,while the third, fourth part has a strong correlation with the front parts.The study is sponsored by the National Nature Science Foundation.(Name:Research about optimization and organization of the Manual Operation System under the mode of Make-to-Order (MTO/MOS), No:70971026).