Research On Lean Advanced Planning And Scheduling In Discrete Manufacturing Industry

According to characteristics of discrete manufacturing industry, the traditional single variety and mass production mode turning to the multi variety and small-batch production mode which is market-oriented, various kinds of wasted phenomena in practical production process which increases the production cost invisibly and minifies the profit of manufacturing industry seriously has been displayed. In order to eliminate the wasted phenomena in practical production process as much as possible,improve the efficiency on production line,promote employee'smorale and the quality of products, this paper introduces the effective management mode of "Lean Production" which has been generally acknowledged by manufacturing industry.As we all know, the production plan plays an very important role in enterprise management of discrete manufacturing industry. Whether the production plan can satisfy the order demands, adapt to market changes or control the cost accurately,has a profound influence of enterprise development. ERP has made an effort to this aspect, but because of the technical bottleneck in current system construction of ERP(System developers are not familiar with technological processes and there exists defects in MRP), few ERP system can be turely succeeful. Appearance of APS makes optimization and supplement of ERP. APS has simulation ability which can shorten the production lead time and provide customers promised due dates under the constraints of production time, production ability and working procedures.In this way, APS has improved the success rate of ERP implementation.Take First Casting Subplant of FAW for instance, although this enterprise has already had ERP system, almost all the production plans have been manual operated, owing to lack of APS system that can make and modify the production plan rapidly according to marketing demands. This manner not only has a large quantity of task,but also formulates the production plan that is different from orders, so that it leads to the overstock of invalid inventory and the increase of production cost.In order to solve this problem, the author proposes a model of APS in Lean Production Mode (LAPS). Aimming at balanced production,This paper builds order-inserting model of LAPS model. Considering the constraints of processing capacity of machining center, order category, market volatility,planners insert the new orders, improving the flexibility of production plans. Compared with original ERP system, APS system shows five different points:constraint of plan, time segment of plan, transmitting direction of plan, promised due dates of plan, simulation ability of plan. After order inserting, APS system generates production task document. Aimming at the minimum penalty cost of advanced delivery and delayed delivery,this paper builds scheduling model of LAPS model with two algorithms:"batch scheduling" and" pipelining scheduling", in order to get detialer scheduling document of work center as the production basis in workshop. Then the author simulates the aboved example. Though data analysis and theoretical demonstration of simulation results,it proves that LAPS modal can optimize the business process of discrete manufacturing industry.