Research Of The Pull Control Method Of Complicated Manufacturing Process Based On Kanban

With the continuous development of society and technology, as well as the constantchange of demand, the product manufacturing process becomes more and more complex.Therefore, it is difficult to establish accurate mathematical model and also make all typesof manufacturing process management and optimization strategy based on abovemathematical model is difficult to directly used for enterprise practice and produce directeffect. Application of pull production in the enterprise can effectively compensate for thedeficiencies of the traditional mode of production, and the establishment of productionmode based on customer demand can achieve the rapid reaction to the market and avoidthe product backlog.Therefore, in this thesis, JIT flexible manufacturing system for complex productmanufacturing process is regard as background. Based on system simulation technology,Kanban control mode, Conwip control mode and hybrid Conwip control mode of threetypical pull control modes are regard as the object to study modeling and optimizationmethods of production process under different production control modes, to establish themechanism of bottleneck resource identification and elimination in production controlprocess, then a comparative analysis of three control effect and optimization capabilitieswill be shown.This thesis use Petri nets theory to describe the production process and present themodel of complex production process under single Kanban control mode, Conwip controlmode and Push/Conwip control mode respectively, and combine control mode and flexiblemanufacturing system to get Petri net model of JIT flexible manufacturing system.On this basis, this thesis use ExSpect simulation platform to analog JIT flexiblemanufacturing system production process. Aim at three control modes, in order to improvethe machine utilization, control the production rhythm, and optimize the systemperformance, respectively simulate JIT flexible manufacturing system with different quantity of demands, whether the buffer limit. Through the analysis of the simulation dataand according to characteristics of control modes, it is concluded that simulationoptimization methods. Specifically including through the system priority setting, so thatthe manufacturing resources allocated averaging and focus; application of Poissondistribution formula and Toyota formula for the initial system kanban setting to satisfy theservice level of system; setting bottleneck area kanban number and buffer size to solve theproblem of bottleneck and hunger; setting processing ratio between bottleneck area andparallel area to eliminate bottleneck and improve system performance.This thesis analyzes and contrasts JIT flexible manufacturing systems simulation dataunder three control modes. The simulation results showed that simulation optimizationmethods can solve the bottleneck problem effectively and optimize the systemperformance. Through the comparison of simulation data, it is concluded that theadvantages and disadvantages of three control modes and their applicable scopes.