TW201428647A - System and method for controlling arrangement of production line - Google Patents
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本發明涉及一種透過電腦控制工業生產的系統及方法,尤其涉及一種透過電腦控制工業生產現場的產線進行生產排配的系統及方法。 The present invention relates to a system and method for controlling industrial production through a computer, and more particularly to a system and method for controlling production and distribution of a production line at an industrial production site through a computer.
目前,在工業生產過程中,上游生產線和下游生產線的資源利用率均沒有達到一個較高的水平。例如,由於上游生產線的速度遠大於下游生產線的速度,當下游生產線在生產時,上游生產線可能處於空閒狀態。為了提高上游生產線的資源利用率,通常的做法是,根據人為的操作經驗將空閒的生產線進行外協加工生產副成品或同步副成品。然而,根據人為的操作經驗進行外協加工的方法生產效率並不高,且準確性也不可靠。同時,當生產線上不同決策者站在各自的操作經驗產生不同的決策意見時,由於缺乏及時有效的資訊傳遞,無法參考每個決策者的意見作出一個合適的生產排配決定。因此,急切需要借助一種電腦控制系統來參考生產線上涉及的各種參數,對產線排配控制進行仿真以輔助產線決策者作出優化的生產排配計畫。 At present, in the industrial production process, the resource utilization rates of the upstream production line and the downstream production line have not reached a high level. For example, because the speed of the upstream production line is much greater than the speed of the downstream production line, the upstream production line may be idle when the downstream production line is in production. In order to improve the resource utilization rate of the upstream production line, it is common practice to independently process the idle production line to produce the finished product or the synchronous by-product according to the human operation experience. However, the method of external processing based on humanized operational experience is not efficient and the accuracy is not reliable. At the same time, when different decision makers on the production line stand on their own operational experience to generate different decision-making opinions, due to the lack of timely and effective information transmission, it is impossible to make a suitable production allocation decision with reference to the opinions of each decision maker. Therefore, it is urgent to use a computer control system to refer to various parameters involved in the production line, and to simulate the production line scheduling control to assist the production line decision makers to optimize the production allocation plan.
鑒於以上內容,有必要提供一種產線排配控制系統,應用於電腦中,該系統包括:參數設定模組,用於設定工業生產過程中的上游生產 線生產加工時涉及的各種基本模型參數,該基本模型參數包括已知參數和未知參數,其中,所述未知參數為上游第i條生產線在第k個調度週期生產的產品數量u i (k),所述已知參數包括上游生產線的條數M、上游生產線的調度週期數N、上游第i條生產線生產的副成品和同步副成品的單位價格γ i 、上游第i條生產線各工位元單位時間的加工成本σ i 、上游第i條生產線各工位在週期k加工M i 種零件所需的時間T i 、上游第i條生產線各工位在週期k加工M i 種零件之前所需要的準備時間、上游第i條生產線各工位元單位時間的準備成本δ i 、上游第i條生產線中每個工位元超負荷造成的成本係數c i 、上游第i條生產線中與設備閒置有關的成本係數、上游第i條生產線各個工位在週期k的可用時間ρ i (k)、以及設備切換的損耗成本w i (k);模型建立模組,用於以上述未知參數作為決策變數,並根據所述已知參數針對一預定規劃目標建立一線性規劃模型,該線性規劃模型為多約束水平的線性規劃模型;計算模組,用於對上述線性規劃模型進行求解,得到該線性規劃模型的最優解;及結果輸出模組,用於將上述求得的最優解透過電腦的顯示設備輸出。 In view of the above, it is necessary to provide a production line arrangement control system for use in a computer, the system comprising: a parameter setting module for setting various basic model parameters involved in the production and processing of an upstream production line in an industrial production process, The basic model parameters include known parameters and unknown parameters, wherein the unknown parameters are the number of products u i ( k ) produced by the upstream i-th production line during the kth scheduling period, the known parameters including the number of upstream production lines M, upstream production line scheduling period N, the i-th upstream of the production line of the sub-finished products and synchronization sub-finished product unit price γ i, the processing cost i-th upstream production line workers bit unit time σ i, i-th upstream time required for each station line in the processing cycle of k kinds of parts M i T i, the i-th line upstream of each station before the processing cycle k M i kinds of parts required for preparation time , The i-th line upstream of each station to prepare cost-bit unit time [delta] i, the i-th line in each station upstream of bit cost by overloading coefficients C i, the i-th line upstream production costs associated with the equipment idle coefficient The available time ρ i ( k ) of each station of the upstream i-th production line in the period k , and the loss cost w i ( k ) of the device switching; the model building module is configured to use the above unknown parameter as the decision variable, and according to The known parameter establishes a linear programming model for a predetermined planning target, the linear programming model is a linear programming model with multiple constraints, and a computing module is used to solve the linear programming model to obtain the most linear programming model. An optimal solution; and a result output module for outputting the optimal solution obtained above through a display device of the computer.
還有必要提供一種產線排配控制方法,包括:參數設定步驟,設定工業生產過程中的上游生產線生產加工時涉及的各種基本模型參數,該基本模型參數包括已知參數和未知參數,其中,所述未知參數為上游第i條生產線在第k個 調度週期生產的產品數量u i (k),所述已知參數包括上游生產線的條數M、上游生產線的調度週期數N、上游第i條生產線生產的副成品和同步副成品的單位價格γ i 、上游第i條生產線各工位元單位時間的加工成本σ i 、上游第i條生產線各工位在週期k加工M i 種零件所需的時間T i 、上游第i條生產線各工位在週期k加工M i 種零件之前所需要的準備時間、上游第i條生產線各工位元單位時間的準備成本δ i 、上游第i條生產線中每個工位元超負荷造成的成本係數c i 、上游第i條生產線中與設備閒置有關的成本係數、上游第i條生產線各個工位在週期k的可用時間ρ i (k)、以及設備切換的損耗成本w i (k);模型建立步驟,以上述未知參數作為決策變數,並根據所述已知參數針對一預定規劃目標建立一線性規劃模型,該線性規劃模型為多約束水平的線性規劃模型;計算步驟,對上述線性規劃模型進行求解,得到該線性規劃模型的最優解;及結果輸出步驟,將上述求得的最優解透過電腦的顯示設備輸出。 It is also necessary to provide a production line arrangement control method, comprising: a parameter setting step of setting various basic model parameters involved in the production and processing of the upstream production line in the industrial production process, wherein the basic model parameters include known parameters and unknown parameters, wherein The unknown parameter is the number of products u i ( k ) produced by the upstream i-th production line in the kth scheduling period, and the known parameters include the number M of the upstream production line, the number of scheduling cycles of the upstream production line N , and the upstream i Article production line sub-finished products and synchronization sub-finished product unit price gamma] i, the processing cost [sigma] i i-th upstream production line workers bits per unit time, the i-th upstream production lines each station in the cycle k processing M i kinds of parts of the The required time required for the time T i and the upstream i-th production line to process the M i parts in the cycle k , The i-th line upstream of each station to prepare cost-bit unit time [delta] i, the i-th line in each station upstream of bit cost by overloading coefficients C i, the i-th line upstream production costs associated with the equipment idle coefficient The available time ρ i ( k ) of each station of the upstream i-th production line in the period k , and the loss cost w i ( k ) of the device switching; the model establishing step, using the above unknown parameter as the decision variable, and according to the Knowing parameters establish a linear programming model for a predetermined planning target. The linear programming model is a linear programming model with multiple constraints. The calculation steps solve the linear programming model to obtain the optimal solution of the linear programming model; and the output of the result In the step, the optimal solution obtained above is output through a display device of the computer.
相較於習知技術,本發明產線排配控制系統及方法,可-根據不同決策者給出的各種資源,如時間、成本等的可利用水平,使用生產線上涉及的各種基本參數建立預定目標的多約束水平的線性規劃模型,然後求解該多約束水平的線性規劃模型的最優解,該最優解對應的生產排配計畫即可提供給產線生產排配人員做參考,以作出較優的生產 排配計畫。由於本發明產線排配控制系統及方法獲取了各產線的參數,並依據優化演算法獲取線性規劃模型的最優解,得出最適當的生產排配計畫,從而得以提高產線的資源利用率。 Compared to conventional techniques, the production line with the exhaust system of the present invention and the control method can be - according to different makers given resources, such as time, cost and the like can be used horizontally, using a variety of basic parameters related to establishment of a predetermined line a multi-constraint horizontal linear programming model of the target, and then solving the optimal solution of the linear programming model of the multi-constraint level, the production allocation plan corresponding to the optimal solution can be provided to the production line production staff for reference, Make a better production allocation plan. Since the production line scheduling control system and method of the invention obtains the parameters of each production line, and obtains the optimal solution of the linear programming model according to the optimization algorithm, the most appropriate production allocation plan is obtained, thereby improving the production line. Resource utilization.
首先,對本發明所需用到的幾個概念進行說明: First, several concepts that are needed for the present invention are explained:
主成品:由工業生產過程中的上游生產線生產並供給下游主生產線使用的成品;其中,本實施例中,下游生產線對上游生產線的主成品的需求量為已知。 Main product: The finished product produced by the upstream production line in the industrial production process and supplied to the downstream main production line; wherein, in this embodiment, the demand for the main product of the upstream production line of the downstream production line is known.
副成品:上游生產線生產的供給下游副生產線使用的不需同步的成品;同步副成品:上游生產線生產的供給下游副生產線的需同步的成品。 By-products: Finished products that are used in downstream production lines for upstream production lines that do not need to be synchronized; Synchronous by-products: Products that need to be synchronized to the downstream sub-production line produced by the upstream production line.
如圖1所示,係本發明產線排配控制系統10功能架構的示意圖。該產線排配控制系統10應用於電腦1中。該電腦1包括記憶體11、處理器12、顯示設備13。該產線排配控制系統10包括參數設定模組101、模型建立模組102、計算模組103以及結果輸出模組104。 As shown in FIG. 1, it is a schematic diagram of the functional architecture of the production line distribution control system 10 of the present invention. This line allocation control system 10 is applied to the computer 1. The computer 1 includes a memory 11, a processor 12, and a display device 13. The line allocation control system 10 includes a parameter setting module 101, a model building module 102, a computing module 103, and a result output module 104.
在本實施例中,考慮到上游生產線生產速度遠大於下游生產線的生產速度,隨著上游生產線的不斷生產,位於上游生產線和下游生產線之間的主成品有限緩衝區(產品暫存區)的產品數量逐漸增加,當其容量達到最大值時,上游生產線切換到副成品或同步副成品的生產加工。本發明的產線排配控制系統10基於所獲取的多種參數建立線 性規劃仿真模型,類比出上游生產線在滿足主成品生產加工的前提下,各條上游生產線在各生產調度週期內需生產各類副成品以及同步副成品的數量,以提供給生產現場排配人員參考,從而使得生產線的產能達到最大效益,使得產線資源利用率處於一個較高的水平。 In this embodiment, considering that the production speed of the upstream production line is much larger than the production speed of the downstream production line, with the continuous production of the upstream production line, the product of the main product limited buffer (product temporary storage area) located between the upstream production line and the downstream production line The quantity is gradually increased, and when its capacity reaches the maximum value, the upstream production line is switched to the production process of the secondary product or the synchronous by-product. The line scheduling control system 10 of the present invention establishes a line based on the acquired plurality of parameters. Sexual planning simulation model, analogous to the upstream production line in the premise of meeting the production and processing of the main finished product, each upstream production line needs to produce various types of by-products and synchronous by-products in each production scheduling cycle, to provide reference to the production site. In order to maximize the production capacity of the production line, the utilization rate of the production line resources is at a high level.
例如圖2所示,係本發明產線排配控制系統10的流程圖。下面結合圖2對產線排配控制系統10包括的各功能模組進行詳細描述。 For example, as shown in FIG. 2, a flow chart of the line allocation control system 10 of the present invention. The functional modules included in the production line distribution control system 10 will be described in detail below with reference to FIG.
步驟S01,所述參數設定模組101設定上游生產線生產時涉及的各種基本模型參數,該基本模型參數包括未知參數和已知參數。本實施例中,所述未知參數為上游第i條生產線在第k個調度週期生產的產品數量u i (k),所述已知參數包括上游生產線的條數M、上游生產線的調度週期數N、上游第i條生產線生產的副成品和同步副成品的單位價格γ i 、上游第i條生產線各工位元單位時間的加工成本σ i 、上游第i條生產線各工位在週期k加工M i 種零件所需的時間T i 、上游第i條生產線各工位在週期k加工M i 種零件之前所需要的準備時間、上游第i條生產線各工位元單位時間的準備成本δ i 、上游第i條生產線中每個工位元超負荷造成的成本係數c i 、上游第i條生產線中與設備閒置有關的成本係數、上游第i條生產線各個工位在週期k的可用時間ρ i (k)、以及設備切換的損耗成本w i (k)。 In step S01, the parameter setting module 101 sets various basic model parameters involved in the production of the upstream production line, and the basic model parameters include unknown parameters and known parameters. In this embodiment, the unknown parameter is the quantity u i ( k ) of the product produced by the upstream i-th production line in the kth scheduling period, and the known parameters include the number M of the upstream production line and the scheduling period of the upstream production line. N, the unit price of the i-th upstream of the production line of the sub-finished products and synchronous subsidiary finished γ i, the processing cost i-th upstream production line workers bit unit time σ i, i-th upstream of the production lines of the bit processing cycle k the time required for kinds of parts M i T i, the i-th line upstream of each station before the processing cycle k M i kinds of parts required for preparation time , The i-th line upstream of each station to prepare cost-bit unit time [delta] i, the i-th line in each station upstream of bit cost by overloading coefficients C i, the i-th line upstream production costs associated with the equipment idle coefficient The available time ρ i ( k ) of each station of the upstream i-th production line in the period k , and the loss cost w i ( k ) of the device switching.
其中,所述產品數量u i (k)為維列向量,m i 為上游第i條生產線加工的副成品的種類數,為上游第i條生產 線加工的同步副成品的種類數;所述加工成本σ i 為f i 維列向量,f i 為第i條生產線加工工位的數量;所述時間T i 為f i ×Mi維矩陣;所述準備時間為f i ×Mi維矩陣;所述準備成本δ i 為f i 維列向量;所述成本係數c i 為f i 維列向量;所述成本係數為f i 維列向量;以及所述可用時間ρ i (k)為f i 維列向量。 Wherein the quantity u i ( k ) of the product is The dimension vector, m i is the number of types of by-products processed by the upstream i-th production line, The number of types of synchronous by-products processed for the upstream i-th production line; the processing cost σ i is a f i -dimensional column vector, f i is the number of processing stations of the i-th production line; and the time T i is f i × M i -dimensional matrix; the preparation time a f i ×M i -dimensional matrix; the preparation cost δ i is a f i -dimensional column vector; the cost coefficient c i is a f i -dimensional column vector; the cost coefficient The vector is a f i -dimensional column; and the available time ρ i ( k ) is a f i -dimensional column vector.
步驟S02,所述模型建立模組102以所述未知參數作為決策變數,並根據所述已知參數針對一預定規劃目標建立一線性規劃模型。本實施例中,該預定的規劃目標為取得上游生產線生產副成品和同步副成品的最高生產效益,建立的線性規劃模型的目標函數為:
其中,參數u i (k)為產線排配的決策變數,其他參數為已知參數。此外,該線性規劃模型為基於多約束水平的線性規劃模型。該線性規劃模型包括預定的成本約束條件、預定的時間約束條件、預定的產品加工數量約束條件、預定的同步副成品約束條件以及每個調度週期生產的產品數量非負的約束條件。 Among them, the parameter u i ( k ) is the decision variable of the production line allocation, and other parameters are known parameters. In addition, the linear programming model is a linear programming model based on multiple constraint levels. The linear programming model includes predetermined cost constraints, predetermined time constraints, predetermined product processing quantity constraints, predetermined synchronized by-product constraints, and non-negative constraints on the number of products produced per scheduling period.
具體地,所述預定的成本約束條件為:
所述預定的時間約束條件為:。其中,P i 和Q i 分別為不同決策者給出的時間約束水平,均代表加工副成品和同步副成品的時間,為f i 維列向量,如P i =[p i1,p i2,...,p ij ,...,p ifi ],其中,S max為上游生產線和下游生產線之間的主成品的有限緩衝區(產品暫存區)可存放主成品的最大容量,S min為上游生產線和下游生產線之間的主成品的有限緩衝區中允許的主成品的最小容量,V為上游生產線生產主成品的的速度,該速度為為已知參數。 The predetermined time constraint is: . Among them, P i and Q i are the time constraint levels given by different decision makers respectively, which represent the time of processing the by-products and the synchronous by-products, which are f i -dimensional column vectors, such as P i =[ p i 1 , p i 2 ,..., p ij ,..., p ifi ], where , S max is the limited buffer of the main finished product between the upstream production line and the downstream production line (product temporary storage area) can store the maximum capacity of the main finished product, and S min is the limited buffer of the main finished product between the upstream production line and the downstream production line. The minimum capacity of the permitted main finished product, V is the speed at which the upstream production line produces the main finished product, which is a known parameter.
所述預定的產品加工數量約束條件為:。其中x i 和y i 分別為不同決策者給出的產品加工數量的約束水平,均為維列向量,用於表示一個生產調度週期中上游第i條生產線計畫生產的產品數量。 The predetermined product processing quantity constraint is: . Where x i and y i are respectively the constraint levels of the number of products processed by different decision makers, Dimension vector, used to represent the number of products produced by the i-th production line plan in a production scheduling cycle.
所述預定的同步副成品約束條件為:
其中:B 1和B 2分別為不同決策者給出的同步副成品個數的約束水平,L表示用戶對上游生產線同步副成品的需求為L組,每組中有s l (l=1,2,...,L)種同步副成品需要保持同步,U lim(k)為第l同步組中第i條上游生產線中第m種同步副成品 的個數,U ljn (k)為第l同步組中第j條上游生產線中第n種同步副成品的個數,λ lim jn 為所述U lim(k)和U ljn (k)的配套之比。 Among them: B 1 and B 2 are the constraint levels of the number of synchronized by-products given by different decision makers respectively, and L indicates that the demand of the user for the synchronous production of the upstream production line is L group, and each group has s l ( l =1, 2, ..., L) one of the sync sub-finished product needs to be synchronized, U lim (k) l is the number of synchronization groups i-th line upstream of the first one of the sync sub-finished m, U ljn (k) for the first l The number of the nth synchronous by-product in the jth upstream production line in the synchronization group, and λ lim jn is the matching ratio of the U lim ( k ) and U ljn ( k ).
所述產品數量非負的約束條件為:u i (k)0。 The constraint that the quantity of the product is non-negative is: u i ( k ) 0.
綜合以上目標函數以及各種約束條件,本實施例建立的線性規劃模型可表示如下:J=MaxF(X)
步驟S03,所述計算模組103對上述線性規劃模型進行求解,得到該線性規劃模型的最優解,該最優解為包括多組解的一個解集,每一組解體現了所述不同的決策者給出的各種約束水平在一個特定的權重組合下,如(0.4,0.6),第k個生產調度週期內第i條上游生產線生產的產品數量u i (k)。透過該解集可以看出第k個生產調度週期內第i條上游生產線生產的各類副成品與同步副成品的數量,由於各類副成品和同步副成品的生產順序為預定的順序,因此根據該解集可進一步體現每個生產調度週期內各類副成品與同步副成品的詳細排配計畫。產線排配人員可根據實際情況(如所述不同決策者給出的約束水平所佔的權重)選擇合適的一組解作為產線生產排配的參考。此外,該解 集考慮了不同決策者的站在各自角度給出的約束水平,可利於產線管理人員參考該解集對產線的生產調度進行優化排配。本實施例中,該計算模組103可使用單純型演算法(Simplex algorithm)求得該線性規劃模型的最優解。該計算模組103可根據需要多次調用單純型演算法,直到求得該線性規劃模型的最優解。 Step S03, the calculation module 103 solves the linear programming model to obtain an optimal solution of the linear programming model, where the optimal solution is a solution set including multiple sets of solutions, and each set of solutions reflects the difference The various constraint levels given by the decision makers are under a specific weight combination, such as (0.4, 0.6), the number of products u i ( k ) produced by the i-th upstream production line in the kth production scheduling period. Through the solution set, the quantity of various types of by-products and synchronous by-products produced by the i-th upstream production line in the kth production scheduling period can be seen. Since the production order of various types of by-products and synchronous by-products is in a predetermined order, According to the solution set, the detailed arrangement plan of various types of by-products and synchronous by-products in each production scheduling cycle can be further embodied. The production line staff can select an appropriate set of solutions as a reference for the production line allocation according to the actual situation (such as the weight of the constraint level given by different decision makers). In addition, the solution set considers the level of constraints given by different decision makers at their respective angles, which can help the production line managers to optimize the production scheduling of the production line with reference to the solution set. In this embodiment, the computing module 103 can obtain an optimal solution of the linear programming model using a simplex algorithm. The calculation module 103 can call the simple type algorithm multiple times as needed until the optimal solution of the linear programming model is obtained.
具體地,在計算所述最優解時,計算模組103首先引入一約束水平參數λ=(λ 1,λ 2)與上述各約束條件中的約束水平相乘,將上述多約束水平的線性約束條件轉化為單約束水平的線性約束條件,其中λ 1,λ 2分別代表上述不同決策者所佔的比重,該λ 1,λ 2的取值區間為[0,1],其中,λ 1+λ 2=1。另外,計算模組再將λ 1,λ 2的取值區間[0,1]網格化(離散化)為多個取值點,並根據離散化後的多個取值點多次調用單純型演算法求得上述線性規劃模型的最優解。本實施例中,引入約束水平參數λ=(λ 1,λ 2)對上述多約束水平的線性約束條件進行轉化後得到的單約束水平的線性約束條件如下:
步驟S04,所述結果輸出模組104將求得的最優解透 過所述顯示設備13輸出,以便於生產管理人員根據該最優解對生產線進行最優的生產排配,從而提高生產線的資源利用率。 Step S04, the result output module 104 will obtain the optimal solution The output of the display device 13 is outputted, so that the production manager can perform optimal production scheduling on the production line according to the optimal solution, thereby improving the resource utilization rate of the production line.
最後應說明的是,以上實施方式僅用以說明本發明的技術方案而非限制,儘管參照較佳實施方式對本發明進行了詳細說明,本領域的普通技術人員應當理解,可以對本發明的技術方案進行修改或等同替換,而不脫離本發明技術方案的精神和範圍。 It should be noted that the above embodiments are merely illustrative of the technical solutions of the present invention, and the present invention is not limited thereto. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that Modifications or equivalents are made without departing from the spirit and scope of the invention.
1‧‧‧電腦 1‧‧‧ computer
10‧‧‧產線排配控制系統 10‧‧‧Production line control system
101‧‧‧參數設定模組 101‧‧‧ parameter setting module
102‧‧‧模型建立模組 102‧‧‧Model building module
103‧‧‧計算模組 103‧‧‧Computation Module
104‧‧‧結果輸出模組 104‧‧‧Result output module
11‧‧‧記憶體 11‧‧‧ memory
12‧‧‧處理器 12‧‧‧ Processor
13‧‧‧顯示設備 13‧‧‧Display equipment
圖1為本發明產線排配控制系統運行於一電腦的示意圖。 1 is a schematic view of the production line control system of the present invention running on a computer.
圖2為本發明產線排配控制方法較佳實施例的流程圖。 2 is a flow chart of a preferred embodiment of a production line arrangement control method of the present invention.
1‧‧‧電腦 1‧‧‧ computer
10‧‧‧產線排配控制系統 10‧‧‧Production line control system
101‧‧‧參數設定模組 101‧‧‧ parameter setting module
102‧‧‧模型建立模組 102‧‧‧Model building module
103‧‧‧計算模組 103‧‧‧Computation Module
104‧‧‧結果輸出模組 104‧‧‧Result output module
11‧‧‧記憶體 11‧‧‧ memory
12‧‧‧處理器 12‧‧‧ Processor
13‧‧‧顯示設備 13‧‧‧Display equipment
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US20220317644A1 (en) * | 2020-02-28 | 2022-10-06 | Boe Technology Group Co., Ltd. | Production programming system and method based on nonlinear program model, and computer-readable storage medium |
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