Atölye tipi üretim için modüler çizelgeleme ve kontrol paketi
Modular scheduling and control package for job shop production
- Tez No: 14393
- Danışmanlar: PROF.DR. MURAT DİNÇMEN
- Tez Türü: Doktora
- Konular: Endüstri ve Endüstri Mühendisliği, Industrial and Industrial Engineering
- Anahtar Kelimeler: Belirtilmemiş.
- Yıl: 1991
- Dil: Türkçe
- Üniversite: İstanbul Teknik Üniversitesi
- Enstitü: Fen Bilimleri Enstitüsü
- Ana Bilim Dalı: Belirtilmemiş.
- Bilim Dalı: Belirtilmemiş.
- Sayfa Sayısı: 228
Özet
ÖZET Bu çalışmada ilk aşamada atölye tipi üretim için çizelgeleme ve kontrol fonksiyonlarının farklı yaklaşımlar da kullanılabilecek şekilde modüler hale getirilmesi amaçlanmıştır. Daha sonra bu fonksiyonel -modül er yapı yardımıyla bir atölye kontrol sistem tasarımının nasıl yapıla cağı açıklanmıştır. Oluşturulan sistem üç ana modülden meydana gelmektedir: 1- imalat veri tabanı 2- imalat çizelgeleme 3- imalat kontrol Bu ana modüller birçok alt modüllere bölünerek, standart modüller elde edilmeye çalışılmıştır. Bunun yanında, bu modülleri besleyen destek modüller de sistemde mevcut tur. imalat veri tabanı çizelgeleme ve kontrol modüllerinin veri ihtiyacını karşılayacak şekilde tasarlanmıştır. Çizelgeleme modülü farklı çizelgeleme teknikleri göz önüne alınarak düzenlenmiş ve bir sınırlı kapasiteli çizelgeleme algoritması geliştirilmiştir. Modül imalat veri tabanı ve ihtiyaç planlama destek modülü yardımıyla kendi veri (sipariş bilgileri) dosyasını oluşturmaktadır. Modüle ilave edilen raporlar ve performans analiz alt modülleri ile çizelgelemenin etkinliği çeşitli ölçütlere göre değerlendirilmektedir. imalat kontrol modülü, öncelik kuralı esaslı MRP-II (Manufacturing Resource Planning) tekniği ile LMC (Load- Oriented Manufacturing Control) olarak adlandırılan atölye yüküne bağlı teknik için çalışılabilecek şekilde tasarlanmıştır. Bu iki teknik gerçek sistem verileri ile çizelgeleme modülü çıktıları kullanılarak, hazırlanan bir simülasyon paketi ile farklı öncelik kuralları ve yük sınırları için simüle edilmiştir. Mevcut sistem için, çeşitli performans kriterlerine göre, elde edilen sonuçlar yüke bağlı imalat kontrol tekniğinin daha iyi neticeler verdiğini göstermiştir. VI
Özet (Çeviri)
SUMMARY MODULAR SCHEDULING AND CONTROL PACKAGE FOR JOB SHOP PRODUCTION In this study it was aimed at making modular sche duling and control functions in job-shop production with a computerized system for different approaches. Characteristics of job-shop production and job-shop scheduling & controlling functions were handled at first. Besides that, the differences between various production plannig and control (PPC) approaches in all over the world were brought into view. These approaches are the followings: 1 - MRP-II (Manufacturing Resource Planning) 2 - JIT (Just-in Time Production) 3 - OPT (Optimized Production Technology) 4 - LMC (Load-oriented Manufacturing Control) MRP systems are considered push systems. This means that a list of reguired materials is generated in order to produce a specific number of output units. This in turn generates purchase orders and production orders. In the Japanese pull environment, materials are not fed into the production cycle until the finished product is actually required. Product requirements, not forecasts, trigger production. In OPT, production is not scheduled with either a“push”or“pull”technique, but on a“bottleneck”basis. The bottleneck areas in a facility are analyzed and then emphasized. Production is planned so that bottleneck work center will be planned to keep the bottleneck depart ments working at full production at all times. Load-oriented manufacturing control is a new appro ach for job shops producing parts in small lots. The nucleus of load-oriented manufacturing control is the technique load-oriented order release. This simple and consistent technique was developed during research at the Institut fiir Fabrikanlagen of the Universitat Hannover, West Germany. Load-oriented manufacturing control app roach was examined in detail in Chapter 3. In Chapter II» after definition of job shop schedu ling problem, solution approaches were illustrated. Many different approaches to the scheduling problem have been suggested. These can be categorised into three main areas: VII1 - Optimal approaches, 2 - Heuristic methods, 3 - Artifical intelligence applications. Research into optimal solutions for the scheduling problem has often been necessary to make various simpli fying assumptions. Heuristic method is a problem-solving procedure or rule of thumb that has been shown to produce good results but cannot guarantee optimal results. In this study, scheduling problem has been with this approach. Knowledge-based systems are still being developed but seems to be quite succesful so far. The time required to produce a schedule is not reported, but it will take some time to search the knowledge base to find a schedule. There are many possible scheduling objectives. The most obvious is to increase the utilization of the resour ces - that is, to reduce the resource idle time. Another important scheduling objective is to reduce in-process inventory - that is, to reduce the average num ber of tasks waiting in a queue while the resources are busy with other tasks. One final objective for scheduling is to reduce some or all of the tasks have due dates and a penalty is incui - red if a task is finished after that date. Related to these objectives, there are various per formance criterias for performance measurement of schedu ling. These can be classified into three groups: - criteria based upon completion times, - criteria based upon due dates, - criteria based upon the inventory and utilisation costs. Besides that different performance values are pro vided for different priority rules used during scheduling process. Some of the priority rules are: - EDD (Earl ist Due Date) - MINSOP (Minimum of Slack Time Per Operation) - CR (Critical Ratio) - FIFO (First in First out) - SPT (Shortest Processing Time) Some differences have appeared in scheduling tech niques compared to MRP in new approaches (KANBAN &. OPT) mentioned above. Scheduling techniques are divided into two types at first: VIII- forward scheduling, - backward scheduling. In MRP oriented approach. the schedule is then backed off by the calculated lead time components. No extra days are included between operations and infinite capacity is assumed. For years, the conventional wisdom has been that the only scheduling systems that work in practice assume infinite capacity during the planning process and use a seperate capacity planning module augumented by the shop foreman's intuition to smooth the load to release orders. Several things have changed. Queue time has been elimina ted since each order is being finitely and exactly schedu led into and out of each work center. The only reasons to include any queue time would be to allow for uncerta inty in the setup and run times for each operation and for unplanned work, not to allow for slop and inaccuracy in the scheduling algorithm. Once we decide to use finite capacity scheduling, a final optimization of the algorithm becomes possible. In many manufacturing shops, it is possible and even desirable to split lots is completed. In fact, on a moving assembly line, the partial lot usually has a quantity of one. This technique is called overlap scheduling and can significantly reduce lead time and work-in-process inven tory if properly used. The Japanese Kanban system is an example of overlap scheduling carried to is logical ext reme. The quantity contained in the standart parts con tainer that, along with Kanban cards, is used to control material movement is the partial lot quantity. In Chapter 3, manufacturing (shop floor) control system and it's functions were handled. The functions that create shop floor control system can be listed as follows: 1- Scheduling, 2- Order release, 3- Dispacthing (Priority control), 4- Monitoring, 5- Performance control. These functions are handled one-by-one and are illustrated usage differences in different approaches, scheduling function, as has been mentioned above, was handled as a seperate context in Chapter 2. Order release is the process of sending orders on time. In load-oriented system, this process is executed related to shop load. When order is released to shop floor a shop packet (documention set) is formed. The shop packet for an order consists of: IX1- Route sheet, 2- Material requisitions, 3- Job cards, 4- Move tickets, 5- Part list. Dispacthing involves the final determination of the job sequence for a workcentre and the dispatching func tion is responsible for coordinating the indiviual work- centre schedules. The dispacthing function is initiated by requests generated by: material transport controller, a part at a workcentre with its operations completed and hence available for its next operation and a new schedule received from the scheduling function. Effective production activity control depends on ac curate timely recording and availability of data from the shop floor. All the functional elements outlined so far relate to activities occuring in quasi-real time in the case of the scheduling function planned to take place in the near future. However, the monitoring function is concerned with activities and events which have already taken place. Da ta collected as a result of these activities is translated into information which may well be the basis for real time control and/or management decisions. The following is so me of the data which is typically collected; process times, part status, material availabilty, inspection data, failu re and downtime data, and scrap and rework data. The usage of the functions in shop floor control, changes according to PPC approaches. MRP is an approach that is based on priority rule. In shop floor operations are started generally favorable with MINSOP and CR rules. In last years, JIT-KANBAN system that is avaible for repetative production types is used in job-shop production environment. Kanban is a method of labelling small production lots in order to attain a tighter control of raw materi als, purchased parts, and work-in-progress, as well as of the rate, total volume, and timing of production. First use of the method is credited to Toyota, where two types of Kanban cards are used. A transfer Kanban identifies work-in-progress while it moves betweeen work centers. A production Kanban may be thought of as a work order. In last years, a control technique especially seen in West Germany is called as“Load-oriented manufacturing control”. Contrary to that, the techniques of load-orien ted manufacturing control apply a statistical view of job shop manufacturing. The idea is to limit and balance workin-process inventory on a level as low as possible in or der to accomplish a high work center utilization as well as rapid and in-time flow of orders through the factory. The philosophy of load-oriented manufacturing con trol can best be explained using the funnel model of a job shop. The model is divided into the two sections: 'order stock', containing the planned orders, and 'job shop', containing the released orders (work-in-process). Each workcenter acts as a funnel in which the funnel outlet represents the workcenter capacity, the contents of the funnel represents the current order queue and channels the flow of orders and from the workcenter. In order to be consistent withn usual feedback system the completions of orders processed at a workcentre are defined as output and the completion of orders processed at the preceeding upstream workcenters are defined as input. In Chapter 4. prepared scheduling & control package's description is presented. The package is formed from three main modules. These are: 1- Manufacturing data-base module, 2- Scheduling module, 3- Control module. Manufacturing data-base module is formed to provide basic datas for scheduling and control modules. It is for med of the following sub-modules: 1- Item master, 2- Product structure, 3- Operations, 4- Work centers, 5- Engineering changes. les : Scheduling module contains the following sub-modu- 1- Constituting of scheduling data file (order data file), 2- Backward scheduling (finite and infinite), 3- Forward scheduling (finite and infinite), 4- Rescheduling, 5- Lists and reports of scheduling, 6- Performance analysis of scheduling. To realize scheduling process, requried datas must be obtained at first. This process is realized in two- ways by constituting of scheduling data file sub- module: 1- By integration of present modules, 2- By required input data. XIBackward and forward scheduling processes are rea ; i- zed by finite and infinite capacity. Rescheduling process happens for the following ca ses : 1- Urgent order case. 2- Examining present case, 3- New order case. In scheduling lists and reports modules, taken la^ts and reports are listed below: 1- List of scheduled all orders, 2- List of scheduled all operations, 3- List of operations based order, 4- List of operations based work station, 5- Report of flow and queue time for all orders, 6- Report of due time and lateness for all orders, 7- Report of load, utilization and queue time f or al 1 work stations. 8- Report of work-in-process inventory variation. In performance measurement sub- module, performance of scheduling is determined in various criterion by anal ysing reported datas. Manufacturing control module is comprized from thr following functional sub-modules. All of the sub-modul«>s are organized to run in according to with MRP and LMC approaches. 1- The first processes, 2- Order release, 3- Operation control, 4- Order monitoring, 5- Performance control. The first processes sub-module is used for the for mation of manufacturing control files, for entry of cont rol parameters and determination of initial work station load. Order release module is determined by two different tecniques (MRP & LMC) orders to be released to shop-f loor in the present date. Operation control sub-module is formed from three section: 1- Operation starting, 2- Operation stopping, 3- Operation finishing. The priority rule in operation starting process is determined by the user.. XIIPosition and progress of orders are monitored by the reports taken in order monitoring module. Some examples of taken reports are: 1- Report of status for all orders, 2- Report of open orders, 3- Report of completed orders, 4- Report of waited orders in quality control, 5- Report of kept orders waiting in operation. Various performance datas are obtained by analysii reported and accumulated datas in report files in perfo: tng perfor mance control sub-module. These are related to: - order, - shop-floor, - work station - center and - labor. There are also support modules which are supporting the mentioned three modules. These are: - Requirement planning and - Capacity control. Requirement planning determines quantity and times of orders that will be demanded from shop-floor. Capacity control, control machine loads during manu facturing. Besides these, a manufacturing control simulation packet was prepared for the aim of testing shop control modu 1 e. Prepared scheduling and control packet with Turbo Pascal computer language, was executed by using real sys tem datas. Scheduling process was made by this real system da tas (approximate 110 machines, 277 orders and 832 opera tion) with infinite and finite capacity. At the result of finite capacity scheduling, sche duling process was re-made and available results were ob tained after determined bottlenecks loads were balanced. However manufacturing control module were run for different priority rules and load limits for two approach in a prepared simulation packet. Obtained results were presented in the study. It was seen that LMC tecnique has provided better results when available load limit selected. XIII
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