工业工程在生产效率方面改善之应用-本科学生毕业设计(论文)外文翻译.doc

吉林化工学院外 文 翻 译工业工程在生产效率方面改善之应用IE to improve the efficiency in production and Application性 质: 毕业设计 毕业论文教 学 院： 机电工程学院系 别：工业工程工程系学生学号：11440323学生姓名：易建伟专业班级：工程1103指导教师：卢伟宏职 称：副教授起止日期：2015.3.12015.3.28吉 林 化 工 学 院Jilin Institute of Chemical Technology14吉林化工学院本科毕业设计（论文）外文翻译中文翻译JIT看板系统的文献回顾摘要：在本文中，通过对JIT（实时）看板文献的调查提交相关的报告。报告介绍部分JIT处理的理念以及概念包含了推式及拉式系统这些内容，同时，对看板系统中的阻塞机制也进行精心地讨论。在后面各节中，介绍JIT看板的应用程序和性能（MOP）在实施中的重要性。此外，文章也讨论了JIT最近出现的“特殊情况”的现象。最后，本文通过对100个先进国家的研究论文进行调查，提出了未来的发展方向。1 介绍被日本称为实时 （JIT） 制造系统的“丰田生产方式”由大野耐一开发的。JIT制造系统是以不断减少和最终清除各种各样的废物为主要目标（布朗等人 5，大野54，苏格莫里等人82）。基于这一原则，日本企业保持非常低的库存，实现极高的质量和生产率（理查德特斯恩62，詹姆斯H格林30）的经营水平。JIT强调“零概念”，这意味着零缺点、零队列、零库存、零故障等目标需要实现。它可以在适当的位置和适当的时间，确保供应正确数量的部件。在此基础上，把重大收购，旧系统更改以及买方和卖方的关系作为新的革命理念来研究（沃马克等，沃马克91，和琼斯92，马凯等人45）。同样，JIT在工厂运营中成为不可避免的制造系统，该系统拥有单元制造，柔性制造，计算机集成制造和机器制造（舍恩伯格63，格兰翰12）。技术的进步以及满足全球竞争的需要，将传统的推动生产系统与物料需求计划（MRP）结合，形成拉式JIT生产系统。在那种情况下，可以对拉式制造系统生产的制品（WIP）进行良好的管理和控制（梅森保罗46）。看板系统是一个新的理念，在JIT生产系统中起着重要作用。看板基本上包含在每个生产阶段，是一种在完成装配中需要很多细节信息的塑料卡。同时，看板系统也是一个需要多阶段生产计划和库存控制的系统。这些塑料卡用来控制生产过程中多余的库存。系统看板的使用可以提高产量和利用率，减少在工作过程中的生产时间。 本文的目标是如下所示：（1）严格审查JIT文献（2）在不同文章中，研究JIT的区别（3）探讨JIT看板系统的最新趋势和未来研究方向本文在精心审查和研究的基础上对提出的看板进行适当的分类，因为作为一种在代理人使用它后需要进行反馈的JIT系统。本文还讨论看板卡，丰田公式，拦截机制，如何实施看板应用程序和性能（MOP）的措施和推拉系统的工作原理，也包括文章中JIT看板系统最新“特殊情况”的处理。最后，对未来的研究提出了方向。1.1 流水作业看板系统是在重复生产环境中广泛实施。单卡看板业务系统可以分成两个被证明具有很高效率的启发式（萨拉德哈勃利亚达等人77）。同时，他们提出单卡看板业务系统与双阻塞的递归方程（萨拉德哈勃利亚达等人78），还提出利用启发式部分加权流量时间的总和计算最小化总加权时间。然而，他在两个单卡流水车间做了N个启发式部分类型的调度工作（拉基杰莱61）。本文针对不同的问题，例如以尽量减少计算在加权时间早到和加权时间迟到这两种模型下的加权总和为目标而开发了一种启发式算法，提交不同的数学模型报告。另外，他们也做了类似的工作（赫马马利尼等人22）。在这项工作中，开发的启发式算法被称为模拟退火算法。通过与其他算法的比较，在相对的基础上只能得到平均增幅，而不是基于在实验的基础上用完整的方差比较分析得出可靠的推论。他们对两个相邻的计算机之间关于容量有限的缓冲区流水作业问题进行了研究（彼得布鲁克等人58）。在计算机上完成作业的处理后，接着，要处理在指定计算机之间的缓冲区中存储的任务。如果缓冲区被完全占用，那当前计算机上作业只有在阻止这台机器的其它工作情况下实施。在本论文中，他们已确定一个可行的时间表，用来尽量减少在最大完工时间里使用禁忌搜索。使用禁忌搜索产生的问题可以通过比较基准来反映结果。该比较基准只是基于相对改善，而不是在实验的基础上通过完整的方差比较分析得到可靠的推论。1.2 装配线商店在经营某些部分时进行类似流动装配线组装的排序。在有多产品组装线情况下，排序工作是一项艰巨的任务。它被认为是一种混合模式装配线排序问题，也是一个组合的问题，他们制定了这个整数规划模型组合解决相应的问题（蒂莱尔等16）。该模型只可用于解决小规模问题，是因为有相关处理变量的限制，这也是目前运筹学软件受到整数规划模型组合的限制。然而，他们已经考虑到类似混流装配线排序有输送时停顿问题现象出现，提出了寻求最优解和次优的混合模式排序问题的解决方案，在总补时阶段分别采用分支和模拟退火算法使得排序最小化（刘晓波等人94）。分支定界算法是专门寻找最优解解决小型问题，而模拟退火法处理规模大的问题取得了良好的次优的解决方案。今后，规模大的问题适用于模拟退火研究，同时，还可以建立一个更好的遗传算法。不过，实际上在确定之前，学者应该花费相当长的时间对模拟退火算法错误方法进行跟踪并且得出解决参数调用限度的问题。1.3 批量生产系统在一个批次的生产体系中，从一种产品转换到其他产品依赖实现增值的水平，不同的优先配置计划，合理的经济设置等许多因素。他认为拉式制造系统可以处理产品多种不同类型的问题（塔夫艾提克等86）。在本论文中，他们制定了使用一个不同的迭代过程来计算近似每个产成品库存平均水平的优先配置计划。还要求被假设处理的时间和设置时间是任意泊松分布的。但是，在实践中，处理时间可能跟随其他的分布，如正常，均匀，指数等，这些不属于本文研究。他们讨论了关于不少厂商从采购原料，并转换成成品的产品这过程中的制造系统问题，估计JIT在配送系统中生产批量的大小，设计了JIT的原料供应体系（汉等35）。就这样一个简单的算法被开发用来计算原材料制造和采购政策的批量大小。2. JIT的集成、实施和效益实时是一种制造理念，需要一个公司阻碍不同的时间不断改进。为了保证不断改善，有必要对任何组织和相关领域实施JIT和JIT的整合。如果从检验真正实践意义上讲，JIT系统的生产性能和财务表现一定会改善。他们重申，适当规划实施的JIT生产系统和一个由最高管理层的承诺是必不可少的先决条件（斯万森等人83）。然而，成本效益分析是进行研究企业财务重点项目的初步知识，就像JIT系统的成本和时间是JIT实施的基础。流水作业型的企业实施JIT，需要改善预测时间，提高时间价值（库克等人11）。TPM和JIT之间实现全面质量管理关系，将导致生产性能的改善（凯利比等37）。此外，他讨论了TPM，准时生产，质量控制和FA（工厂自动化）一体化的重要性（黄23）。另外，他认为TQM和TPM是实施JIT生产系统的两个支柱（今井27）。有人提出了一种新的JIT管理系统，这有助于管理策略转移到管理技术（卡库罗艾玛萨克32）。他们在美国进行了一项研究，即从253家公司的财务经营业绩的好坏程度，评价实施JIT做法影响公司的兴衰（富勒顿等人65）。他们研究用改善财务的表现衡量JIT可持续在生产系统中获得回报。此外，还研究了美国95家公司实施JIT得到好处。他们的结论是实施JIT基于时间合理利用和员工的灵活性，提高该系统的性能质量和降低库存水平，由此产生的盈利能力提高。3.结论不断的全球竞争迫使许多公司减少其投入的成本，这样的公司可以有更大的利润空间。在现实技术的进步和解决方案增多的情况下，公司把达到最大限度地降低投入成本作为目标。JIT看板是一项在许多产业生产线中起到重要作用的系统，通过尽量减少工作中的进程和吞吐量的时间，最大限度地提高生产线效率。在本文中，作者尝试在研究先进文章的同时去探索JIT看板系统在该领域使用的先进设备。在简要介绍推拉系统，不同看板类型，阻断机制及其工作原理后，作者将JIT看板系统的研究文章分为五个大内容：即实证理论，建模方法，多变性和其效果，竞争的在制品和JIT供应链管理。此外，作者们提供了一个JIT模式下，出现部分看板的特殊情况。本文将帮助研究人员对不同问题下的JIT看板系统提供目前的更新发展方向，这将进一步引导他们未来研究的方向。对未来的研究方向介绍如下：启发式算法，模拟退火算法，遗传算法和禁忌搜索可能被用来寻找解决像流水车间混合装配属于组合这类问题的最优方案。当需要使用模拟退火算法时，研究人员也可以考虑使用遗传算法，这将能保证解决问题需要更好的方案。在大部份的文件中，相互间的比较仅是基于相对改善。而不是在实验的基础上通过完整的方差比较分析得到可靠的推论。他们开发了这个算法，仅使用了两个点的交叉遗传算法（伊丽莎白，贝尔加拉等人18）。后来可能引入遗传操作，进一步提高了遗传算法的性能。遗传算法在处理复杂的供应链问题可能被修改。在JIT供应链管理相关的研究工作中，应该努力在启发式概率条件下得出开发仿真的结果。关于单链分析多个连锁经营提出了一个悬而未决的问题，它是一个由单一制品水平为所有产品提供单位产品水平的问题（萨拉米娃蒂等69）。此外，大多数研究利用电脑模拟。因此，为了研究的发展，今后的研究方向应是发展以及改善看板系统在制品搜索程序中的水平（克里格等38）。一个分解算法可开发多种符合计算国家相关的设置看板系统的产品的方法。该合理方法是由他所提出的（塔蒂夫等85）。该方法可适用于扩展到多产品多级看板系统。有人为了研究该算法的延伸性进行并实验，包括更多的变数和因素，如在需求和随机需求的突然增加情况下以及在各种条件下，对不同类型的客户系统使用生产模式的稳定性进行行为试验（励等41）。嵌套分区方法是由他们提供的，可以精心划分纳入任何一个或其它的许多如抽样，回溯方案，仿真等增强启发式的组合（乐苑世与赵树理男士43）。然后，他们可以应用这种方法解决这种类型的组合问题。蚂蚁的蚁群优化算法是最近加入到现有的启发式，模拟退火算法，遗传算法和禁忌搜索中去的。因此，研究人员可以根据自己的兴趣和所需的计算时间针对JTI问题的组合分别采取不同的算法，研究其他三种启发式（启发式）的结果并比较结果的准确性。出处：印度 C.塞蒂库马尔，R.帕尔塞沃玛，JIT看板系统的文献回顾，先进制造技术国际杂志，第32卷（5），2007（8）：393-408.翻译部分为摘要、第一、六、七节。Literature review of JIT-KANBAN systemAbstract In this paper, JIT (Just-In-Time) -KANBAN literature survey was carried out and presented.The introductory section deals with the philosophy of JIT,and the concept involved in the push and pull system. The blocking mechanisms in the kanban system are also discussed elaborately. Besides these sections, the importance of measure of performance (MOP) and the application of the same with respect to JIT-KANBAN are presented. The recent trends in the JIT-KANBAN are discussed under the heading “Special cases”. In this review, 100 state-of-art research papers have been surveyed. The directions for the future works are also presented.1 IntroductionJust -In-Time (JIT) manufacturing system was developed by Taiichi Ohno which is called Japanese “Toyota production system”JIT manufacturing system has the primary goal of continuously reducing and ultimately eliminating all forms of wastes (Brown et al. 5,Ohno 54, Sugimori et al. 82). Based on this principle,Japanese companies are operating with very low level of inventory and realizing exceptionally high level of quality and productivity (Richard J. Tersine 62, James H. Greene 30). JIT emphasizes “zero concept” which means achievement of the goals of zero defects, zero queues，zero inventories, zero breakdown and so on. It ensures the supply of right parts in right quantity in the right place and at the right time. Hence, the old system of material acquisition and, buyer and seller relationships are changed to new revolutionary concepts (Womack et al. 91, Womack and Jones 92, Markey et al. 45). Similarly, JIT becomes an inevitable system at plant level, which integrates the cellular manufacturing, flexible manufacturing, computer integrated manufacturing and Robotics (Schonberger 63, Golhar 12).Due to the technological advancement, the conventional method of push production system linked with Material Requirement Planning (MRP) was changed to pull type JIT production system to meet out the global competition, where the work-in-process (WIP) can be managed and controlled more accurately than the push- production system (Mason Paul 46).KANBAN system is a new philosophy, which plays a significant role in the JIT production system. Kanban is basically a plastic card containing all the information required for production assembly of a product at each stage and details of its path of completion. The kanban system is a multistage production scheduling and inventory control ystem. These cards are used to control production flow sand inventory. This system facilitates high production volume and high capacity utilization with reduced production time and work-in-process.The objectives of this paper are as listed below1) Critical review of JIT literature.2) Segregating the different research articles of JIT.3) Exploring the recent trends in JIT-Kanban system and deriving directions for future research.In this paper, the articles are reviewed and an appropriate classification is presented.The kanban study was made elaborately, since it acts as a basic communicator and feedback agent to the JIT system. Push and pull system, principle of operation of kanban cards, Blocking mechanism, Toyotas formula, and the measures of performances (MOP) are also discussed in this paper. The latest trends in JIT-Kanban system are also addressed separately under the heading “Special cases”. Finally, the directions for future researches are presented.1.1 Flow shopKanban system is widely implemented in repetitive manufacturing environment. For a single card operational system, Sharadhapriyadarishini et al. 77 have developed two heuristics and proved that these are more efficient. Saradhapriyadarishini et al. 78 have proposed a recursive equation for scheduling the single card kanban system with dual blocking. They proposed a heuristic with twin objectives of minimizing the sum of total weighted time of containers and weighted flow time of part-types. Rajendran 61 has done a work on two card flow shop scheduling with n part-types. In this paper, mathematical models for time tabling of containers for different problems have been formulated. Then, a heuristic was developed to minimize the sumof weighted flow time, weighted earliness, and weighted tardiness of containers. Hemamalini et al. 22 have done similar work. In this work, the heuristic developed is simulated annealing algorithm. This is compared with randomsearchmethod. In these papers, the comparisons are done only based on mean relative percentage increase. Instead of this approach, comparisons based on complete ANOVA experiments would provide reliable inference.Peter Brucker et al. 58 have carried out research on flow shop problem with a buffer of limited capacity between two adjacent machines. After finishing the processing of a job on a machine, either the job is to be processed on the following machine or it is to be stored in the buffer between these machines. If the buffer is completely occupied, the job has to wait on its current machine but blocks this machine for other jobs. In this paper, they determined a feasible schedule to minimize the makespan using tabu search. The results of the problem using tabu search were compared with that of benchmark instances. The comparisons are done only based on relative improvements. Instead of this approach, comparisons based on complete ANOVA experiments would provide reliable inference.1.2 Assembly lineAssembly lines are similar to the flow shops in which assembly of parts are carried out in a line sequence. In a multi product assembly line, the sequencing of the jobs is a challenging task. Drexl et al. 16 considered an assembly line sequencing mixed model problem. It is a combinatorial problem. They formulated this combinational problem as integer programming model. This model can be used only for small size problems due to the limitations of operations research software with respect to handling the number of variables and constraints, which are present in the integerprogramming model. Xiaobo et al. 94 have considered similar work on mixed model assembly line sequencing problem with conveyor stoppages. They proposed branch and bound algorithm, and simulated annealing algorithm for finding the optimal solution and sub-optimal solution of the mixed-model sequencing problem, respectively to minimize the total conveyor stoppage time. The branchand- bound method was devoted to find the optimal solution of small-sized problems, whereas the simulated annealing method was used to cope with large-scale problems to obtain a good sub-optimal solution. Future, research on simulated annealing applied to this problem can be directed to establish a better seed generation algorithm. However, the practitioner should spend considerable time in fixing the parameter called temperature (T) in the simulated annealing algorithm by trail and error method before actually solving the problem.1.3 Batch production systemIn a batch production system, the switching over from one product to other product depends on many factors such as stock reaching to the threshold level, different priority schemes, economical setups, etc. Tafur Altiok et al. 86 have dealt this issue differently for the pull type manufacturing system with multi product types. In this paper, they developed an iterative procedure to approximately compute the average inventory level of each product as finished goods using different priority schemes. In this paper, the demand arrival process is assumed to be a poisson distribution and processing times and the set-up times are arbitrarily distributed. But, in practice, the processing times may follow other distributions, viz., normal, uniform, exponential, etc. which are not experimented in this paper. Khan et al. 35 addressed the problem of manufacturing system that procures raw materials from vendors in lot and convert them into finished products. They estimated production batch sizes for JIT delivery system and designed a JIT raw material supply system. A simple algorithm was developed to compute the batch sizes for both manufacturing and raw material purchasing policies.2. JIT integration, implementation and benefitsJust-in-time is a manufacturing philosophy by which an organization seeks continuous improvements. For ensuring continuous improvements, it is necessary for any organization to implement and integrate the JIT and JIT related areas. If it is practiced in its true sense, the manufacturing performance and the financial performance of the system will definitely improve.Swanson et al. 83 have reiterated that proper planning is essential for implementation of a JIT manufacturing system and a commitment from top management is a prerequisite. Cost benefit analysis is to be studied initially with the knowledge of key items such as the cost of conversion to a JIT system and time period of conversion. Cook et al. 11, in their case study for applying JIT in the continuous process industry, show improvements in demand forecast and decrease in lead-time variability.The relationship between implementation of TQM, TPM and JIT will lead to improvement in the manufacturing performance (Kribty et al. 37). Further Huang 23 discusses the importance of considering the integration of TPM, JIT, Quality control and FA (Factory Automization). Imai 27 believes that TQM and TPM are the two pillars supporting the JIT production system. Kakuro Amasaka 32 proposes a new JIT management system, which helps to transfer the management technology into management strategy.Fullerton et al. 65 have conducted a study in 253 firms in USA to evaluate empirically whether the degree with which a firm implements the JIT practices affects the firms financial performance. From their study, JIT manufacturing system will reap sustainable rewards as measured by improved financial performance. Also, they studied the benefits of JIT implementation in 95 firms in USA. They have concluded that JIT implementation improves the performance of the system, because of resultant quality benefits, time based benefits, employees flexibility, accounting simplification, firms profitability and reduced inventory level.3.ConclusionThe growing global competition forces many companies to reduce the costs of their inputs so that the companies can have greater profit margin. There are considerable advancements in technology and solution procedures in reality, to achieve the goal of minimizing the costs of inputs. JIT-KANBAN is an important system, which is used in production lines of many industries to minimize work-in-process and throughput time, and maximize line efficiency. In this paper, the authors have made an attempt to review the state-of-art of the research articles in the area “JIT-KANBAN system”. After a brief introduction to push and pull systems, different types of kanban and their operating principles, blocking mechanisms, the authors have classified the research articles under JIT-KANBAN system into five major headings, viz., empirical theory, modeling approach, variability and its effect, CONWIP and JIT-SCM. Also, the authors have provided a section for special cases under JIT-KANBAN. This paper would help the researchers to update themselves about the current directions and different issues under JIT-KANBAN system, which would further guide them for their future researches.The directions for future researches are presented below.The flow shop as well as mixed model assembly line problems come under combinatorial category. Hence, meta-heuristics viz., simulated annealing, genetic algorithm and tabu search may be used to find solution to determine the minimum number of kanbans and other measures. In simulated annealing algorithm, researchers can aim to device a better seed generation algorithm which will ensures better starting solution. In most of the papers, comparisons are done only based on relative improvements. Instead of this approach, comparisons based on complete ANOVA experiments would provide reliable inferences.This algorithm developed by Elizabeth Vergara et al. 18 uses only two-point crossover genetic operators. A third genetic operator may be introduced to further improve the performance of the evolutionary algorithm. The evolutionary algorithm may be modified to handle complex supply chain problem. In JIT-SCM related research works, effort should be directed to develop simulation as well as meta-heuristics to derive results under probabilistic conditions.In the work of Sarah M. Rayan et al