工艺选择与设施布置解析课件

1、工艺选择与设施布置Process Selection and Facility Layout周伟华 博士浙江大学Dr. Weihua ZhouZhejiang University提纲 Outline工艺选择Process selection:工艺类型 Process Type产品工艺矩阵 Production-Process Matrix 设施布置Facility layout:布置的类型Layout types产品原则布置：生产线平衡Product layout: Line-balancing problems工艺原则布置：各部门间的工作流量Process layout: Interdep

2、artmental Work Flows工艺原则布置：系统规划设计Process layout: Systematic Layout Planning服务布置Service Layout2022/8/9Dr. Weihua Zhou Zhejiang University2简介 Introduction工艺Process一个组织将输入品转化为输出品的过程中的任何一个环节。(注意和流程的区别）工艺选择Process selection组织产品生产或服务提供的方式Deciding on the way production of goods or services will be organize

3、d主要根据Major implications劳动密集度Capacity planning设施布置Layout of facilities设备Equipment作业系统的设计Design of work systems2022/8/9Dr. Weihua Zhou Zhejiang University3工艺选择 Process Selection品种Variety系统需要处理多少品种的产品/服务？How much灵活性Flexibility需要具有什么样柔性的设备？What degree产量Volume 期望的产量是多少？Expected output2022/8/9Dr. Weihua Z

4、hou Zhejiang University4工艺类型 Process Types工艺专业化生产Job shop小规模Small scale批量生产Batch中等规模Moderate volume装配线生产Repetitive/assembly line标准化程度较高的产品/服务High volumes of standardized goods or services连续流程 Continuous生产高度标准化的产品/服务Very high volumes of non-discrete goods2022/8/9Dr. Weihua Zhou Zhejiang University5工艺

5、专业化生产Job shop2022/8/9Dr. Weihua Zhou Zhejiang University6一个中西医结合的医院医生会诊过程，设计心导管检查术A job shop process: A midwestern hospital medical team performs a diagnostic procedure involving a cardiac catheterization. 批量生产Batch2022/8/9Dr. Weihua Zhou Zhejiang University7食物准备，一次一个菜单项，在美国内华达州拉斯维加斯的凯撒宫的Spago厨房。A b

6、atch process: Food is prepared, one menu item at a time, in the kitchen of the Spago Restaurant in the Forum at Caesars Palace, Las Vegas, Nevada. 装配线生产Repetitive/assembly line2022/8/9Dr. Weihua Zhou Zhejiang University8位于巴勒斯坦伊斯顿的宾尼和史密斯克雷奥拉产品制造商每年生产近30亿支蜡笔。A repetitive process: Binney & Smith, maker

7、 of Crayola products, produces nearly 3 billion crayons each year in its Easton, PA, manufacturing facility. 连续流程 Continuous2022/8/9Dr. Weihua Zhou Zhejiang University9一个炼油厂的持续生产过程，把原油分解为石油，化工原油，以及其他产品。 A continuous process: An oil refinery performs a continuous process, breaking down crude oil into

8、 petroleum, chemicals, and many other products. 2022/8/9Dr. Weihua Zhou Zhejiang University10提纲 Outline工艺选择Process selection:工艺类型 Process Type产品工艺矩阵 Production-Process Matrix 设施布置Facility layout:布置的类型Layout types产品原则布置：生产线平衡Product layout: Line-balancing problems工艺原则布置：各部门间的工作流量Process layout: Inter

9、departmental Work Flows工艺原则布置：系统规划设计Process layout: Systematic Layout Planning服务布置Service Layout产品-工艺矩阵Product Process MatrixDimension工艺专业化生产Job Shop批量生产Batch装配线生产Repetitive连续流程 Continuous工作变化Job variety很高Very High一般Moderate较低Low很低Very low生产灵活性Process flexibility很高Very High一般Moderate较低Low很低Very low单

10、位成本Unit cost很高Very High一般Moderate较低Low很低Very low产量Volume of output很低Very Low较低Low较高High很高Very high2022/8/9Dr. Weihua Zhou Zhejiang University11产品工艺矩阵Production-Process Matrix2022/8/9Dr. Weihua Zhou Zhejiang University12产品结构、产品生命周期多品种小产量品种较多高产量标准化大量生产顾客化低产量广告重型机器中型机器食品加工汽车装配麦当劳石油化工面粉加工工艺专业化批量生产装配线生产连

11、续流程过程结构不可行不可行效率测量柔性(高)单件成本(高)柔性(低)单件成本(低2022/8/9Dr. Weihua Zhou Zhejiang University13提纲 Outline工艺选择Process selection:工艺类型 Process Type产品工艺矩阵 Production-Process Matrix 设施布置Facility layout:布置的类型Layout types产品原则布置：生产线平衡Product layout: Line-balancing problems工艺原则布置：各部门间的工作流量Process layout: Interdepartme

12、ntal Work Flows工艺原则布置：系统规划设计Process layout: Systematic Layout Planning服务布置Service Layout设备布置 Facilities Layout布置：对业务部门、工作中心和设备进行布局，以确保系统中工作流运行顺畅。Layout: the configuration of departments, work centers, and equipment, with particular emphasis on movement of work (customers or materials) through the sy

13、stem产品原则布置Product layouts工艺原则布置Process layouts成组技术单元布置Group technology (cellular) layout定点布置Fixed-Position layout2022/8/9Dr. Weihua Zhou Zhejiang University14设施布置的目标Objective of Layout Design有助于达到产品和服务的质量水平Facilitate attainment of product or service quality有效利用空间和人力Use workers and space efficiently避

14、免出现瓶颈Avoid bottlenecks搬运成本最低Minimize unnecessary material handling costs消除工人或物料的不必要搬运Eliminate unnecessary movement of workers or materials缩短生产和顾客服务时间Minimize production time or customer service time实现安全生产Design for safety2022/8/9Dr. Weihua Zhou Zhejiang University15布置决策的重要性Importance of Layout Deci

15、sions投入大量资金和精力Requires substantial investments of money and effort具有长期性Involves long-term commitments对短期运营的费用和效率有很大影响Has significant impact on cost and efficiency of short-term operations2022/8/9Dr. Weihua Zhou Zhejiang University16布置决策的必要性The Need for Layout Decisions2022/8/9Dr. Weihua Zhou Zhejian

16、g University17无效率运营Inefficient operations如：高成本、瓶颈For Example:High Cost Bottlenecks产品或服务设计上的改变Changes in the design of products or services推出新产品或服务The introduction of newproducts or services意外Accidents安全危害Safety hazards2022/8/9Dr. Weihua Zhou Zhejiang University18环境或其他法律要求的改变Changes inenvironmentalor

17、 other legalrequirements产量或产品组合的改变Changes in volume ofoutput or mix ofproducts方法或设备的改变Changes in methodsand equipment情绪问题Morale problems布置决策的必要性The Need for Layout Decisions工艺与布置Process and Layout2022/8/9Dr. Weihua Zhou Zhejiang University192022/8/9Dr. Weihua Zhou Zhejiang University20提纲 Outline工艺选择

18、Process selection:工艺类型 Process Type产品工艺矩阵 Production-Process Matrix 设施布置Facility layout:布置的类型Layout types产品原则布置：生产线平衡Product layout: Line-balancing problems工艺原则布置：各部门间的工作流量Process layout: Interdepartmental Work Flows工艺原则布置：系统规划设计Process layout: Systematic Layout Planning服务布置Service Layout基本布置方式 Basi

19、c Layout Types产品原则布置Product Layout使大量产品或顾客顺利且迅速通过系统Layout that uses standardized processing operations to achieve smooth, rapid, high-volume flow采用生产线工作站方法生产产品Linear arrangement of workstations to produce a specific product工艺原则布置Process Layout用来加工或提供涉及许多工艺要求的产品或服务。Layout that can handle varied proce

20、ssing requirements以完成相似活动的部门或其他职能组为特征Centers/machines grouped by process they perform固定位置布置Fixed Position Layout加工对象保持不动，工人、材料和设备按需要四处移动Layout in which the product or project remains stationary; workers, materials, and equipment are moved as needed用于产品无法移动的项目中Used in projects where the product canno

21、t be moved2022/8/9Dr. Weihua Zhou Zhejiang University21混合布置 Hybrid Layouts单元布置Group technology (cellular) layouts成组加工单元机group machines into machining cells柔性制造系统Flexible manufacturing systems自动化加工和材料处理系统automated machining & material handling systems混合装配线Mixed-model assembly lines一条生产线上生产多种型号的产品prod

22、uce variety of models on one line2022/8/9Dr. Weihua Zhou Zhejiang University22产品原则布置 Product Layout2022/8/9Dr. Weihua Zhou Zhejiang University23原材料或顾客Raw materialsor customer产成品Finished item工作中心1工作中心1工作中心1材料/劳动力Material and/or labor工作中心1用于高重复性的生产流程Used for Repetitive or Continuous Processing材料/劳动力Ma

23、terial and/or labor材料/劳动力Material and/or labor材料/劳动力Material and/or labor产品原则布置的优点Advantages of Product Layout产量高High rate of output成本低Low unit cost劳力专门化Labor specialization物料运输费低Low material handling cost工人和设备的利用率高High utilization of labor and equipment工艺路线选择及进程安排都在初步设计中确定下来 Established routing and

24、 scheduling会计、采购程序化Routing accounting and purchasing2022/8/9Dr. Weihua Zhou Zhejiang University24产品原则布置的缺点Disadvantages of Product Layout工作重复单调Creates dull, repetitive jobs技术低的工人可能对维持设备或产出质量缺乏兴趣Poorly skilled workers may not maintain equipment or quality of output对产量变化以及产品或工艺设计变化的适应性差Fairly inflexib

25、le to changes in volume设备故障对生产系统的影响很大Highly susceptible to shutdowns需要预防性维修能力Needs preventive maintenance与个人产量相联系的激励计划是不可行的Individual incentive plans are impractical2022/8/9Dr. Weihua Zhou Zhejiang University25U型生产线A U-Shaped Production Line2022/8/9Dr. Weihua Zhou Zhejiang University2612345678910开始I

26、n结束Out工人Workers工艺原则布置 Process Layout2022/8/9Dr. Weihua Zhou Zhejiang University27Dept. ADept. BDept. DDept. CDept. FDept. E用于间断加工单件小批和成批过程Used for Intermittent processing Job Shop or Batch Processes按功能制造过程布置Manufacturing Process Layout2022/8/9Dr. Weihua Zhou Zhejiang University28LLLLLLLLLLMMMMDDDDDD

27、DDGGGGGGPPAAAReceiving andShippingAssemblyPainting DepartmentLathe DepartmentMilling DepartmentDrilling DepartmentGrinding Department服务过程布置 Service Process Layout女士内衣WomensLingerie鞋子Shoes居家衣服House-wares女裙WomensDresses化妆品及珠宝Cosmetics& Jewelry孩子区ChildrensDepartment女运动装WomensSportswear季节性Entry &Seasona

28、l男士区MensDepartment2022/8/9Dr. Weihua Zhou Zhejiang University29工艺原则的优点Advantages of Process Layouts满足多样的工艺要求Can handle a variety of processing requirements系统受个别设备出故障的影响不大Not particularly vulnerable to equipment failures设备不会太昂贵Equipment used is less costly可采用个人激励机制Possible to use individual incentive

29、 plans2022/8/9Dr. Weihua Zhou Zhejiang University30工艺原则的缺点Disadvantages of Process Layouts制品库存量较大In-process inventory costs can be high要经常进行工艺路线选择及安排Challenging routing and scheduling设备利用率低Equipment utilization rates are low物料运输慢、效率低Material handling slow and inefficient工艺复杂化使监督跨度减少Complexities ofte

30、n reduce span of supervision对每一产品或顾客需求都特别关注Special attention for each product or customer会计、库存控制较复杂Accounting and purchasing are more involved2022/8/9Dr. Weihua Zhou Zhejiang University31固定位置布置Fixed Position Layouts混合布置Fixed Position Layout: 加工对象保持固定，而工人、材料及设备需要转移Layout in which the product or proje

31、ct remains stationary, and workers, materials, and equipment are moved as needed.产品的性质决定了这种类型的布局Nature of the product dictates this type of layout质量Weight尺寸Size 批量Bulk大型建设项目Large construction projects2022/8/9Dr. Weihua Zhou Zhejiang University32单元布置Cellular Layouts生产单元Cellular Production将工作分组，组的划分是有

32、一系列相似零件所需要的运营决定Layout in which machines are grouped into a cell that can process items that have similar processing requirements成组技术Group Technology按相似工艺特征分组，保证生产效率The grouping into part families of items with similar design or manufacturing characteristics2022/8/9Dr. Weihua Zhou Zhejiang University

33、33比较 A Comparison2022/8/9Dr. Weihua Zhou Zhejiang University34Group TechnologyMachine 1Machine 2Machine 3Machine 4Machine 5Materials inFinished goods out一个工人多台机器One Worker, Multiple Machines成组技术 Group Technology2022/8/9Dr. Weihua Zhou Zhejiang University36Parts FamiliesGroup TechnologyDrillingDDDDGr

34、indingGGGGGGMillingMMMMMMAssemblyAAAALathingReceiving and shipping LLLLLLLLGroup Technology(a) Jumbled flows in a job shop without GT cellsDrillingDDDDGrindingGGGGGGMillingMMMMMMAssemblyAAAALathingReceiving and shipping LLLLLLLLGroup Technology(a) Jumbled flows in a job shop without GT cellsDrilling

35、DDDDGrindingGGGGGGMillingMMMMMMAssemblyAAAALathingReceiving and shipping LLLLLLLLGroup Technology(a) Jumbled flows in a job shop without GT cellsDrillingDDDDGrindingGGGGGGMillingMMMMMMAssemblyAAAALathingReceiving and shipping LLLLLLLLGroup Technology(b) Line flows in a job shop with three GT cells C

36、ell 3LMGGCell 1Cell 2Assembly areaAALMDLLMShippingDReceivingGGroup Technology(b) Line flows in a job shop with three GT cells Cell 3LMGGCell 1Cell 2Assembly areaAALMDLLMShippingDReceivingGGroup Technology(b) Line flows in a job shop with three GT cells Cell 3LMGGCell 1Cell 2Assembly areaAALMDLLMShip

37、pingDReceivingGGroup Technology(b) Line flows in a job shop with three GT cells Cell 3LMGGCell 1Cell 2Assembly areaAALMDLLMShippingDReceivingG工艺原则布置与单元布置的比较Functional vs. Cellular Layouts方面Dimension工艺原则Functional单元式Cellular部门之间移动次数Number of moves between departments很多many很少few移动距离Travel distances较长l

38、onger较短shorter移动路线Travel paths变化variable固定fixed加工等待时间Job waiting times较长greater较短shorter加工时间Throughput time较长higher较短lower在制品数量Amount of work in process较大higher较小lower管理难度Supervision difficulty较大higher较小lower排程复杂性Scheduling complexity较大higher较小lower设备利用率Equipment utilization较低lower较高higher2022/8/9Dr

39、. Weihua Zhou Zhejiang University452022/8/9Dr. Weihua Zhou Zhejiang University46提纲 Outline工艺选择Process selection:工艺类型 Process Type产品工艺矩阵 Production-Process Matrix 设施布置Facility layout:布置的类型Layout types产品原则布置：生产线平衡Product layout: Line-balancing problems工艺原则布置：各部门间的工作流量Process layout: Interdepartmental

40、Work Flows工艺原则布置：系统规划设计Process layout: Systematic Layout Planning服务布置Service Layout产品布置：生产线平衡Design Product Layouts: Line Balancing2022/8/9Dr. Weihua Zhou Zhejiang University47生产线平衡决定如何将作业分配到工作地，使分到各工作地的作业所需要的时间大致相等。Line Balancing is the process of assigning tasks to workstations in such a way that

41、the workstations have approximately equal time requirements. 流程或生产线平衡Line Balancing生产线平衡涉及把作业分配到工作地的决策。一般每个工作地只有一个工人来完成所有作业。完全平衡的生产线，其线上的各活动完全同步进行，能够实现工人和设备的最大利用。生产线平衡的目标，是在技术以及产量的约束下，使生产线的闲置时间最少，效率最高。2022/8/9Dr. Weihua Zhou Zhejiang University48Cycle Time（节拍）2022/8/9Dr. Weihua Zhou Zhejiang Univers

42、ity49节拍是指各工作地完成分配给它的作业所容许的最大时间。Cycle time is the maximum time allowed at each workstation to complete its set of tasks on a unit.产量 Determine Maximum Output2022/8/9Dr. Weihua Zhou Zhejiang University50工作地数的理论最小值Determine the Minimum Number of Workstations Required2022/8/9Dr. Weihua Zhou Zhejiang Uni

43、versity51节拍和产量Example: Cycle time and Output tate2022/8/9Dr. Weihua Zhou Zhejiang University52作业紧后作业作业时间/分钟ab0.2be0.2cd0.8df0.6ef0.3fg1.0gh0.4h-0.3Total3.8Example 2022/8/9Dr. Weihua Zhou Zhejiang University53cdabefgh0.20.20.30.80.61.00.40.3OT=480 minutes/day, D=400 /day, CT=1.2 minutes生产线平衡算法1. 确定节拍

44、，求出最少所需的工作地数2.从工作地1开始，按顺序给工作地分配作业。作业的分配按作业先后顺序图由左至右进行。每个工作地的初始剩余时间为节拍。3.在每一分配前，利用下列标准确定哪些作业够资格分配到一个工作地：A.该作业所有先行作业都已被分配B.该作业时间不超过该工作地的剩余时间4.如果没有够资格分配的作业，则开始下一个工作地的分配，转步骤3；如果出现多个够资格分配的作业，可采用以下方法进行分配：A.分配后续作业数最多的作业B.分配加工时间最长的作业如果还是一样，任意选择一个作业。5. 每当一个作业分配后，计算该工作地的剩余时间。剩余时间等于原有剩余时间减去当前分配作业的时间。6. 继续步骤35，

45、直到所有作业分配完毕。7. 计算指标（如闲置百分比、效率）2022/8/954Dr. Weihua Zhou Zhejiang University生产线平衡原则Line Balancing Rules先分配后续作业数最多的作业Assign tasks in order of most following tasks.根据位置权数分配任务Break the tie: assign tasks in order of greatest positional weight. 2022/8/9Dr. Weihua Zhou Zhejiang University55生产线平衡Process of L

46、ine Balancing2022/8/9Dr. Weihua Zhou Zhejiang University56工作地剩余时间候选作业可行作业分配作业闲置时间11.2a, ca, ca (0.2)1.0b, cb, cc (0.8)0.2b, dbb (0.2)0e, d-0.021.2e, de, dd (0.6)0.6eee (0.3)0.3f-0.331.2fff (1.0)0.2g-0.241.2ggg (0.4)0.8hhh (0.3)0.5-0.5Total1.0bdefgcah分配结果 Allocation Outcome2022/8/9Dr. Weihua Zhou Zhe

47、jiang University57Workstation 4(0.7)Workstation 3(1.0)Workstation 2(0.9)Workstation 1(1.2)bdefgcahWorkstation 4(0.7)Workstation 3(1.0)Workstation 2(1.1)Workstation 1(1.0)bdefgcah2022/8/9Dr. Weihua Zhou Zhejiang University58瓶颈工作地 Bottleneck Workstation1 min.2 min.1 min.1 min.30/hr.30/hr.30/hr.30/hr.瓶

48、颈工作地 Bottleneck平行工作地 Parallel Workstations2022/8/9Dr. Weihua Zhou Zhejiang University591 min.2 min.1 min.1 min.60/hr.30/hr.30/hr.60/hr.2 min.30/hr.30/hr.平行工作地Parallel Workstations服务业的流程平衡分析活动描述时间（秒）1检查申请书的正确性152处理和记录收费303检查违规和限制情况604眼睛测试405为申请人拍照206颁发临时执照302022/8/9Dr. Weihua Zhou Zhejiang University

49、60例：汽车驾照申请服务的布局与流程24015112030260603180404180205120306入口出口65551.412030260603180205120306入口出口6060365551.4入口2022/8/9Dr. Weihua Zhou Zhejiang University6111121111111112022/8/9Dr. Weihua Zhou Zhejiang University62提纲 Outline工艺选择Process selection:工艺类型 Process Type产品工艺矩阵 Production-Process Matrix 设施布置Facili

50、ty layout:布置的类型Layout types产品原则布置：生产线平衡Product layout: Line-balancing problems工艺原则布置：各部门间的工作流量Process layout: Interdepartmental Work Flows工艺原则布置：系统规划设计Process layout: Systematic Layout Planning服务布置Service Layout工艺布置设计Designing Process Layouts信息要求Information Requirements:一系列要安排的工作部门或工作中心List of depar

51、tments个工作中心之间未来工作流的平面图Projection of work flows位置间的距离及单位距离物料运输费用Distance between locations投资于该布置的金额Amount of money to be invested一系列需特别考虑的事项List of special considerations现有建筑物内关键设施的位置、进出点以及载货处Location of key utilities2022/8/9Dr. Weihua Zhou Zhejiang University63工艺布置：各部门间的工作流量Process Layout: Interdepa

52、rtmental Flow已知信息Given各部门间实际的或预计的工作流量The flow (number of moves) to and from all departments各部门间运输成本费用The cost of moving from one department to another实际的或预计的布局The existing or planned physical layout of the plant决策Determine合理分布各部门，达到运费最少或距离最短的工艺专业化布置The “best” locations for each department, where bes

53、t means maximizing flow, which minimizing costs 2022/8/9Dr. Weihua Zhou Zhejiang University64从至表法 From-to matrix根据零部件或作业在各种设备或加工中心之间移动的次数，合理安排设备布置方案的尝试性方法目标是找出整个生产单元间物料总运输量最小的布置方案适用于多品种小批量的生产方式2022/8/9Dr. Weihua Zhou Zhejiang University65Example 2022/8/9Dr. Weihua Zhou Zhejiang University66部门间工作流量In

54、terdepartmental work flow 位置间的距离Distance between locations部门分配及两部门相互间的工作流量Example : Interdepartmental Work Flowsfor Assigned Departments2022/8/9Dr. Weihua Zhou Zhejiang University6713230170100ABC从至表法 From-to matrix2022/8/9Dr. Weihua Zhou Zhejiang University68tofrom12345611520218210251632043155206126

55、354ld7545201840198例：一金属加工车间有六台设备，已知其生产的零件品种及加工路线，并据此给出如表1所示的零件在设备之间的每月移动次数，表2给出了单位距离运输成本。请用这些数据确定该车间的最佳布置方案。2022/8/9Dr. Weihua Zhou Zhejiang University692022/8/9Dr. Weihua Zhou Zhejiang University70求解步骤及结果1. 将运输次数矩阵与单位距离运输成本矩阵的相同位置的数据相乘，得到从一台机器到另一台机器的每月运输成本，如表3所示。2. 将对角线对称的成本元素相加得到两台机器间的每月总的运输成本，如表4

56、所示。3. 按总运输成本的大小，可得机器（或部门）之间的紧密相邻程度。最紧密的5项按降序排列为：(1)、(2)、(3)、(4)、(5)，因而应将磨床与钻床、锯床与磨床、钻床与车床、车床与插床相邻布置。2022/8/9Dr. Weihua Zhou Zhejiang University712022/8/9Dr. Weihua Zhou Zhejiang University72计算机辅助设施规划技术软件Process Layout: CRAFT ApproachCRAFT (computerized relative allocation of facilities technique)是美国

57、人开发的应用从至表的启发式辅助设备布置软件这是一个启发式的程序，它使用作出评价一个简单的规则：It is a heuristic program; it uses a simple rule of thumb in making evaluations: “同时比较两个部门、，如果它降低了总成本的布局则相互交换。” Compare two departments at a time and exchange them if it reduces the total cost of the layout.它并不能保证最佳解决方案It does not guarantee an optimal s

58、olution按不同行程方向，两位之间的行程受电梯等因素影响大小可能不同，但在此假定两位置间的距离相同。CRAFT assumes the existence of variable path material handling equipment such as forklift trucks2022/8/9Dr. Weihua Zhou Zhejiang University732022/8/9Dr. Weihua Zhou Zhejiang University74提纲 Outline工艺选择Process selection:工艺类型 Process Type产品工艺矩阵 Produc

59、tion-Process Matrix 设施布置Facility layout:布置的类型Layout types产品原则布置：生产线平衡Product layout: Line-balancing problems工艺原则布置：各部门间的工作流量Process layout: Interdepartmental Work Flows工艺原则布置：系统规划设计Process layout: Systematic Layout Planning服务布置Service Layout工艺原则布置：系统规划设计Process Layout: Systematic Layout Planning各部门间

60、的工作流量Numerical flow of items between departments Can be impractical to obtainDoes not account for the qualitative factors that may be crucial to the placement decision系统规划设计Systematic Layout Planning确定各部门间的关系和接近程度Accounts for the importance of having each department located next to every other depar