基于鼓-缓冲器-绳子理论的整合式生产作业控制系统研究

• 论文 •

基于鼓-缓冲器-绳子理论的整合式生产作业控制系统研究

郭永辉，钱省三

上海理工大学管理学院，上海 200093

收稿日期:2005-03-10 修回日期:2005-04-21 出版日期:2006-02-15 发布日期:2006-02-25
基金资助:
上海市白玉兰科技人才基金资助项目（200474）；上海市教委重点学科资助项目（第4期）；高等学校博士点基金资助项目(20050252008)。

Integrated production planning & control system based on drum-buffer-rope theory

GUO Yong-hui,QIAN Xing-san

Sch. of Management, Univ. of Shanghai for S & T, Shanghai 200093, China

Received:2005-03-10 Revised:2005-04-21 Online:2006-02-15 Published:2006-02-25
Supported by:
Project supported by the Shanghai S&T Development Foundation,China(No.200474),the Key Subject Foundation of Shanghai Municipal Commission of Education,China(No.4)and the National Researth Fundation for Program of Higher Education,China(No.20050252008).

摘要/Abstract

摘要： 现有的鼓缓冲器绳子理论存在3方面不足：首先，缓冲区大小凭经验估计，当生产环境发生变化时，容易造成瓶颈生产安排、订单投料安排与实际生产脱节；其次，侧重于对瓶颈生产的安排和投料安排，对生产作业控制仅以先进先出法则或最早交货期法则为调度策略，无法保证制定的作业规划与实际生产作业控制相一致；再则，鼓缓冲器绳子理论所强调的系统绩效指标存在冲突。为解决上述问题，提出了一种基于鼓缓冲器绳子理论的整合式生产作业控制系统，将生产作业计划与生产控制加以集成。另外，为有效应对生产系统的动态变化，采用仿真技术，以及时调整系统缓冲区大小。同时，为兼顾多个绩效指标，针对瓶颈前设备、瓶颈设备、瓶颈后设备提出了一个三段式调度策略。进一步的仿真实验，证明了该控制系统的有效性。

关键词: 鼓, 缓冲器, 绳子, 瓶颈资源, 生产作业计划, 生产调度

Abstract: The traditional Drum-Buffer-Rope (DBR) theory has three shortcomings in practice. Firstly, the buffer size is defined by experience which will lead to gap of production planning and control with actual production whenever there is change in production. Secondly, DBR mainly focuses on the planning of bottlenecks and customer orders, and simple dispatching rules such as FIFO rule or EDD rule cant tally with production planning. Thirdly, there is conflict existing in performance indexes for DBR. To solve these problems, the integrated production planning and control system based on DBR theory was proposed. To dynamically adapt to manufacturing environment, buffer size was regulated in time by simulation. Meanwhile, a three-policy scheduling method was also presented to satisfy multi- performance indexes according to non-bottlenecks and bottlenecks. The results of simulation experiments illustrated the validity of this integrated system.

Key words: drum-buffer-rope theory, capacity constraints resources, production planning, production Scheduling

中图分类号:

TP278

郭永辉，钱省三. 基于鼓-缓冲器-绳子理论的整合式生产作业控制系统研究[J]. .

GUO Yong-hui,QIAN Xing-san. Integrated production planning & control system based on drum-buffer-rope theory[J]. .

参考文献

［1］ SCHRODER R G,ANDERSON J C,TUPY S E,et al.A study of MRP benefits and costs［J］.Journal of Operations Management，1981,2(1):1-9.

[2] GOLDRATT E M,COX J.Theory of constraints［M］.Croton-on-Hudson,NY,USA:North River Press,1990.

[3] GARDINER S C,BLACKSTONE J H,GARDINER L R.The evolution of the theory of constraints［J］.Industrial Management,1994,36(3):13-16.

[4] COOK D P.A simulation comparison of traditional,JIT and TOC manufacturing system in a flow shop with bottlenecks［J］.Production and Inventory Management Journal,1994,35(1):73-78.

[5] MILTENBURG J.Comparing JIT,MRP and TOC and embedding TOC into MRP［J］.International Journal of Production Research,1997,33(4):1147-1169.

[6] BLACKSTONE J H,GARDINER L R,GARDINER S C.A framework for the systemic control of organizations［J］.International Journal of Production Research,1997, 35(3): 597-605.

[7] MILLER B.Applying TOC in the real world［J］.IIE Solution,2000,32(5):49-55.

[8] ZHOU Feng.Study on the production schedule and control mechanism in DBR ［J］.Chinses Journal of Management Science,2000,8(1): 17-21( in Chinese) .［周峰.DBR管理模式的生产计划与控制机制探讨［J］.中国管理科学,2000,8(1)：17-21.］

[9] SCHRAGEHEIM E,RONEN B.Drum-Buffer-Rope shop floor control［J］.Production and Inventory Management Journal,1990,(third quarter):18-22.

[10] RONEN B,STARR M K.Synchronized manufacturing as in OPT: from practice to theory［J］.Computers Industrial Engineering,1990,18(4):585-600.

[11] SCHRAGENHEIM E,RONEN B.Buffer management: a diagnostic tool for production control［J］.Production and Inventory Management Journal,1991,2(2):74-79.

[12] WU S Y,JOHN S M,THOMAS M G.A simulation analysis of the effectiveness of Drum-Buffer-Rope scheduling in furniture manufacturing［J］.Computers Industrial Engineering,1994,26(4):757-764.

[13] TU Y M,LI R K.Constraint time determianation model［J］.International Journal of Production Research,1998,36(4):1091-1103.

[1]	秦旋,房子涵,张赵鑫. 考虑资源约束的预制构件多目标生产调度优化[J]. 计算机集成制造系统, 2021, 27(8): 2248-2259.
[2]	马丽萌,乔非,马玉敏,刘鹃. 基于SO-GP的智能车间组合调度规则挖掘[J]. 计算机集成制造系统, 2021, 27(5): 1351-1360.
[3]	吴秀丽,张志强,赵宁,李俊青. 超启发式文化基因算法优化生产与预维修集成调度问题[J]. 计算机集成制造系统, 2019, 25(第8): 1885-1896.
[4]	王旭亮,柴旭东,张程,赵晓芳. 云制造环境下跨企业协同生产调度算法[J]. 计算机集成制造系统, 2019, 25(第2): 412-420.
[5]	费杨阳,马慧民. 批—离散机重入车间调度与设备维护联合优化[J]. 计算机集成制造系统, 2019, 25(第1): 44-52.
[6]	袁帅鹏,李铁克,王柏琳. 多目标炼钢—连铸生产调度的改进带精英策略的快速非支配排序遗传算法[J]. 计算机集成制造系统, 2019, 25(第1): 115-124.
[7]	张燕华,陈伟达,孟祥虎. 基于PBIL算法的炼钢生产低碳调度问题[J]. 计算机集成制造系统, 2018, 24(第10): 2407-2414.
[8]	姜天华. 基于灰狼优化算法的低碳车间调度问题[J]. 计算机集成制造系统, 2018, 24(第10): 2428-2435.
[9]	杨宏兵,沈露,成明,陶来发. 带退化效应多态生产系统调度与维护集成优化[J]. 计算机集成制造系统, 2018, 24(第1): 80-88.
[10]	廖雯竹,张秀芳,江敏. 成组方式下考虑故障率限制的生产调度模型[J]. 计算机集成制造系统, 2017, 23(第3期): 599-608.
[11]	龚永民,郑忠,龙建宇,高小强. 连铸机开浇炉次与时间决策的多目标优化[J]. 计算机集成制造系统, 2017, 23(第2期): 261-272.
[12]	廖雯竹,张秀芳. 成组生产方式下生产调度和设备维护的多目标联合决策问题[J]. 计算机集成制造系统, 2017, 23(第1期): 82-92.
[13]	苏志雄,伊俊敏. 基于正逆序策略的混合流水车间遗传调度算法[J]. 计算机集成制造系统, 2016, 22(第4期): 1059-1069.
[14]	焦磊,刘晓军,刘庭煜,倪中华. 一种面向生产调度规则挖掘的数据离散化方法[J]. 计算机集成制造系统, 2016, 22(第1期): 257-264.
[15]	肖莹莹,李伯虎,庄长辉,柴旭东,林廷宇. 面向用户多品种定制的分布式供应链调度[J]. 计算机集成制造系统, 2015, 21(第3期): 800-812.