工藝選擇與設(shè)施布置解析課件

1、工藝選擇與設(shè)施布置Process Selection and Facility Layout周偉華 博士浙江大學(xué)Dr. Weihua ZhouZhejiang University提綱 Outline工藝選擇Process selection:工藝類型 Process Type產(chǎn)品工藝矩陣 Production-Process Matrix 設(shè)施布置Facility layout:布置的類型Layout types產(chǎn)品原則布置：生產(chǎn)線平衡Product layout: Line-balancing problems工藝原則布置：各部門間的工作流量Process layout: Interdep

2、artmental Work Flows工藝原則布置：系統(tǒng)規(guī)劃設(shè)計(jì)Process layout: Systematic Layout Planning服務(wù)布置Service Layout2022/8/9Dr. Weihua Zhou Zhejiang University2簡介 Introduction工藝Process一個(gè)組織將輸入品轉(zhuǎn)化為輸出品的過程中的任何一個(gè)環(huán)節(jié)。(注意和流程的區(qū)別）工藝選擇Process selection組織產(chǎn)品生產(chǎn)或服務(wù)提供的方式Deciding on the way production of goods or services will be organize

3、d主要根據(jù)Major implications勞動(dòng)密集度Capacity planning設(shè)施布置Layout of facilities設(shè)備Equipment作業(yè)系統(tǒng)的設(shè)計(jì)Design of work systems2022/8/9Dr. Weihua Zhou Zhejiang University3工藝選擇 Process Selection品種Variety系統(tǒng)需要處理多少品種的產(chǎn)品/服務(wù)？How much靈活性Flexibility需要具有什么樣柔性的設(shè)備？What degree產(chǎn)量Volume 期望的產(chǎn)量是多少？Expected output2022/8/9Dr. Weihua Z

4、hou Zhejiang University4工藝類型 Process Types工藝專業(yè)化生產(chǎn)Job shop小規(guī)模Small scale批量生產(chǎn)Batch中等規(guī)模Moderate volume裝配線生產(chǎn)Repetitive/assembly line標(biāo)準(zhǔn)化程度較高的產(chǎn)品/服務(wù)High volumes of standardized goods or services連續(xù)流程 Continuous生產(chǎn)高度標(biāo)準(zhǔn)化的產(chǎn)品/服務(wù)Very high volumes of non-discrete goods2022/8/9Dr. Weihua Zhou Zhejiang University5工藝

5、專業(yè)化生產(chǎn)Job shop2022/8/9Dr. Weihua Zhou Zhejiang University6一個(gè)中西醫(yī)結(jié)合的醫(yī)院醫(yī)生會診過程，設(shè)計(jì)心導(dǎo)管檢查術(shù)A job shop process: A midwestern hospital medical team performs a diagnostic procedure involving a cardiac catheterization. 批量生產(chǎn)Batch2022/8/9Dr. Weihua Zhou Zhejiang University7食物準(zhǔn)備，一次一個(gè)菜單項(xiàng)，在美國內(nèi)華達(dá)州拉斯維加斯的凱撒宮的Spago廚房。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. 裝配線生產(chǎn)Repetitive/assembly line2022/8/9Dr. Weihua Zhou Zhejiang University8位于巴勒斯坦伊斯頓的賓尼和史密斯克雷奧拉產(chǎn)品制造商每年生產(chǎn)近30億支蠟筆。A repetitive process: Binney & Smith, maker

7、 of Crayola products, produces nearly 3 billion crayons each year in its Easton, PA, manufacturing facility. 連續(xù)流程 Continuous2022/8/9Dr. Weihua Zhou Zhejiang University9一個(gè)煉油廠的持續(xù)生產(chǎn)過程，把原油分解為石油，化工原油，以及其他產(chǎn)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提綱 Outline工藝選擇Process selection:工藝類型 Process Type產(chǎn)品工藝矩陣 Production-Process Matrix 設(shè)施布置Facility layout:布置的類型Layout types產(chǎn)品原則布置：生產(chǎn)線平衡Product layout: Line-balancing problems工藝原則布置：各部門間的工作流量Process layout: Inter

9、departmental Work Flows工藝原則布置：系統(tǒng)規(guī)劃設(shè)計(jì)Process layout: Systematic Layout Planning服務(wù)布置Service Layout產(chǎn)品-工藝矩陣Product Process MatrixDimension工藝專業(yè)化生產(chǎn)Job Shop批量生產(chǎn)Batch裝配線生產(chǎn)Repetitive連續(xù)流程 Continuous工作變化Job variety很高Very High一般Moderate較低Low很低Very low生產(chǎn)靈活性Process flexibility很高Very High一般Moderate較低Low很低Very low單

10、位成本Unit cost很高Very High一般Moderate較低Low很低Very low產(chǎn)量Volume of output很低Very Low較低Low較高High很高Very high2022/8/9Dr. Weihua Zhou Zhejiang University11產(chǎn)品工藝矩陣Production-Process Matrix2022/8/9Dr. Weihua Zhou Zhejiang University12產(chǎn)品結(jié)構(gòu)、產(chǎn)品生命周期多品種小產(chǎn)量品種較多高產(chǎn)量標(biāo)準(zhǔn)化大量生產(chǎn)顧客化低產(chǎn)量廣告重型機(jī)器中型機(jī)器食品加工汽車裝配麥當(dāng)勞石油化工面粉加工工藝專業(yè)化批量生產(chǎn)裝配線生產(chǎn)連

11、續(xù)流程過程結(jié)構(gòu)不可行不可行效率測量柔性(高)單件成本(高)柔性(低)單件成本(低2022/8/9Dr. Weihua Zhou Zhejiang University13提綱 Outline工藝選擇Process selection:工藝類型 Process Type產(chǎn)品工藝矩陣 Production-Process Matrix 設(shè)施布置Facility layout:布置的類型Layout types產(chǎn)品原則布置：生產(chǎn)線平衡Product layout: Line-balancing problems工藝原則布置：各部門間的工作流量Process layout: Interdepartme

12、ntal Work Flows工藝原則布置：系統(tǒng)規(guī)劃設(shè)計(jì)Process layout: Systematic Layout Planning服務(wù)布置Service Layout設(shè)備布置 Facilities Layout布置：對業(yè)務(wù)部門、工作中心和設(shè)備進(jìn)行布局，以確保系統(tǒng)中工作流運(yùn)行順暢。Layout: the configuration of departments, work centers, and equipment, with particular emphasis on movement of work (customers or materials) through the sy

13、stem產(chǎn)品原則布置Product layouts工藝原則布置Process layouts成組技術(shù)單元布置Group technology (cellular) layout定點(diǎn)布置Fixed-Position layout2022/8/9Dr. Weihua Zhou Zhejiang University14設(shè)施布置的目標(biāo)Objective of Layout Design有助于達(dá)到產(chǎn)品和服務(wù)的質(zhì)量水平Facilitate attainment of product or service quality有效利用空間和人力Use workers and space efficiently避

14、免出現(xiàn)瓶頸Avoid bottlenecks搬運(yùn)成本最低Minimize unnecessary material handling costs消除工人或物料的不必要搬運(yùn)Eliminate unnecessary movement of workers or materials縮短生產(chǎn)和顧客服務(wù)時(shí)間Minimize production time or customer service time實(shí)現(xiàn)安全生產(chǎn)Design for safety2022/8/9Dr. Weihua Zhou Zhejiang University15布置決策的重要性Importance of Layout Deci

15、sions投入大量資金和精力Requires substantial investments of money and effort具有長期性Involves long-term commitments對短期運(yùn)營的費(fèi)用和效率有很大影響Has significant impact on cost and efficiency of short-term operations2022/8/9Dr. Weihua Zhou Zhejiang University16布置決策的必要性The Need for Layout Decisions2022/8/9Dr. Weihua Zhou Zhejian

16、g University17無效率運(yùn)營Inefficient operations如：高成本、瓶頸For Example:High Cost Bottlenecks產(chǎn)品或服務(wù)設(shè)計(jì)上的改變Changes in the design of products or services推出新產(chǎn)品或服務(wù)The introduction of newproducts or services意外Accidents安全危害Safety hazards2022/8/9Dr. Weihua Zhou Zhejiang University18環(huán)境或其他法律要求的改變Changes inenvironmentalor

17、 other legalrequirements產(chǎn)量或產(chǎn)品組合的改變Changes in volume ofoutput or mix ofproducts方法或設(shè)備的改變Changes in methodsand equipment情緒問題Morale problems布置決策的必要性The Need for Layout Decisions工藝與布置Process and Layout2022/8/9Dr. Weihua Zhou Zhejiang University192022/8/9Dr. Weihua Zhou Zhejiang University20提綱 Outline工藝選擇

18、Process selection:工藝類型 Process Type產(chǎn)品工藝矩陣 Production-Process Matrix 設(shè)施布置Facility layout:布置的類型Layout types產(chǎn)品原則布置：生產(chǎn)線平衡Product layout: Line-balancing problems工藝原則布置：各部門間的工作流量Process layout: Interdepartmental Work Flows工藝原則布置：系統(tǒng)規(guī)劃設(shè)計(jì)Process layout: Systematic Layout Planning服務(wù)布置Service Layout基本布置方式 Basi

19、c Layout Types產(chǎn)品原則布置Product Layout使大量產(chǎn)品或顧客順利且迅速通過系統(tǒng)Layout that uses standardized processing operations to achieve smooth, rapid, high-volume flow采用生產(chǎn)線工作站方法生產(chǎn)產(chǎn)品Linear arrangement of workstations to produce a specific product工藝原則布置Process Layout用來加工或提供涉及許多工藝要求的產(chǎn)品或服務(wù)。Layout that can handle varied proce

20、ssing requirements以完成相似活動(dòng)的部門或其他職能組為特征Centers/machines grouped by process they perform固定位置布置Fixed Position Layout加工對象保持不動(dòng)，工人、材料和設(shè)備按需要四處移動(dòng)Layout in which the product or project remains stationary; workers, materials, and equipment are moved as needed用于產(chǎn)品無法移動(dòng)的項(xiàng)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單元布置Group technology (cellular) layouts成組加工單元機(jī)group machines into machining cells柔性制造系統(tǒng)Flexible manufacturing systems自動(dòng)化加工和材料處理系統(tǒng)automated machining & material handling systems混合裝配線Mixed-model assembly lines一條生產(chǎn)線上生產(chǎn)多種型號的產(chǎn)品prod

22、uce variety of models on one line2022/8/9Dr. Weihua Zhou Zhejiang University22產(chǎn)品原則布置 Product Layout2022/8/9Dr. Weihua Zhou Zhejiang University23原材料或顧客Raw materialsor customer產(chǎn)成品Finished item工作中心1工作中心1工作中心1材料/勞動(dòng)力Material and/or labor工作中心1用于高重復(fù)性的生產(chǎn)流程Used for Repetitive or Continuous Processing材料/勞動(dòng)力Ma

23、terial and/or labor材料/勞動(dòng)力Material and/or labor材料/勞動(dòng)力Material and/or labor產(chǎn)品原則布置的優(yōu)點(diǎn)Advantages of Product Layout產(chǎn)量高High rate of output成本低Low unit cost勞力專門化Labor specialization物料運(yùn)輸費(fèi)低Low material handling cost工人和設(shè)備的利用率高High utilization of labor and equipment工藝路線選擇及進(jìn)程安排都在初步設(shè)計(jì)中確定下來 Established routing and

24、 scheduling會計(jì)、采購程序化Routing accounting and purchasing2022/8/9Dr. Weihua Zhou Zhejiang University24產(chǎn)品原則布置的缺點(diǎn)Disadvantages of Product Layout工作重復(fù)單調(diào)Creates dull, repetitive jobs技術(shù)低的工人可能對維持設(shè)備或產(chǎn)出質(zhì)量缺乏興趣Poorly skilled workers may not maintain equipment or quality of output對產(chǎn)量變化以及產(chǎn)品或工藝設(shè)計(jì)變化的適應(yīng)性差Fairly inflexib

25、le to changes in volume設(shè)備故障對生產(chǎn)系統(tǒng)的影響很大Highly susceptible to shutdowns需要預(yù)防性維修能力Needs preventive maintenance與個(gè)人產(chǎn)量相聯(lián)系的激勵(lì)計(jì)劃是不可行的Individual incentive plans are impractical2022/8/9Dr. Weihua Zhou Zhejiang University25U型生產(chǎn)線A U-Shaped Production Line2022/8/9Dr. Weihua Zhou Zhejiang University2612345678910開始I

26、n結(jié)束Out工人Workers工藝原則布置 Process Layout2022/8/9Dr. Weihua Zhou Zhejiang University27Dept. ADept. BDept. DDept. CDept. FDept. E用于間斷加工單件小批和成批過程Used for Intermittent processing Job Shop or Batch Processes按功能制造過程布置Manufacturing Process Layout2022/8/9Dr. Weihua Zhou Zhejiang University28LLLLLLLLLLMMMMDDDDDD

27、DDGGGGGGPPAAAReceiving andShippingAssemblyPainting DepartmentLathe DepartmentMilling DepartmentDrilling DepartmentGrinding Department服務(wù)過程布置 Service Process Layout女士內(nèi)衣WomensLingerie鞋子Shoes居家衣服House-wares女裙WomensDresses化妝品及珠寶Cosmetics& Jewelry孩子區(qū)ChildrensDepartment女運(yùn)動(dòng)裝WomensSportswear季節(jié)性Entry &Seasona

28、l男士區(qū)MensDepartment2022/8/9Dr. Weihua Zhou Zhejiang University29工藝原則的優(yōu)點(diǎn)Advantages of Process Layouts滿足多樣的工藝要求Can handle a variety of processing requirements系統(tǒng)受個(gè)別設(shè)備出故障的影響不大Not particularly vulnerable to equipment failures設(shè)備不會太昂貴Equipment used is less costly可采用個(gè)人激勵(lì)機(jī)制Possible to use individual incentive

29、 plans2022/8/9Dr. Weihua Zhou Zhejiang University30工藝原則的缺點(diǎn)Disadvantages of Process Layouts制品庫存量較大In-process inventory costs can be high要經(jīng)常進(jìn)行工藝路線選擇及安排Challenging routing and scheduling設(shè)備利用率低Equipment utilization rates are low物料運(yùn)輸慢、效率低Material handling slow and inefficient工藝復(fù)雜化使監(jiān)督跨度減少Complexities ofte

30、n reduce span of supervision對每一產(chǎn)品或顧客需求都特別關(guān)注Special attention for each product or customer會計(jì)、庫存控制較復(fù)雜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: 加工對象保持固定，而工人、材料及設(shè)備需要轉(zhuǎn)移Layout in which the product or proje

31、ct remains stationary, and workers, materials, and equipment are moved as needed.產(chǎn)品的性質(zhì)決定了這種類型的布局Nature of the product dictates this type of layout質(zhì)量Weight尺寸Size 批量Bulk大型建設(shè)項(xiàng)目Large construction projects2022/8/9Dr. Weihua Zhou Zhejiang University32單元布置Cellular Layouts生產(chǎn)單元Cellular Production將工作分組，組的劃分是有

32、一系列相似零件所需要的運(yùn)營決定Layout in which machines are grouped into a cell that can process items that have similar processing requirements成組技術(shù)Group Technology按相似工藝特征分組，保證生產(chǎn)效率The grouping into part families of items with similar design or manufacturing characteristics2022/8/9Dr. Weihua Zhou Zhejiang University

33、33比較 A Comparison2022/8/9Dr. Weihua Zhou Zhejiang University34Group TechnologyMachine 1Machine 2Machine 3Machine 4Machine 5Materials inFinished goods out一個(gè)工人多臺機(jī)器One Worker, Multiple Machines成組技術(shù) 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工藝原則布置與單元布置的比較Functional vs. Cellular Layouts方面Dimension工藝原則Functional單元式Cellular部門之間移動(dòng)次數(shù)Number of moves between departments很多many很少few移動(dòng)距離Travel distances較長l

38、onger較短shorter移動(dòng)路線Travel paths變化variable固定fixed加工等待時(shí)間Job waiting times較長greater較短shorter加工時(shí)間Throughput time較長higher較短lower在制品數(shù)量Amount of work in process較大higher較小lower管理難度Supervision difficulty較大higher較小lower排程復(fù)雜性Scheduling complexity較大higher較小lower設(shè)備利用率Equipment utilization較低lower較高h(yuǎn)igher2022/8/9Dr

39、. Weihua Zhou Zhejiang University452022/8/9Dr. Weihua Zhou Zhejiang University46提綱 Outline工藝選擇Process selection:工藝類型 Process Type產(chǎn)品工藝矩陣 Production-Process Matrix 設(shè)施布置Facility layout:布置的類型Layout types產(chǎn)品原則布置：生產(chǎn)線平衡Product layout: Line-balancing problems工藝原則布置：各部門間的工作流量Process layout: Interdepartmental

40、Work Flows工藝原則布置：系統(tǒng)規(guī)劃設(shè)計(jì)Process layout: Systematic Layout Planning服務(wù)布置Service Layout產(chǎn)品布置：生產(chǎn)線平衡Design Product Layouts: Line Balancing2022/8/9Dr. Weihua Zhou Zhejiang University47生產(chǎn)線平衡決定如何將作業(yè)分配到工作地，使分到各工作地的作業(yè)所需要的時(shí)間大致相等。Line Balancing is the process of assigning tasks to workstations in such a way that

41、the workstations have approximately equal time requirements. 流程或生產(chǎn)線平衡Line Balancing生產(chǎn)線平衡涉及把作業(yè)分配到工作地的決策。一般每個(gè)工作地只有一個(gè)工人來完成所有作業(yè)。完全平衡的生產(chǎn)線，其線上的各活動(dòng)完全同步進(jìn)行，能夠?qū)崿F(xiàn)工人和設(shè)備的最大利用。生產(chǎn)線平衡的目標(biāo)，是在技術(shù)以及產(chǎn)量的約束下，使生產(chǎn)線的閑置時(shí)間最少，效率最高。2022/8/9Dr. Weihua Zhou Zhejiang University48Cycle Time（節(jié)拍）2022/8/9Dr. Weihua Zhou Zhejiang Univers

42、ity49節(jié)拍是指各工作地完成分配給它的作業(yè)所容許的最大時(shí)間。Cycle time is the maximum time allowed at each workstation to complete its set of tasks on a unit.產(chǎn)量 Determine Maximum Output2022/8/9Dr. Weihua Zhou Zhejiang University50工作地?cái)?shù)的理論最小值Determine the Minimum Number of Workstations Required2022/8/9Dr. Weihua Zhou Zhejiang Uni

43、versity51節(jié)拍和產(chǎn)量Example: Cycle time and Output tate2022/8/9Dr. Weihua Zhou Zhejiang University52作業(yè)緊后作業(yè)作業(yè)時(shí)間/分鐘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生產(chǎn)線平衡算法1. 確定節(jié)拍

44、，求出最少所需的工作地?cái)?shù)2.從工作地1開始，按順序給工作地分配作業(yè)。作業(yè)的分配按作業(yè)先后順序圖由左至右進(jìn)行。每個(gè)工作地的初始剩余時(shí)間為節(jié)拍。3.在每一分配前，利用下列標(biāo)準(zhǔn)確定哪些作業(yè)夠資格分配到一個(gè)工作地：A.該作業(yè)所有先行作業(yè)都已被分配B.該作業(yè)時(shí)間不超過該工作地的剩余時(shí)間4.如果沒有夠資格分配的作業(yè)，則開始下一個(gè)工作地的分配，轉(zhuǎn)步驟3；如果出現(xiàn)多個(gè)夠資格分配的作業(yè)，可采用以下方法進(jìn)行分配：A.分配后續(xù)作業(yè)數(shù)最多的作業(yè)B.分配加工時(shí)間最長的作業(yè)如果還是一樣，任意選擇一個(gè)作業(yè)。5. 每當(dāng)一個(gè)作業(yè)分配后，計(jì)算該工作地的剩余時(shí)間。剩余時(shí)間等于原有剩余時(shí)間減去當(dāng)前分配作業(yè)的時(shí)間。6. 繼續(xù)步驟35，

45、直到所有作業(yè)分配完畢。7. 計(jì)算指標(biāo)（如閑置百分比、效率）2022/8/954Dr. Weihua Zhou Zhejiang University生產(chǎn)線平衡原則Line Balancing Rules先分配后續(xù)作業(yè)數(shù)最多的作業(yè)Assign tasks in order of most following tasks.根據(jù)位置權(quán)數(shù)分配任務(wù)Break the tie: assign tasks in order of greatest positional weight. 2022/8/9Dr. Weihua Zhou Zhejiang University55生產(chǎn)線平衡Process of L

46、ine Balancing2022/8/9Dr. Weihua Zhou Zhejiang University56工作地剩余時(shí)間候選作業(yè)可行作業(yè)分配作業(yè)閑置時(shí)間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分配結(jié)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瓶頸工作地 Bottleneck Workstation1 min.2 min.1 min.1 min.30/hr.30/hr.30/hr.30/hr.瓶

48、頸工作地 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服務(wù)業(yè)的流程平衡分析活動(dòng)描述時(shí)間（秒）1檢查申請書的正確性152處理和記錄收費(fèi)303檢查違規(guī)和限制情況604眼睛測試405為申請人拍照206頒發(fā)臨時(shí)執(zhí)照302022/8/9Dr. Weihua Zhou Zhejiang University

49、60例：汽車駕照申請服務(wù)的布局與流程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提綱 Outline工藝選擇Process selection:工藝類型 Process Type產(chǎn)品工藝矩陣 Production-Process Matrix 設(shè)施布置Facili

50、ty layout:布置的類型Layout types產(chǎn)品原則布置：生產(chǎn)線平衡Product layout: Line-balancing problems工藝原則布置：各部門間的工作流量Process layout: Interdepartmental Work Flows工藝原則布置：系統(tǒng)規(guī)劃設(shè)計(jì)Process layout: Systematic Layout Planning服務(wù)布置Service Layout工藝布置設(shè)計(jì)Designing Process Layouts信息要求Information Requirements:一系列要安排的工作部門或工作中心List of depar

51、tments個(gè)工作中心之間未來工作流的平面圖Projection of work flows位置間的距離及單位距離物料運(yùn)輸費(fèi)用Distance between locations投資于該布置的金額Amount of money to be invested一系列需特別考慮的事項(xiàng)List of special considerations現(xiàn)有建筑物內(nèi)關(guān)鍵設(shè)施的位置、進(jìn)出點(diǎn)以及載貨處Location of key utilities2022/8/9Dr. Weihua Zhou Zhejiang University63工藝布置：各部門間的工作流量Process Layout: Interdepa

52、rtmental Flow已知信息Given各部門間實(shí)際的或預(yù)計(jì)的工作流量The flow (number of moves) to and from all departments各部門間運(yùn)輸成本費(fèi)用The cost of moving from one department to another實(shí)際的或預(yù)計(jì)的布局The existing or planned physical layout of the plant決策Determine合理分布各部門，達(dá)到運(yùn)費(fèi)最少或距離最短的工藝專業(yè)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從至表法 From-to matrix根據(jù)零部件或作業(yè)在各種設(shè)備或加工中心之間移動(dòng)的次數(shù)，合理安排設(shè)備布置方案的嘗試性方法目標(biāo)是找出整個(gè)生產(chǎn)單元間物料總運(yùn)輸量最小的布置方案適用于多品種小批量的生產(chǎn)方式2022/8/9Dr. Weihua Zhou Zhejiang University65Example 2022/8/9Dr. Weihua Zhou Zhejiang University66部門間工作流量In

54、terdepartmental work flow 位置間的距離Distance between locations部門分配及兩部門相互間的工作流量Example : Interdepartmental Work Flowsfor Assigned Departments2022/8/9Dr. Weihua Zhou Zhejiang University6713230170100ABC從至表法 From-to matrix2022/8/9Dr. Weihua Zhou Zhejiang University68tofrom12345611520218210251632043155206126

55、354ld7545201840198例：一金屬加工車間有六臺設(shè)備，已知其生產(chǎn)的零件品種及加工路線，并據(jù)此給出如表1所示的零件在設(shè)備之間的每月移動(dòng)次數(shù)，表2給出了單位距離運(yùn)輸成本。請用這些數(shù)據(jù)確定該車間的最佳布置方案。2022/8/9Dr. Weihua Zhou Zhejiang University692022/8/9Dr. Weihua Zhou Zhejiang University70求解步驟及結(jié)果1. 將運(yùn)輸次數(shù)矩陣與單位距離運(yùn)輸成本矩陣的相同位置的數(shù)據(jù)相乘，得到從一臺機(jī)器到另一臺機(jī)器的每月運(yùn)輸成本，如表3所示。2. 將對角線對稱的成本元素相加得到兩臺機(jī)器間的每月總的運(yùn)輸成本，如表4

56、所示。3. 按總運(yùn)輸成本的大小，可得機(jī)器（或部門）之間的緊密相鄰程度。最緊密的5項(xiàng)按降序排列為：(1)、(2)、(3)、(4)、(5)，因而應(yīng)將磨床與鉆床、鋸床與磨床、鉆床與車床、車床與插床相鄰布置。2022/8/9Dr. Weihua Zhou Zhejiang University712022/8/9Dr. Weihua Zhou Zhejiang University72計(jì)算機(jī)輔助設(shè)施規(guī)劃技術(shù)軟件Process Layout: CRAFT ApproachCRAFT (computerized relative allocation of facilities technique)是美國

57、人開發(fā)的應(yīng)用從至表的啟發(fā)式輔助設(shè)備布置軟件這是一個(gè)啟發(fā)式的程序，它使用作出評價(jià)一個(gè)簡單的規(guī)則：It is a heuristic program; it uses a simple rule of thumb in making evaluations: “同時(shí)比較兩個(gè)部門、，如果它降低了總成本的布局則相互交換?！?Compare two departments at a time and exchange them if it reduces the total cost of the layout.它并不能保證最佳解決方案It does not guarantee an optimal s

58、olution按不同行程方向，兩位之間的行程受電梯等因素影響大小可能不同，但在此假定兩位置間的距離相同。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提綱 Outline工藝選擇Process selection:工藝類型 Process Type產(chǎn)品工藝矩陣 Produc

59、tion-Process Matrix 設(shè)施布置Facility layout:布置的類型Layout types產(chǎn)品原則布置：生產(chǎn)線平衡Product layout: Line-balancing problems工藝原則布置：各部門間的工作流量Process layout: Interdepartmental Work Flows工藝原則布置：系統(tǒng)規(guī)劃設(shè)計(jì)Process layout: Systematic Layout Planning服務(wù)布置Service Layout工藝原則布置：系統(tǒng)規(guī)劃設(shè)計(jì)Process Layout: Systematic Layout Planning各部門間

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系統(tǒng)規(guī)劃設(shè)計(jì)Systematic Layout Planning確定各部門間的關(guān)系和接近程度Accounts for the importance of having each department located next to every other depar