近來企業為承接大量多變的訂單需求,藉由擴建新廠、合併他廠的方式來增加產能,使產業製造環境由單廠變為多廠。面對多廠區的生產環境,企業考量的是多廠間資源的整合規劃。又各廠區製造技術的不同,產品的生產製造需規劃至多廠區的不同製程,以完成訂單產品需求,降低廠區製程段的閒置產能,與物料短缺或物料存貨過多的情況,並提升產能與物料資源利用率,達到最小化的生產與物料規劃總成本,因而產生多廠區多階製程規劃問題。故本研究欲探討如何在多廠區多階製程的生產環境下,考量有限的產能與物料資源,進行跨廠區多階製程訂單分配。 本研究探討有限產能與物料下之跨廠區多階製程訂單分配,建構兩階段的規劃模式:1.多階製程物料需求展開模式:以各訂單需求為基礎,利用生產途程與物料表建構製造物料表,計算各訂單於各階製程生產所需的物料項目與數量;2.跨廠區多階製程訂單分配模式:以最小化生產與物料規劃總成本為目標,考量各廠區各階製程的產能與物料資源,利用混合整數規劃法建構模式,並藉由模擬退火法(SA)求解問題模式,依產品製程段順序,將訂單需求分配至各廠區生產。又本研究建構一初始解演算法,改善模擬退火法利用隨機方式產生初始解求解效率不佳的缺失。 本研究提出的兩階段規劃模式,除了提供管理者精確計算各筆訂單的物料需求量,亦可在最小化的生產與物料規劃總成本下,取得最佳的訂單分配結果。分配結果有助於企業妥善規劃產能與物料資源,降低各廠區的產能閒置與物料存貨,並提升多廠間各階製程段的生產作業支援與物料備料能力。
In order to receive a large number of orders, a company might expand the number of plants or the product lines to increase the capacity for satisfying lots of and various orders. Therefore, a company should take a multi-plant and multi-stage coordinated manufacturing stratege to decrease the idle capacity, the material inventory and to increase the average utilization of capacity and material of each plant to achieve the minimum of the product and material cost. Under this consideration, it is important to develop a coordinated capacity and material planning to assign the orders properly to all plants based on the sequence of the manufacturing processes. In this research, two phases of order assignment are presented: 1.Multi-stage manufacturing processes material requirement expansion model is to transform the material items and quantities of each manufacturing process based on product requirements. 2.Multi-plant and multi-stage process order assignment for coordinated manufacturing model is to use mixed integer programming to formulate the model of order assignment of minimizing the total production and material cost accoreding to capacity and material constraints, and then use simulated annealing (SA) method to find the (near) optimal solution. To improve the SA solution qulity, a heuristic is proposed to find an initial solution based on capacity of each plant. Finally, the results could help a company to use finite capacity and material resources properly, reduce the idle capacity and material inventory, enhance the operation support and material preparation ability.
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