非全能工下分割式单元(Seru)系统的优化设计与调度

Seru production is recognized a new production patten applied widely in Asian industries, especially the electronics industry. Seru production is developed to cope with a volatile market that is described as shorter product life-cycles, uncertain product types, and fluctuating production volumes. All of the researches on seru production are based on the assumption of fully multi-skilled workers. However, fully multi-skilled worker is seldom in practical manufacturing, but partial multi-skilled worker is common condition and the initial stage of seru production. Therefore, the project aims to investigate optimal seru formation and seru scheduling for divisional seru system under partial multi-skilled workers. The findings of this project will not only make theoretical contribution to seru production systems, but also proposes the management insights on successful seru formation and seru scheduling for divisional seru system for the companies which want to adopt seru system under partial multi-skilled workers. The achievement of the project will help domestic enterprises to increase the productivity. To this end, the research activities will be conducted in the following parts: (P1) Seru formation and main performances evaluation of divisional seru system under partial multi-skilled workers; (P2) Mathematical model and theoretical analysis of the basic problem of pure and hybrid divisional seru system under partial multi-skilled workers; (P3) Optimal seru formation and seru scheduling for divisional seru system under partial multi-skilled workers; (P4) Characteristics of divisional seru system whose performance is close to the performance seru system under fully multi-skilled workers.

日本式单元(Seru)生产被认为是一种新生产模式，相关研究也刚起步。但大多研究都基于全能工假设，而全能工在实际生产中很少见、非全能工才是生产现场的常见状态。本项目以非全能工所对应的分割式单元(Seru)系统为研究对象，旨在探索流水线向分割式单元系统最优转化的基本理论与方法。首先，研究分割式单元构造方法及常用生产指标的定量描述。其次，构建流水线向(纯/混合)分割式单元系统转化的数学模型，分析该转化的可行性及其基本理论问题。然后，探索流水线向(纯/混合)分割式单元系统转化的最优设计和调度方法。最后，探索近似全能工下单元系统性能的分割式单元系统的特征，以构建非全能工下最优的分割式单元系统。研究成果不仅在理论上，扩展了生产运作管理的研究领域，拓展了单元生产的实施范围；我国正在产业转型期，目前仍以流水线生产模式为主，若能成功应用该成果，将能通过人力资源的合理组织提高生产效率，获得良好的经济效益。

赛汝生产方式是一种新的生产模式，本项目以非全能工赛汝生产系统为研究对象，旨在探索非全能工赛汝生产系统最优运作的基本理论与方法，以实现利用最少的多能工培训获得理想的赛汝生产效率。取得了如下的研究成果：针对非全能工所对应的一种赛汝生产系统（分割式赛汝系统），构建了分割式赛汝系统最小makespan的数学模型，开发了精确算法，利用该精确算法研究了其makespan和多能工需求之间的关系；针对非全能工所对应的另一种赛汝生产系统（混合式赛汝系统），构建了混合式赛汝系统最小makespan的数学模型，开发了精确算法研究了其makespan和多能工需求之间的关系；研究了常用评价指标(总拖期最小、平衡性最好、工人数最小等)下赛汝系统的最优运作方法，开发了基于分解的精确算法求解小规模实例，和基于联合优化的智能算法求解大规模实例；研究了常用调度规则对赛汝生产系统性能的影响；利用仿真优化分析了非确定下赛汝生产系统的合理赛汝构造。