工藝選擇與設(shè)施布置

ProcessSelectionandFacilityLayout周偉華

博士浙江大學(xué)Dr.WeihuaZhouZhejiangUniversity提綱Outline工藝選擇Processselection:工藝類型ProcessType產(chǎn)品工藝矩陣Production-ProcessMatrix設(shè)施布置Facilitylayout:布置的類型Layouttypes產(chǎn)品原則布置：生產(chǎn)線平衡

Productlayout:Line-balancingproblems工藝原則布置：各部門間的工作流量

Processlayout:InterdepartmentalWorkFlows工藝原則布置：系統(tǒng)規(guī)劃設(shè)計(jì)

Processlayout:SystematicLayoutPlanning服務(wù)布置ServiceLayout2025/4/25Dr.WeihuaZhouZhejiangUniversity2簡(jiǎn)介Introduction工藝Process一個(gè)組織將輸入品轉(zhuǎn)化為輸出品的過(guò)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Processselection組織產(chǎn)品生產(chǎn)或服務(wù)提供的方式

Decidingonthewayproductionofgoodsorserviceswillbeorganized主要根據(jù)Majorimplications勞動(dòng)密集度Capacityplanning設(shè)施布置Layoutoffacilities設(shè)備Equipment作業(yè)系統(tǒng)的設(shè)計(jì)Designofworksystems2025/4/25Dr.WeihuaZhouZhejiangUniversity3工藝選擇ProcessSelection品種Variety系統(tǒng)需要處理多少品種的產(chǎn)品/服務(wù)？

Howmuch靈活性Flexibility需要具有什么樣柔性的設(shè)備？

Whatdegree產(chǎn)量Volume期望的產(chǎn)量是多少？

Expectedoutput2025/4/25Dr.WeihuaZhouZhejiangUniversity4工藝類型ProcessTypes工藝專業(yè)化生產(chǎn)Jobshop小規(guī)模Smallscale批量生產(chǎn)Batch中等規(guī)模Moderatevolume裝配線生產(chǎn)Repetitive/assemblyline標(biāo)準(zhǔn)化程度較高的產(chǎn)品/服務(wù)

Highvolumesofstandardizedgoodsorservices連續(xù)流程Continuous生產(chǎn)高度標(biāo)準(zhǔn)化的產(chǎn)品/服務(wù)

Veryhighvolumesofnon-discretegoods2025/4/25Dr.WeihuaZhouZhejiangUniversity5工藝專業(yè)化生產(chǎn)Jobshop2025/4/25Dr.WeihuaZhouZhejiangUniversity6一個(gè)中西醫(yī)結(jié)合的醫(yī)院醫(yī)生會(huì)診過(guò)程，設(shè)計(jì)心導(dǎo)管檢查術(shù)

Ajobshopprocess:Amidwesternhospitalmedicalteamperformsadiagnosticprocedureinvolvingacardiaccatheterization.批量生產(chǎn)Batch2025/4/25Dr.WeihuaZhouZhejiangUniversity7食物準(zhǔn)備，一次一個(gè)菜單項(xiàng)，在美國(guó)內(nèi)華達(dá)州拉斯維加斯的凱撒宮的Spago廚房。

Abatchprocess:Foodisprepared,onemenuitematatime,inthekitchenoftheSpagoRestaurantintheForumatCaesar’sPalace,LasVegas,Nevada.裝配線生產(chǎn)Repetitive/assemblyline2025/4/25Dr.WeihuaZhouZhejiangUniversity8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。

Arepetitiveprocess:Binney&Smith,makerofCrayolaproducts,producesnearly3billioncrayonseachyearinitsEaston,PA,manufacturingfacility.連續(xù)流程Continuous2025/4/25Dr.WeihuaZhouZhejiangUniversity9一個(gè)煉油廠的持續(xù)生產(chǎn)過(guò)程，把原油分解為石油，化工原油，以及其他產(chǎn)品。

Acontinuousprocess:Anoilrefineryperformsacontinuousprocess,breakingdowncrudeoilintopetroleum,chemicals,andmanyotherproducts.2025/4/25Dr.WeihuaZhouZhejiangUniversity10提綱Outline工藝選擇Processselection:工藝類型ProcessType產(chǎn)品工藝矩陣Production-ProcessMatrix設(shè)施布置Facilitylayout:布置的類型Layouttypes產(chǎn)品原則布置：生產(chǎn)線平衡

Productlayout:Line-balancingproblems工藝原則布置：各部門間的工作流量

Processlayout:InterdepartmentalWorkFlows工藝原則布置：系統(tǒng)規(guī)劃設(shè)計(jì)

Processlayout:SystematicLayoutPlanning服務(wù)布置ServiceLayout產(chǎn)品-工藝矩陣

Product–ProcessMatrixDimension工藝專業(yè)化生產(chǎn)

JobShop批量生產(chǎn)

Batch裝配線生產(chǎn)Repetitive連續(xù)流程Continuous工作變化Jobvariety很高VeryHigh一般Moderate較低Low很低Verylow生產(chǎn)靈活性Processflexibility很高VeryHigh一般Moderate較低Low很低Verylow單位成本Unitcost很高VeryHigh一般Moderate較低Low很低Verylow產(chǎn)量Volumeofoutput很低VeryLow較低Low較高High很高Veryhigh2025/4/25Dr.WeihuaZhouZhejiangUniversity11產(chǎn)品工藝矩陣

Production-ProcessMatrix2025/4/25Dr.WeihuaZhouZhejiangUniversity12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)連續(xù)流程過(guò)程結(jié)構(gòu)不可行不可行效率測(cè)量柔性(高)單件成本(高)柔性(低)單件成本(低2025/4/25Dr.WeihuaZhouZhejiangUniversity13提綱Outline工藝選擇Processselection:工藝類型ProcessType產(chǎn)品工藝矩陣Production-ProcessMatrix設(shè)施布置Facilitylayout:布置的類型Layouttypes產(chǎn)品原則布置：生產(chǎn)線平衡

Productlayout:Line-balancingproblems工藝原則布置：各部門間的工作流量

Processlayout:InterdepartmentalWorkFlows工藝原則布置：系統(tǒng)規(guī)劃設(shè)計(jì)

Processlayout:SystematicLayoutPlanning服務(wù)布置ServiceLayout設(shè)備布置FacilitiesLayout布置：對(duì)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:theconfigurationofdepartments,workcenters,andequipment,withparticularemphasisonmovementofwork(customersormaterials)throughthesystem產(chǎn)品原則布置Productlayouts工藝原則布置Processlayouts成組技術(shù)單元布置Grouptechnology(cellular)layout定點(diǎn)布置Fixed-Positionlayout2025/4/25Dr.WeihuaZhouZhejiangUniversity14設(shè)施布置的目標(biāo)

ObjectiveofLayoutDesign有助于達(dá)到產(chǎn)品和服務(wù)的質(zhì)量水平

Facilitateattainmentofproductorservicequality有效利用空間和人力

Useworkersandspaceefficiently避免出現(xiàn)瓶頸Avoidbottlenecks搬運(yùn)成本最低

Minimizeunnecessarymaterialhandlingcosts消除工人或物料的不必要搬運(yùn)

Eliminateunnecessarymovementofworkersormaterials縮短生產(chǎn)和顧客服務(wù)時(shí)間

Minimizeproductiontimeorcustomerservicetime實(shí)現(xiàn)安全生產(chǎn)Designforsafety2025/4/25Dr.WeihuaZhouZhejiangUniversity15布置決策的重要性

ImportanceofLayoutDecisions投入大量資金和精力

Requiressubstantialinvestmentsofmoneyandeffort具有長(zhǎng)期性

Involveslong-termcommitments對(duì)短期運(yùn)營(yíng)的費(fèi)用和效率有很大影響

Hassignificantimpactoncostandefficiencyofshort-termoperations2025/4/25Dr.WeihuaZhouZhejiangUniversity16布置決策的必要性

TheNeedforLayoutDecisions2025/4/25Dr.WeihuaZhouZhejiangUniversity17無(wú)效率運(yùn)營(yíng)Inefficientoperations如：高成本、瓶頸ForExample:HighCostBottlenecks產(chǎn)品或服務(wù)設(shè)計(jì)上的改變Changesinthedesignofproductsorservices推出新產(chǎn)品或服務(wù)Theintroductionofnew

productsorservices意外Accidents安全危害Safetyhazards2025/4/25Dr.WeihuaZhouZhejiangUniversity18環(huán)境或其他法律要求的改變Changesinenvironmentalorotherlegalrequirements產(chǎn)量或產(chǎn)品組合的改變Changesinvolumeofoutputormixofproducts方法或設(shè)備的改變Changesinmethodsandequipment情緒問(wèn)題Moraleproblems布置決策的必要性

TheNeedforLayoutDecisions工藝與布置

ProcessandLayout2025/4/25Dr.WeihuaZhouZhejiangUniversity192025/4/25Dr.WeihuaZhouZhejiangUniversity20提綱Outline工藝選擇Processselection:工藝類型ProcessType產(chǎn)品工藝矩陣Production-ProcessMatrix設(shè)施布置Facilitylayout:布置的類型Layouttypes產(chǎn)品原則布置：生產(chǎn)線平衡

Productlayout:Line-balancingproblems工藝原則布置：各部門間的工作流量

Processlayout:InterdepartmentalWorkFlows工藝原則布置：系統(tǒng)規(guī)劃設(shè)計(jì)

Processlayout:SystematicLayoutPlanning服務(wù)布置ServiceLayout基本布置方式BasicLayoutTypes產(chǎn)品原則布置ProductLayout使大量產(chǎn)品或顧客順利且迅速通過(guò)系統(tǒng)

Layoutthatusesstandardizedprocessingoperationstoachievesmooth,rapid,high-volumeflow采用生產(chǎn)線工作站方法生產(chǎn)產(chǎn)品

Lineararrangementofworkstationstoproduceaspecificproduct工藝原則布置ProcessLayout用來(lái)加工或提供涉及許多工藝要求的產(chǎn)品或服務(wù)。

Layoutthatcanhandlevariedprocessingrequirements以完成相似活動(dòng)的部門或其他職能組為特征

Centers/machinesgroupedbyprocesstheyperform固定位置布置FixedPositionLayout加工對(duì)象保持不動(dòng)，工人、材料和設(shè)備按需要四處移動(dòng)

Layoutinwhichtheproductorprojectremainsstationary;workers,materials,andequipmentaremovedasneeded用于產(chǎn)品無(wú)法移動(dòng)的項(xiàng)目中

Usedinprojectswheretheproductcannotbemoved2025/4/25Dr.WeihuaZhouZhejiangUniversity21混合布置HybridLayouts單元布置Grouptechnology(cellular)layouts成組加工單元機(jī)groupmachinesintomachiningcells柔性制造系統(tǒng)Flexiblemanufacturingsystems自動(dòng)化加工和材料處理系統(tǒng)

automatedmachining&materialhandlingsystems混合裝配線Mixed-modelassemblylines一條生產(chǎn)線上生產(chǎn)多種型號(hào)的產(chǎn)品

producevarietyofmodelsononeline2025/4/25Dr.WeihuaZhouZhejiangUniversity22產(chǎn)品原則布置ProductLayout2025/4/25Dr.WeihuaZhouZhejiangUniversity23原材料或顧客

Rawmaterialsorcustomer產(chǎn)成品Finisheditem工作中心1工作中心1工作中心1材料/勞動(dòng)力Material

and/orlabor工作中心1用于高重復(fù)性的生產(chǎn)流程

UsedforRepetitiveorContinuousProcessing材料/勞動(dòng)力Material

and/orlabor材料/勞動(dòng)力Material

and/orlabor材料/勞動(dòng)力Material

and/orlabor產(chǎn)品原則布置的優(yōu)點(diǎn)

AdvantagesofProductLayout產(chǎn)量高Highrateofoutput成本低Lowunitcost勞力專門化Laborspecialization物料運(yùn)輸費(fèi)低Lowmaterialhandlingcost工人和設(shè)備的利用率高

Highutilizationoflaborandequipment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(lái)

Establishedroutingandscheduling會(huì)計(jì)、采購(gòu)程序化Routingaccountingandpurchasing2025/4/25Dr.WeihuaZhouZhejiangUniversity24產(chǎn)品原則布置的缺點(diǎn)

DisadvantagesofProductLayout工作重復(fù)單調(diào)Createsdull,repetitivejobs技術(shù)低的工人可能對(duì)維持設(shè)備或產(chǎn)出質(zhì)量缺乏興趣

Poorlyskilledworkersmaynotmaintainequipmentorqualityofoutput對(duì)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

Fairlyinflexibletochangesinvolume設(shè)備故障對(duì)生產(chǎn)系統(tǒng)的影響很大

Highlysusceptibletoshutdowns需要預(yù)防性維修能力Needspreventivemaintenance與個(gè)人產(chǎn)量相聯(lián)系的激勵(lì)計(jì)劃是不可行的

Individualincentiveplansareimpractical2025/4/25Dr.WeihuaZhouZhejiangUniversity25U型生產(chǎn)線

AU-ShapedProductionLine2025/4/25Dr.WeihuaZhouZhejiangUniversity2612345678910開(kāi)始In結(jié)束Out工人Workers工藝原則布置ProcessLayout2025/4/25Dr.WeihuaZhouZhejiangUniversity27Dept.ADept.BDept.DDept.CDept.FDept.E用于間斷加工單件小批和成批過(guò)程

UsedforIntermittentprocessingJobShoporBatchProcesses按功能制造過(guò)程布置

ManufacturingProcessLayout2025/4/25Dr.WeihuaZhouZhejiangUniversity28LLLLLLLLLLMMMMDDDDDDDDGGGGGGPPAAAReceivingandShippingAssemblyPaintingDepartmentLatheDepartmentMillingDepartmentDrillingDepartmentGrindingDepartment服務(wù)過(guò)程布置ServiceProcessLayout女士?jī)?nèi)衣Women’sLingerie鞋子Shoes居家衣服House-wares女裙

Women’sDresses化妝品及珠寶Cosmetics&Jewelry孩子區(qū)Children’sDepartment女運(yùn)動(dòng)裝Women’sSportswear季節(jié)性Entry&Seasonal男士區(qū)Men’sDepartment2025/4/25Dr.WeihuaZhouZhejiangUniversity29工藝原則的優(yōu)點(diǎn)

AdvantagesofProcessLayouts滿足多樣的工藝要求

Canhandleavarietyofprocessingrequirements系統(tǒng)受個(gè)別設(shè)備出故障的影響不大

Notparticularlyvulnerabletoequipmentfailures設(shè)備不會(huì)太昂貴Equipmentusedislesscostly可采用個(gè)人激勵(lì)機(jī)制

Possibletouseindividualincentiveplans2025/4/25Dr.WeihuaZhouZhejiangUniversity30工藝原則的缺點(diǎn)

DisadvantagesofProcessLayouts制品庫(kù)存量較大In-processinventorycostscanbehigh要經(jīng)常進(jìn)行工藝路線選擇及安排

Challengingroutingandscheduling設(shè)備利用率低Equipmentutilizationratesarelow物料運(yùn)輸慢、效率低Materialhandlingslowandinefficient工藝復(fù)雜化使監(jiān)督跨度減少

Complexitiesoftenreducespanofsupervision對(duì)每一產(chǎn)品或顧客需求都特別關(guān)注

Specialattentionforeachproductorcustomer會(huì)計(jì)、庫(kù)存控制較復(fù)雜

Accountingandpurchasingaremoreinvolved2025/4/25Dr.WeihuaZhouZhejiangUniversity31固定位置布置

FixedPositionLayouts混合布置FixedPositionLayout:

加工對(duì)象保持固定，而工人、材料及設(shè)備需要轉(zhuǎn)移

Layoutinwhichtheproductorprojectremainsstationary,andworkers,materials,andequipmentaremovedasneeded.產(chǎn)品的性質(zhì)決定了這種類型的布局

Natureoftheproductdictatesthistypeoflayout質(zhì)量Weight尺寸Size批量Bulk大型建設(shè)項(xiàng)目

Largeconstructionprojects2025/4/25Dr.WeihuaZhouZhejiangUniversity32單元布置CellularLayouts生產(chǎn)單元CellularProduction將工作分組，組的劃分是有一系列相似零件所需要的運(yùn)營(yíng)決定

Layoutinwhichmachinesaregroupedintoacellthatcanprocessitemsthathavesimilarprocessingrequirements成組技術(shù)GroupTechnology按相似工藝特征分組，保證生產(chǎn)效率

Thegroupingintopartfamiliesofitemswithsimilardesignormanufacturingcharacteristics2025/4/25Dr.WeihuaZhouZhejiangUniversity33比較AComparison2025/4/25Dr.WeihuaZhouZhejiangUniversity34GroupTechnologyMachine1Machine2Machine3Machine4Machine5MaterialsinFinishedgoodsout一個(gè)工人多臺(tái)機(jī)器OneWorker,MultipleMachines成組技術(shù)GroupTechnology2025/4/25Dr.WeihuaZhouZhejiangUniversity36PartsFamiliesGroupTechnologyDrillingDDDDGrindingGGGGGGMillingMMMMMMAssemblyAAAALathingReceivingandshippingLLLLLLLLGroupTechnology(a)JumbledflowsinajobshopwithoutGTcellsDrillingDDDDGrindingGGGGGGMillingMMMMMMAssemblyAAAALathingReceivingandshippingLLLLLLLLGroupTechnology(a)JumbledflowsinajobshopwithoutGTcellsDrillingDDDDGrindingGGGGGGMillingMMMMMMAssemblyAAAALathingReceivingandshippingLLLLLLLLGroupTechnology(a)JumbledflowsinajobshopwithoutGTcellsDrillingDDDDGrindingGGGGGGMillingMMMMMMAssemblyAAAALathingReceivingandshippingLLLLLLLLGroupTechnology(b)LineflowsinajobshopwiththreeGTcellsCell3LMGGCell1Cell2AssemblyareaAALMDLLMShippingDReceivingGGroupTechnology(b)LineflowsinajobshopwiththreeGTcellsCell3LMGGCell1Cell2AssemblyareaAALMDLLMShippingDReceivingGGroupTechnology(b)LineflowsinajobshopwiththreeGTcellsCell3LMGGCell1Cell2AssemblyareaAALMDLLMShippingDReceivingGGroupTechnology(b)LineflowsinajobshopwiththreeGTcellsCell3LMGGCell1Cell2AssemblyareaAALMDLLMShippingDReceivingG工藝原則布置與單元布置的比較

Functionalvs.CellularLayouts方面Dimension工藝原則Functional單元式Cellular部門之間移動(dòng)次數(shù)Numberofmovesbetweendepartments很多many很少few移動(dòng)距離Traveldistances較長(zhǎng)longer較短shorter移動(dòng)路線Travelpaths變化variable固定fixed加工等待時(shí)間Jobwaitingtimes較長(zhǎng)greater較短shorter加工時(shí)間Throughputtime較長(zhǎng)higher較短lower在制品數(shù)量Amountofworkinprocess較大higher較小lower管理難度Supervisiondifficulty較大higher較小lower排程復(fù)雜性Schedulingcomplexity較大higher較小lower設(shè)備利用率Equipmentutilization較低lower較高h(yuǎn)igher2025/4/25Dr.WeihuaZhouZhejiangUniversity452025/4/25Dr.WeihuaZhouZhejiangUniversity46提綱Outline工藝選擇Processselection:工藝類型ProcessType產(chǎn)品工藝矩陣Production-ProcessMatrix設(shè)施布置Facilitylayout:布置的類型Layouttypes產(chǎn)品原則布置：生產(chǎn)線平衡

Productlayout:Line-balancingproblems工藝原則布置：各部門間的工作流量

Processlayout:InterdepartmentalWorkFlows工藝原則布置：系統(tǒng)規(guī)劃設(shè)計(jì)

Processlayout:SystematicLayoutPlanning服務(wù)布置ServiceLayout產(chǎn)品布置：生產(chǎn)線平衡

DesignProductLayouts:LineBalancing2025/4/25Dr.WeihuaZhouZhejiangUniversity47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。

LineBalancingistheprocessofassigningtaskstoworkstationsinsuchawaythattheworkstationshaveapproximatelyequaltimerequirements.流程或生產(chǎn)線平衡

LineBalancing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(lái)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。2025/4/25Dr.WeihuaZhouZhejiangUniversity48CycleTime（節(jié)拍）2025/4/25Dr.WeihuaZhouZhejiangUniversity49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。Cycletimeisthemaximumtimeallowedateachworkstationtocompleteitssetoftasksonaunit.產(chǎn)量DetermineMaximumOutput2025/4/25Dr.WeihuaZhouZhejiangUniversity50工作地?cái)?shù)的理論最小值

DeterminetheMinimumNumberofWorkstationsRequired2025/4/25Dr.WeihuaZhouZhejiangUniversity51節(jié)拍和產(chǎn)量

Example:CycletimeandOutputtate2025/4/25Dr.WeihuaZhouZhejiangUniversity52作業(yè)緊后作業(yè)作業(yè)時(shí)間/分鐘ab0.2be0.2cd0.8df0.6ef0.3fg1.0gh0.4h-0.3Total3.8Example2025/4/25Dr.WeihuaZhouZhejiangUniversity53cdabefgh0.20.20.30.80.61.00.40.3OT=480minutes/day,D=400/day,CT=1.2minutes生產(chǎn)線平衡算法1.確定節(jié)拍，求出最少所需的工作地?cái)?shù)2.從工作地1開(kāi)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(guò)該工作地的剩余時(shí)間4.如果沒(méi)有夠資格分配的作業(yè)，則開(kāi)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(zhǎng)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3－5，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）2025/4/2554Dr.WeihuaZhouZhejiangUniversity生產(chǎn)線平衡原則

LineBalancingRules先分配后續(xù)作業(yè)數(shù)最多的作業(yè)

Assigntasksinorderofmostfollowingtasks.根據(jù)位置權(quán)數(shù)分配任務(wù)

Breakthetie:assigntasksinorderofgreatestpositionalweight.2025/4/25Dr.WeihuaZhouZhejiangUniversity55生產(chǎn)線平衡

ProcessofLineBalancing2025/4/25Dr.WeihuaZhouZhejiangUniversity56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AllocationOutcome2025/4/25Dr.WeihuaZhouZhejiangUniversity57Workstation4(0.7)Workstation3(1.0)Workstation2(0.9)Workstation1(1.2)bdefgcahWorkstation4(0.7)Workstation3(1.0)Workstation2(1.1)Workstation1(1.0)bdefgcah2025/4/25Dr.WeihuaZhouZhejiangUniversity58瓶頸工作地

BottleneckWorkstation1min.2min.1min.1min.30/hr.30/hr.30/hr.30/hr.瓶頸工作地Bottleneck平行工作地ParallelWorkstations2025/4/25Dr.WeihuaZhouZhejiangUniversity591min.2min.1min.1min.60/hr.30/hr.30/hr.60/hr.2min.30/hr.30/hr.平行工作地ParallelWorkstations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(qǐng)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(cè)試405為申請(qǐng)人拍照206頒發(fā)臨時(shí)執(zhí)照302025/4/25Dr.WeihuaZhouZhejiangUniversity60例：汽車駕照申請(qǐng)服務(wù)的布局與流程24015112030260603180404180205120306入口出口65551.412030260603180205120306入口出口6060365551.4入口2025/4/25Dr.WeihuaZhouZhejiangUniversity6111121111111112025/4/25Dr.WeihuaZhouZhejiangUniversity62提綱Outline工藝選擇Processselection:工藝類型ProcessType產(chǎn)品工藝矩陣Production-ProcessMatrix設(shè)施布置Facilitylayout:布置的類型Layouttypes產(chǎn)品原則布置：生產(chǎn)線平衡

Productlayout:Line-balancingproblems工藝原則布置：各部門間的工作流量

Processlayout:InterdepartmentalWorkFlows工藝原則布置：系統(tǒng)規(guī)劃設(shè)計(jì)

Processlayout:SystematicLayoutPlanning服務(wù)布置ServiceLayout工藝布置設(shè)計(jì)

DesigningProcessLayouts信息要求InformationRequirements:一系列要安排的工作部門或工作中心

Listofdepartments個(gè)工作中心之間未來(lái)工作流的平面圖

Projectionofworkflows位置間的距離及單位距離物料運(yùn)輸費(fèi)用

Distancebetweenlocations投資于該布置的金額

Amountofmoneytobeinvested一系列需特別考慮的事項(xiàng)

Listofspecialconsiderations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

Locationofkeyutilities2025/4/25Dr.WeihuaZhouZhejiangUniversity63工藝布置：各部門間的工作流量

ProcessLayout:InterdepartmentalFlow已知信息Given各部門間實(shí)際的或預(yù)計(jì)的工作流量

Theflow(numberofmoves)toandfromalldepartments各部門間運(yùn)輸成本費(fèi)用

Thecostofmovingfromonedepartmenttoanother實(shí)際的或預(yù)計(jì)的布局

Theexistingorplannedphysicallayoutoftheplant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”locationsforeachdepartment,wherebestmeansmaximizingflow,whichminimizingcosts2025/4/25Dr.WeihuaZhouZhejiangUniversity64從至表法

From-tomatrix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2025/4/25Dr.WeihuaZhouZhejiangUniversity65Example2025/4/25Dr.WeihuaZhouZhejiangUniversity66部門間工作流量Interdepartmentalworkflow位置間的距離

Distancebetweenlocations部門分配及兩部門相互間的工作流量

Example:InterdepartmentalWorkFlows

forAssignedDepartments2025/4/25Dr.WeihuaZhouZhejiangUniversity6713230170100ABC從至表法

From-tomatrix2025/4/25Dr.WeihuaZhouZhejiangUniversity68tofrom12345611520－21821025163－20－43155206126354ld7545201840198例：一金屬加工車間有六臺(tái)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(qǐng)用這些數(shù)據(jù)確定該車間的最佳布置方案。2025/4/25Dr.WeihuaZhouZhejiangUniversity692025/4/25Dr.WeihuaZhouZhejiangUniversity70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(tái)機(jī)器到另一臺(tái)機(jī)器的每月運(yùn)輸成本，如表3所示。2.將對(duì)角線對(duì)稱的成本元素相加得到兩臺(tái)機(jī)器間的每月總的運(yùn)輸成本，如表4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。2025/4/25Dr.WeihuaZhouZhejiangUniversity712025/4/25Dr.WeihuaZhouZhejiangUniversity72計(jì)算機(jī)輔助設(shè)施規(guī)劃技術(shù)軟件

ProcessLayout:CRAFTApproachCRAFT(computerizedrelativeallocationoffacilitiestechnique)是美國(guó)人開(kāi)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(píng)價(jià)一個(gè)簡(jiǎn)單的規(guī)則：

Itisaheuristicprogram;itusesasimpleruleofthumbinmakingevaluations:“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。”"Comparetwodepartmentsatatimeandexchangethemifitreducesthetotalcostofthelayout."

它并不能保證最佳解決方案

Itdoesnotguaranteeanoptimalsolution

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。

CRAFTassumestheexistenceofvariablepathmaterialhandlingequipmentsuchasforklifttrucks2025/4/25Dr.WeihuaZhouZhejiangUniversity732025/4/25Dr.WeihuaZhouZhejiangUniversity74提綱Outline工藝選擇Processselection:工藝類型ProcessType產(chǎn)品工藝矩陣Production-ProcessMatrix設(shè)施布置Facilitylayout:布置的類型Layouttypes產(chǎn)品原則布置：生產(chǎn)線平衡

Productlayout:Line-balancingproblems工藝原則布置：各部門間的工作流量

Processlayout:InterdepartmentalWorkFlows工藝原則布置：系統(tǒng)規(guī)劃設(shè)計(jì)

Processlayout:SystematicLayoutPlanning服務(wù)布置ServiceLayout工藝原則布置：系統(tǒng)規(guī)劃設(shè)計(jì)

ProcessLayout:SystematicLayoutPlanning各部門間的工作流量

NumericalflowofitemsbetweendepartmentsCanbeimpracticaltoobtainDoesnotaccountforthequalitativefactorsthatmaybecrucialtotheplacementdecision系統(tǒng)規(guī)劃設(shè)計(jì)SystematicLayoutPlanning確定各部門間的關(guān)系和接近程度

Accountsfortheimportanceofhavingeachdepartmentlocatednexttoeveryotherdepartment由反復(fù)試驗(yàn)的結(jié)果確定

Isalsoguidedbytrialanderror交換部門位置后查看各部門接近程度

Switchingdepartmentsthencheckingtheresultsofthe“closeness”score2025/4/25Dr.WeihuaZhouZhejiangUniversity75系統(tǒng)規(guī)劃設(shè)計(jì)

SystematicLayoutPlanning也叫作業(yè)（活動(dòng)）相關(guān)圖法通過(guò)企業(yè)各個(gè)部門之間活動(dòng)關(guān)系的密切程度確定其相對(duì)位置主要用于對(duì)職能部門和功能區(qū)域進(jìn)行平面布置以此方法為指導(dǎo)發(fā)展了ALDEP(automatedlayoutdesignprogram）軟件系統(tǒng)隨機(jī)選擇一個(gè)活動(dòng)單元，選擇與其有最強(qiáng)相對(duì)關(guān)系的作為第二個(gè)選擇與第二個(gè)選擇與其有最強(qiáng)相對(duì)關(guān)系的作為第三個(gè)，依此類推給每個(gè)方案進(jìn)行評(píng)分，供決策者參考2025/4/25Dr.WeihuaZhouZhejiangUniversity76系統(tǒng)規(guī)劃設(shè)計(jì)：接近程度

SystematicLayoutPlanning:ReasonsforCloseness2025/4/25Dr.WeihuaZhouZhejiangUniversity77Code123456Reason客戶類型Typeofcustomer易于監(jiān)督Easeofsupervision普通人員Commonpersonnel必要的聯(lián)系Contactnecessary使用相同價(jià)格Sharesameprice心理

Psychology接近程度默澤網(wǎng)絡(luò)圖

ExampleofSystematicLayoutPlanning:ImportanceofCloseness2025/4/25Dr.WeihuaZhouZhejiangUniversity78Value符號(hào)Closeness接近程度weights分?jǐn)?shù)AAbsolutelynecessary6EEspeciallynecessary5IImportant4OOrdinarycloseness3UUnimportant2XUndesirable0部門1部門2部門3部門4部門5部門6OUXAAEUIAXAXOAA分配過(guò)程AllocationProcess2025/4/25Dr.WeihuaZhouZhejiangUniversity79接近程度為A接近程度為X1-21-41-33-62-63-43-54-65-61263542645264531A列中出現(xiàn)次數(shù)最多的是部門6考慮A列中的其他部門考慮X列中的部門4316XXX2025/4/25Dr.WeihuaZhouZhejiangUniversity80提綱Outline工藝選擇Processselection:工藝類型ProcessType產(chǎn)品工藝矩陣