流程線啟發式重排程方法之研究

Abstract

現今工廠在面對動態與不確定因素之製造環境下, 常受以下主要變動因素 或方案影響, 而必須重排整個排程: 1. 缺料 (Material shortage) 2. 緊急訂單插入 (Rush order insert) 3. 機器故障 (Machine shutdown) 4. 訂單變更 (Order changes) 5. 品質問題 (Quality issue) 6. 工程設計變更和試作 (ECO and Pilot run) 7. 生產進度超 前或落後 (Build ahead or backlog) 8. 新產品加入與舊產品結束 (New product phase in and End of Life product phase out) 9. 人員差勤異常 10. 瓶頸站漂移 (Bottleneck shift). 然而在執行重 排程時又會面臨到重排程的時機及頻率、是否執行重排程評估之標準、所 涵蓋時程長度、 排程計劃修正的方法、應變方案之擬訂以及控制架構和 程序之設計等決策問題. 本研究問題主要在探討以重排程因素為導向的 啟發式重排程之方法, 並應用於電子廠流程線. 針對不同的變動因素, 單 項抑或多項同時發生, 而必須重排時, 可先將重排程因素變動處理狀況予 以歸類, 再考慮限制條件之設定, 選擇適當的應變方案、排程方法與演算 法則, 配合人性化電腦排程系統(Human Oriented Scheduling System ;HOSS) 與現場監控系統 (Shop Floor Control System; SFC), 以發展一套有效可行能反應實際狀況的動態及時生產重排程系統. Currently most of factories are under stochastic and uncertain manufacturing environment, which often affected by the following factors or alternatives induce to we have to reschedule the whole schedule: 1. Material shortage 2. Rush order insert 3. Machine shutdown 4. Order changes 5. Quality issue 6. ECO and Pilot run 7. Build ahead or backlog 8. New product phase in and End of Life product phase out 9. Operator leave abnormal 10. Bottleneck shift. When to perform the reschedule also will ecounter the timing & frequency of rescheduling、the length of cover horizon、the method of updatingschedule and to set the reactive alternatives...etc problems. In this research, we propose a heuristic rescheduling algorithm which oriented by reschedulingfactors, it can be applied to Electronic flow line. Focus on single or multiple factors occur simultaneously, when rescheduling is required. These rescheduling factors can be classified, and then to consider the constraints, try to combine HOSS (Human Oriented Scheduling System) and SFC (Shop Floor Control System) to develop a real-time and dynamic rescheduling system, which can to reflect manufacturing reality effeciently.