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題名：靈活製造環境下快速變換生產線最佳生產策略之研發與構建
作者：林添佑
校院名稱：國立中正大學
系所名稱：企業管理研究所
指導教授：陳明德
陳武林
學位類別：博士
出版日期：2003
主題關鍵詞：靈活製造；換線；排程；批量；數理規劃；班德氏解構法；麥可丹尼爾解構法；agile manufacturing；changeover；scheduling；lot sizing；mathematical programming；Benders decomposition；McDaniel decomposition
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在這一篇論文中，我們發展一個數理規劃的〝若─則〞模式來解決一條生產線在靈活製造環境下生產不同產品的排程問題；在這個模式下，需求被假設為確定性的動態情形且允許欠撥；而由產品別或順序別來決定的換線成本在模型中是重要而不可被忽略的。因此，我們的目標是找尋最適生產策略來最小化總製造成本，包括啟動成本、生產成本、設置成本、換線生產、生產水準變化成本、解雇成本、晉用成本、勞力成本、缺貨成本和存貨成本等相關成本。由於發展的數理規劃模型可以完全將換線成本和上述成本緊密結合，所以我們的數理規劃模型比現有文獻記載的模型更完整，而且可以提供決策者在靈活製造環境下來決定生產排程，批量提供勞力水準及缺、存貨等相關資訊。
包含〝二次式模型〞、〝時間跨距網路模型〞及〝縮減變數模型〞的三個修正數理規劃模型被我們依系統特性構建來嘗試改善計算的效率。而以班德氏和麥可丹尼爾解構法為基礎的兩個演算法同時也在論文中被發展來解決大型的問題。
除此之外，一個允許在大週期內可生產多種產品，但在小週期內僅能生產一種產品的一般化模型也被我們發展出來。此模型縮減了現場排程和傳統總體生產規劃的間隙，同時也提供了短期與中期規劃銜接的重要工具。
關鍵詞：靈活製造、換線、排程、批量、數理規劃、班德氏解構法、麥可丹尼爾解構法
In this dissertation, a mathematical programming formulation, named If-Then model, was proposed for scheduling a production line (or workstation) capable of producing a variety of different products in an agile manufacturing environment. Demand is assumed dynamic but deterministic and can be backordered. Changeover costs can be product-dependent or sequence-dependent and cannot be neglected. The objective is to find an optimal strategy that minimizes the total manufacturing costs and/or times including startup costs, production costs, setup costs, changeover costs, change-level costs, layoff and hiring costs, labor costs, back-order costs, and storage costs. The developed math-programming models are more comprehensive than the existing ones, since they fully captured each type of costs associated with changeovers as described above. The proposed optimal strategy provides decision-maker the essential information including production schedule, lot size, workforce level, and periodic inventory or back-order for each product.
Based on the system characteristics, three modified math-programming models including quadratic model, time-spanning network model and reduced-variable model were constructed to improve the computational efficiency. Two algorithms based on Benders and McDaniel decompositions were also developed to assist in solving the large-scale problems.
In addition, a generalized model, in which multiple products can be manufactured in a “macro-period” while only one product is allowed in a “micro-period,” was developed. It bridges the gaps between the shop floor scheduling and the traditional aggregate production planning, and is suited for both the short-term and medium-term planning horizon.
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