大规模定制家具OPF生产锯图排序优化  

Optimization of cutting diagrams sorting in mass customization furniture OPF production

作　　者：欧阳周洲 吴义强[1,2,3] 陶涛[1,2,3] 戴向东 陈星艳[1,2,3] 蔡丰[4] 王迅 OUYANG Zhouzhou;WU Yiqiang;TAO Tao;DAI Xiangdong;CHEN Xingyan;CAI Feng;WANG Xun(School of Materials Science&Engineering,Central South University of Forestry&Technology,Changsha 410004,Hunan,China;National and Local Joint Engineering Research Center for Green Processing Technology of Agricultural and Forestry Biomass,Central South University of Forestry&Technology,Changsha 410004,Hunan,China;Efficient Utilization of Wood and Bamboo Resources-Provincial and Ministerial Co Construction of Collaborative Innovation Centers,Central South University of Forestry&Technology,Changsha 410004,Hunan,China;Oppein Home Group INC.,Guangzhou 510475,Guangdong,China;Smart Home Design Center,Lushan Innovation Lab,Changsha 410004,Hunan,China)

机构地区：[1]中南林业科技大学材料科学与工程学院,湖南长沙410004 [2]中南林业科技大学农林生物质绿色加工技术国家地方联合工程研究中心,湖南长沙410004 [3]中南林业科技大学木竹资源高效利用省部共建协同创新中心,湖南长沙410004 [4]欧派家居集团股份有限公司,广东广州510475 [5]麓山实验室智能家居设计中心,湖南长沙410004

出　　处：《中南林业科技大学学报》2024年第3期149-158,共10页Journal of Central South University of Forestry & Technology

基　　金：国家重点研发计划项目(2023YFD2201500);中国工程院战略研究与咨询项目(2023-XY-32);麓山实验室研究计划项目(Z202333452565);湖南省财政科研专项(2050205)。

摘　　要：【目的】大规模定制是家具制造业转型升级的重要模式,高度自动化的OPF生产是其智能制造的主要发展方向之一。揉单生产是定制家具提升板材利用率从而缩减生产成本的重要手段,在OPF生产中对分拣工序提出了较高的要求。本研究着眼于大规模定制家具OPF生产中揉单与分拣的矛盾,通过锯图排序优化实现分拣来料的有序,进而使订单齐套进程更为平顺,缩减分拣仓峰值库存,达到缓解分拣压力、压缩分拣仓库容和扩大揉单规模的目的,推动实现大规模定制家具OPF生产的稳定。【方法】通过在定制家具生产一线展开长期研究,从OPF生产下的制造基本逻辑着手,探索基于现有设备条件在不引起板材利用率损失的前提下实施优化,提出以各订单板件在批次加工中的离散程度最小化为目标开展锯图排序优化,形成相关基础数据的采集与处理方法,构建锯图排序优化问题数学模型,运用遗传算法实现问题的求解并从订单板件离散程度、订单齐套进程以及分拣仓峰值库存3个维度进行优化效果评价,实现了大规模定制家具OPF生产锯图排序优化问题的求解。【结果】从欧派家居集团柜身生产线采集基础数据并进行处理,通过小规模测试验证可行性,并通过大规模测试测定总体效果。3个批次的小规模测试表明本研究提出的锯图排序优化方法具有可行性,各批次中订单板件的离散程度不同程度的缩小,批次订单齐套进程相比优化前更为平滑,分拣仓峰值库存相比优化前明显降低。3个工作日共51个批次的大规模测试各批次平均分散度缩减21.73%;首单及批次1/4订单齐套所需锯图数量降低37.27%与19.86%;分拣仓峰值库存平均降低105.25张板件,降低15.17%,表明锯图排序优化具有普遍适用性。【结论】通过锯图排序优化,可以在OPF生产的现有设备条件和板材利用率不变的前提下,以降低订单�【Objective】Mass customization is an important mode of transformation and upgrading of furniture manufacturing industry,and highly automated OPF production is one of the main development directions of its intelligent manufacturing.Mixing production is an important means for custom furniture to improve board utilization and reduce production costs,but in OPF production,there are high requirements for the sorting process.This paper focuses on the contradiction between mixing and sorting in the OPF production of mass customization furniture.By optimizing the cutting diagrams sorting,the sorting of incoming materials is achieved in an orderly manner,which makes the order completion process smoother,reduces the peak inventory of sorting warehouses,alleviates sorting pressure,compresses sorting warehouse capacity,and expands mixing scale,promoting the stability of mass customization furniture OPF production.【Method】By conducting long-term research on the production line of leading domestic custom furniture enterprises and analyzing the cabinet production line as a typical case,starting from the basic manufacturing logic under OPF production,exploring the implementation of optimization based on existing equipment conditions without causing loss of board utilization rate,this paper carries out cutting diagrams sorting optimization with the goal of minimizing the dispersion degree of each order’s parts in batch processing,forms a collection and processing method for relevant basic data,constructs a mathematical model for the optimization problem of cutting diagrams sorting,uses GA to solve the problem,and evaluates the optimization effect from three dimensions:order’s parts dispersion,order completion process,and sorting warehouse peak inventory.It achieves the solution of the optimization problem of cutting diagram sorting in mass customization furniture OPF production.【Result】This paper collects basic data from the cabinet production line of Oppein Group and processes it.The feasibility was verified throu

关 键 词：大规模定制家具 锯图排序 OPF 遗传算法 家具制造 智能制造 

分 类 号：S785[农业科学—林学] TS68[轻工技术与工程]