A simulation method and system for maintenance projects of four discrete logic factors based on FLEXSIM

Abstract

The present invention discloses a simulation method and system for maintenance projects of four discrete logic factors based on FLEXSIM, including the following steps: establishing a FLEXSIM simulation model for the maintenance project, and determining the processes and the number of devices corresponding to the four discrete logic factors; generating a status Gantt chart of the blockage ratio and output ratio of the four discrete logic factors, and taking the discrete logic factor with the highest blockage ratio as the factor to be adjusted; adjusting the input sequence priority of the first input device of the factor to be adjusted to the highest; continuously optimizing the simulation until the output ratio meets the process requirements; determining the final output ratio. The four discrete logic factors include: equipment factor, process factor, sudden factor, and process factor. Through the simulation of the four discrete logic factors based on FLEXSIM, the present invention establishes a simulation method and system for small maintenance projects with a large variety of products and many discrete events, greatly improving the maintenance efficiency and optimizing the production line.

Description

Technical Field

[0001] The present invention relates to the technical field of production line simulation optimization, and particularly to a simulation method and system for maintenance projects of four discrete logic factors based on FLEXSIM. Background Art

[0002] Due to the complex production line involved in the processing mode of multiple varieties and small batches, and the need for irregular adjustments according to the production line, the current adjustment methods are mostly simple empirical adjustments or adjustments made after analysis and calculation using mathematical models. The adjustment variables of the production line are mostly dynamic factors such as equipment, time, logic, and processes, belonging to a discrete system. The analysis and calculation using mathematical models are too cumbersome and it is not easy to accurately analyze discrete events. Therefore, a more efficient FLEXSIM system simulation software is adopted. According to the actual needs of the production line manufacturer, a discrete event virtual production line is established. Under the condition of the input raw material mode and unchanged time, the total quantity of the output products is used as an evaluation index. Through the FLEXSIM system simulation software, a virtual production line is established for modeling and simulation optimization, and a reasonable utilization and allocation of the production line are made under the condition that the existing equipment, raw material input mode, etc. remain unchanged. However, the existing simulation technologies consider single factors and are limited to FLEXSIM simulation analysis for factors such as processes, equipment, and products. Most of them optimize the mature production lines and do not effectively integrate and analyze the comprehensive factors affecting the output ratio, resulting in poor optimization effects. Summary of the Invention

[0003] The present invention provides a simulation method and system for maintenance projects of four discrete logic factors based on FLEXSIM to overcome the problem of poor optimization effects of the existing simulation technologies for maintenance projects with small varieties, many batches, and many discrete events.

[0004] To achieve the above object, the technical solution of the present invention is as follows:

[0005] A simulation method for maintenance projects of four discrete logic factors based on FLEXSIM includes the following steps:

[0006] S1. Establish a FLEXSIM simulation model for the maintenance project, determine the four discrete logic factors and the corresponding processes, and determine the number of devices corresponding to the processes;

[0007] S2. Generate a state Gantt chart of the blockage ratio and output ratio of the four discrete logic factors, and use the discrete logic factor with the highest blockage ratio as the factor to be adjusted;

[0008] S3. Determine the first input device of the first process of the factor to be adjusted, determine the other upper-level input devices of the first input device, and adjust the input order of the factor to be adjusted to before the other upper-level input devices as the highest priority;

[0009] S4. Re - simulate the FLEXSIM simulation model of the adjusted maintenance project after optimization;

[0010] S5. Determine whether the output ratio in the optimized FLEXSIM simulation model of the maintenance project meets the process requirements. If it meets, go to step S6; if not, go to step S7;

[0011] S6. Obtain the final simulation conclusion, determine the final output ratio, and calculate the output quantity improvement rate;

[0012] S7. Re - optimize the discrete logic factor with the minimum output ratio in the optimized FLEXSIM simulation model of the maintenance project and re - simulate, then go to step S8;

[0013] S8. Determine whether the output ratio meets the process requirements. If it meets, go to step S6; if not, repeat step S7.

[0014] Furthermore, the four major discrete logic factors in step S1 include: equipment factors, process factors, emergency factors, and process flow factors.

[0015] Furthermore, step S4 includes the following steps:

[0016] S41. Take the discrete logic factor with the minimum output ratio in the adjusted FLEXSIM simulation model of the maintenance project as the factor to be optimized;

[0017] S42. Determine the first input device of the first process of the factor to be optimized, determine the other upper - level input devices of the first input device, and adjust the input order of the factor to be optimized to before the other upper - level input devices as the highest priority;

[0018] S43. Re - simulate and calculate the output ratio.

[0019] Furthermore, a simulation system for maintenance projects of four major discrete logic factors based on FLEXSIM includes:

[0020] Discrete logic factor module; the discrete logic factor module is the output end of the four major discrete logic factors, and the four major discrete logic factors include equipment factors, process factors, emergency factors, and logic factors;

[0021] Equipment processing module; the equipment processing module is the processing hardware device end, including multiple processes, and each process includes multiple devices. The input end of the equipment processing module is connected to the output end of the discrete logic factor module, and is used to process products sequentially according to the input logic and automatically count the processing time;

[0022] Optimization simulation module; the output end of the optimization simulation module is connected to the input end of the equipment processing module, and is used to adjust and optimize the input logic received by the equipment processing module;

[0023] Finished product storage module; the finished product storage module is a finished product storage area, connected to the output end of the equipment processing module, and is used to store and count the product output ratio and quantity.

[0024] Further, the number of finished product storage areas corresponding to the finished product storage module is the same as that of the discrete logic factors, both being four; a mesh link structure exists between the discrete logic factor module, the equipment processing module, and the finished product storage module

[0025] Beneficial effects: Through the simulation of the four major discrete logic factors of FLEXSIM, the present invention establishes a simulation method and system for small maintenance projects with a large variety and a large number of batch discrete events, greatly improving the maintenance efficiency and the optimization effect of the production line. Description of the Drawings

[0026] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or in the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the following drawings are some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0027] Figure 1 It is a flowchart of the maintenance project simulation method of the present invention;

[0028] Figure 2 It is a blockage ratio diagram of the four major discrete logic factors before applying the method of the present invention;

[0029] Figure 3 It is a processing rate ratio diagram of each device before applying the method of the present invention;

[0030] Figure 4 It is a blockage ratio diagram of the four major discrete logic factors after applying the method of the present invention;

[0031] Figure 5 It is a processing rate ratio diagram of each device after applying the method of the present invention;

[0032] Figure 6 It is a structure diagram of the maintenance project simulation system of the present invention. Detailed Embodiments

[0033] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, rather than all of them. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts belong to the scope of protection of the present invention.

[0034] Embodiment 1

[0035] This embodiment provides a simulation method for overhaul projects of four discrete logical factors based on FLEXSIM, as Figure 1 shown, including the following steps:

[0036] S1. Establish an FLEXSIM simulation model for the overhaul project, determine the four discrete logical factors and the corresponding processes, and determine the number of devices corresponding to the processes;

[0037] S2. Generate a status Gantt chart of the blockage ratio and output ratio of the four discrete logical factors, and use the discrete logical factor with the highest blockage ratio as the factor to be adjusted;

[0038] S3. Determine the first input device of the first process of the factor to be adjusted, determine the other superior input devices of the first input device, and adjust the input order of the factor to be adjusted to be before the other superior input devices as the highest priority;

[0039] S4. Optimize the adjusted FLEXSIM simulation model for the overhaul project and then resimulate;

[0040] S5. Judge whether the output ratio in the optimized FLEXSIM simulation model for the overhaul project meets the process requirements. If it meets, go to step S6; if it does not meet, go to step S7;

[0041] S6. Obtain the final simulation conclusion, determine the final output ratio, and calculate the output quantity improvement rate;

[0042] S7. Re-optimize the discrete logical factor with the smallest output ratio in the optimized FLEXSIM simulation model for the overhaul project and resimulate, and go to step S8;

[0043] S8. Judge whether the output ratio meets the process requirements. If it meets, go to step S6; if it does not meet, repeat step S7.

[0044] The four discrete logical factors in step S1 include: equipment factor, process factor, sudden factor, and process factor.

[0045] Step S4 includes the following steps:

[0046] S41. Take the discrete logic factor with the minimum output ratio in the adjusted maintenance item FLEXSIM simulation model as the factor to be optimized;

[0047] S42. Determine the first input device of the first process of the factor to be optimized, determine the other superior input devices of the first input device, and adjust the input order of the factor to be optimized to before the other superior input devices as the highest priority;

[0048] S43. Resimulate and calculate the output ratio.

[0049] Specifically, corresponding to step S1, take the power module maintenance line of a certain company as an example for modeling. This company repairs 19 power module products every 1000 minutes. Each power module product is affected by four discrete logic factors: equipment factor, power factor, sudden factor, and process factor. The inputs of the four discrete logic factors of equipment factor, power factor, sudden factor, and process factor are in a fixed exponential distribution mode. Table 1 shows the system data table of the four discrete logic factors. Taking the equipment factor as an example, it needs to go through four processes: 1, 3, 4, and 5. The processing time of process 1 is 10 minutes, and the processing times of other processes are 5 minutes, 16 minutes, and 30 minutes respectively; Table 2 shows the relationship table between equipment and processes. There are two devices, device 11 and device 12, on process 1, one device, device 21, on process 2, one device, device 31, on process 3, three devices, device 31, device 32, and device 33, on process 4, and one device, the power module finished product area, on process 5. This company hopes to increase the output quantity of power module products, balance the input of the four discrete logic factors, and appropriately reduce the processing rate of the equipment to improve the overall output ratio of the maintenance line under the condition that the logistics mode and the number of devices for the input of the special four discrete logic factors remain unchanged.

[0050] Specifically, corresponding to step S2, according to the input of the four discrete logic factors, generate a status Gantt chart, and at the same time introduce the processing rate of the equipment in the model, as Figure 2 shown are the charts of the processing rate ratios of device 11, device 12, device 21, device 31, device 41, device 42, and device 43 respectively. In addition, there are also the blockage rate and the idle rate; Subsequently, add a dashboard in the FLEXSIM model and call the status Gantt chart, take the equipment factor, process factor, sudden factor, and process factor as four raw materials and as the tracking targets of the Gantt chart to output the blockage ratio and the output ratio, as Figure 3 shown. It can be seen that the blockage ratio of the sudden factor is the highest at 55%, so the sudden factor is taken as the factor to be adjusted for the first optimization.

[0051] Specifically, corresponding to step S3, determine the factor to be adjusted, that is, the first input device of the first process of the sudden factor. According to Table 1, the first process of the sudden factor is Process 2, and the first input device corresponding to Process 2 is Device 21. Moreover, Process 1 in the process factor also outputs to Process 2, so the other upper-level devices of Process 2 also include Device 11 and Device 12. At this time, adjust the priority of the sudden factor before Device 11 and Device 12 to make the input priority of the sudden factor the highest level, and the first optimization of this model can be completed.

[0052] Specifically, corresponding to S41 to S43 in step S4, after adjusting the priority of the sudden factor to the highest level at the input end of Device 21, it is found through simulation that the output volume of the process factor is small and does not meet the process requirements of the company. Therefore, the model needs to be further optimized. The optimization principle is similar to step S3. The first device corresponding to the first process of the raw material of the process factor is Device 31, and Process 1 in the device factor also outputs to Process 3, so the other upper-level devices of Process 3 also include Device 11 and Device 12; at the same time, Process 2 in the sudden factor also outputs to Process 3, so the other upper-level devices of Process 3 also include Device 21. Therefore, all the upper-level inputs of Process 3 include the process factor, Device 11, Device 12, and Device 21. Adjust the priority of the process factor before Device 11, Device 12, and Device 21 to make the priority of the process factor the highest level, and the further optimization of this model can be completed.

[0053] Specifically, corresponding to steps S5 to S8, judge whether the output ratio in the optimized maintenance item FLEXSIM simulation model meets the process requirements. If it meets, the simulation conclusion can be directly obtained, and the output quantity increase rate can be calculated to verify the practicability of this model; if it does not meet, this method can be used to iteratively optimize this model until the simulated output ratio meets the process requirements. Finally, the final simulation conclusion is obtained, and the final output ratio and quantity increase rate are calculated.

[0054] Specifically, calculate the quantity in the finished product area after each optimization respectively, and judge whether it meets the process requirements expected by the company. After the first optimization, the quantity in the power module finished product area increased from 19 to 23. After the second optimization, the quantity in the power module finished product area increased from 23 to 26, with a total increase of 36.84%, which can prove that the optimization effect of this model is significant. Finally, the optimized model can be verified through the state Gantt chart and the processing rate ratio chart. As Figure 5 shown, after optimization, the blockage ratio of the sudden factor is 20.9%, which is close to the blockage ratios of the device factor, process factor, and process factor. The blockage ratios of the four raw materials reach balance, ensuring the operation efficiency of the model and the output quantity of the power module in the finished product area; as Figure 4 shown, take Figure 4 andFigure 2 Upon comparison, the processing rates of Devices 21 and 31 have increased, while the processing rates of the other five devices have decreased, resulting in a decline in the overall processing rate. However, the finished product output rate of the overall process has increased significantly.

[0055]

[0056]

[0057] Table 1

[0058] Process Number of equipment Equipment code 1 2 Equipment 11, Equipment 12 2 1 Equipment 21 3 1 Equipment 31 4 3 Equipment 41, 42, 43 5 1 Equipment 51

[0059] Table 2

[0060] Example 2

[0061] This example provides a simulation system for the overhaul project of four major discrete logic factors based on FLEXSIM, including:

[0062] A discrete logic factor module; the discrete logic factor module is the output end of the four major discrete logic factors, and the four major discrete logic factors include equipment factors, process factors, sudden factors, and logic factors;

[0063] An equipment processing module; the equipment processing module is the processing hardware device end, including multiple processes, and each process includes multiple devices. The input end of the equipment processing module is connected to the output end of the discrete logic factor module, and is used to sequentially process products according to the input logic and automatically count the processing time;

[0064] An optimization simulation module; the output end of the optimization simulation module is connected to the input end of the equipment processing module, and is used to adjust and optimize the input logic received by the equipment processing module;

[0065] Specifically, the optimization simulation module includes a primary adjustment module, a secondary optimization module, and a repeated optimization module. Among them, the primary adjustment module corresponds to steps S2 and S3 in the method for simulating the maintenance items of the four major discrete logic factors based on FLEXSIM of the present invention, that is, taking the discrete logic factor with the highest blockage ratio as the factor to be adjusted, determining the first input device of the first process of the factor to be adjusted, determining other superior input devices of the first input device, and adjusting the input order of the factor to be adjusted to before other superior input devices as the highest priority. The secondary optimization module corresponds to step S4 in the method for simulating the maintenance items of the four major discrete logic factors based on FLEXSIM of the present invention, that is, steps S41 to S43, taking the discrete logic factor with the smallest output ratio in the adjusted FLEXSIM simulation model of the maintenance items as the factor to be optimized, determining the first input device of the first process of the factor to be optimized, determining other superior input devices of the first input device, and adjusting the input order of the factor to be optimized to before other superior input devices as the highest priority, re-simulating and calculating the output ratio. The repeated optimization module corresponds to steps S5 to S8 in the method for simulating the maintenance items of the four major discrete logic factors based on FLEXSIM of the present invention, performing iterative optimization on this model until the output ratio simulated meets the process requirements, finally obtaining the final simulation conclusion, and calculating the final output ratio and the quantity increase rate.

[0066] Finished product storage module; the finished product storage module is a finished product storage area, connected to the output end of the equipment processing module, and is used for storing and counting the product output ratio and quantity.

[0067] The number of the finished product storage areas corresponding to the finished product storage module is the same as that of the discrete logic factors, both being four; a mesh link structure exists among the discrete logic factor module, the equipment processing module, and the finished product storage module.

[0068] Specifically, such as Figure 6As shown, first, the discrete logic factor module serves as an analog output end, including the logical outputs of device factors, process factors, sudden factors, and process flow factors, and enters the device processing module as influencing factors to facilitate the subsequent analysis of the impacts of these four discrete logic factors; in addition to receiving the four discrete logic factors from the discrete logic factor module, the device processing module also has the input impacts of the corresponding devices in each process, arranging the four discrete logic factors, corresponding processes, and corresponding devices in a logical order to ensure the successful processing of products and the output of finished products; the optimization simulation module can adjust the input order of the four discrete logic factors according to different process requirements, generate new input logics, and feedback them to the device processing module. The device processing module can reorder the original logic according to the new input logics, but still perform logical optimization on the basis of ensuring the successful processing of finished products. The finally produced finished products will be transported to the finished product storage module. The finished product storage module is an area for storing finished products, connected to the output end of the device processing module, and is used to store and count the production ratio and quantity of products to facilitate the subsequent judgment and analysis of the actual effects of this optimization.

[0069] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements on some or all of the technical features; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A simulation method for the maintenance project of four discrete logic factors based on FLEXSIM, characterized in that, It includes the following steps: S1. Establish a FLEXSIM simulation model for maintenance projects, determine the four major discrete logic factors and the corresponding processes, and determine the number of devices corresponding to the processes; The four major discrete logic factors include device factors, process factors, sudden factors, and process flow factors; S2. Generate a status Gantt chart of the blockage ratio and output ratio of the four major discrete logic factors, and take the discrete logic factor with the highest blockage ratio as the factor to be adjusted; S3. Determine the first input device of the first process of the factor to be adjusted, determine the other upper-level input devices of the first input device, and adjust the input order of the factor to be adjusted to before the other upper-level input devices as the highest priority; S4. Optimize the adjusted FLEXSIM simulation model for maintenance projects and then re-simulate; S5. Judge whether the output ratio in the optimized FLEXSIM simulation model for maintenance projects meets the process requirements. If it meets, go to step S6; if it does not meet, go to step S7; S6. Obtain the final simulation conclusion, determine the final output ratio, and calculate the output quantity increase rate; S7. Re-optimize the discrete logic factor with the smallest output ratio in the optimized FLEXSIM simulation model for maintenance projects and re-simulate, and go to step S8; S8. Judge whether the output ratio meets the process requirements. If it meets, go to step S6; if it does not meet, repeat step S7.

2. The simulation method for the overhaul project of the four major discrete logic factors based on FLEXSIM according to claim 1, characterized in that The four major discrete logic factors in step S1 include: device factors, process factors, sudden factors, and process flow factors.

3. A simulation method for the overhaul project of four discrete logic factors based on FLEXSIM according to claim 1, characterized in that, The optimization in step S4 includes the following steps: S41. Take the discrete logic factor with the smallest output ratio in the adjusted FLEXSIM simulation model for maintenance projects as the factor to be optimized; S42. Determine the first input device of the first process of the factor to be optimized, determine the other upper-level input devices of the first input device, and adjust the input order of the factor to be optimized to before the other upper-level input devices as the highest priority; S43. Re-simulate and calculate the output ratio.

4. A simulation system for the maintenance project of the four discrete logic factors based on FLEXSIM, which is based on the simulation method for the maintenance project of the four discrete logic factors based on FLEXSIM according to any one of claims 1 to 3, characterized in that, It includes: Discrete logic factor module; The discrete logic factor module is the output end of the four major discrete logic factors. The four major discrete logic factors include device factors, process factors, sudden factors, and process flow factors; Device processing module; The device processing module is the processing hardware device end, including multiple processes, and each process includes multiple devices. The input end of the device processing module is connected to the output end of the discrete logic factor module, and is used to sequentially process products according to the input logic and automatically count the processing time; Optimization simulation module; The output end of the optimization simulation module is connected to the input end of the device processing module, and is used to adjust and optimize the input logic received by the device processing module; Finished product storage module; The finished product storage module is the finished product storage area, which is connected to the output end of the device processing module, and is used to store and count the product output ratio and quantity.

5. The simulation system for the overhaul project of the four major discrete logic factors based on FLEXSIM according to claim 4, characterized in that, The number of the finished product storage areas corresponding to the finished product storage module is the same as that of the discrete logic factors, both are four; The discrete logic factor module, the device processing module, and the finished product storage module are all in a mesh link structure.

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