High-mix manufacturing systems require production plans that are both profitable and refinable into executable machine-level schedules under heterogeneous resources, mold-dependent compatibility, setup losses,delivery windows, and accessory synchronization. We study this problem as a production-envelope refinement task. A rolling-horizon mixed-integer linear programming (MILP) planner generates a valid production envelope that fixes daily production, fulfillment, mold states, inventory flows, outsourcing, and unmet-demand variables. A structure-aware constructive scheduler then refines this envelope into concrete order-machine allocations while preserving capacity feasibility, product-mold-machine compatibility, and delivery-window compliance. The scheduler enforces a one-mold-per-machine-per-day stability rule to avoid intra-day mold fragmentation. We establish residual invariants and prove a soundness theorem: whenever refinement terminates with zero residual fulfillment, the returned allocation is executable with respect to the valid envelope. The framework is implemented as an Advanced Planning and Scheduling (APS) prototype and evaluated on a real industrial case from a Jiangsu smartphone-case manufacturer in China with 37 product types, 150 orders, and over 8.3 million requested units. The proposed stable refinement achieves 100% on-time delivery, eliminates outsourcing, and bounds changeover-driven capacity loss to 1.9-4.6%. Across nine demand and changeover perturbation scenarios, it maintains robust delivery performance, showing that sound envelope refinement is a practical mechanism for reliable manufacturing scheduling.
翻译:高混合制造系统需要兼具盈利性与可精化性,能够将生产计划转化为可执行机器级调度,同时需考虑异构资源、模具依赖性兼容性、准备损耗、交付窗口及配件同步问题。我们将此问题建模为生产包络精化任务:基于滚动时域混合整数线性规划(MILP)的规划器生成有效生产包络,固定日产量、履约量、模具状态、库存流动、外协及未满足需求变量;随后,结构感知的构造式调度器将此包络精化为具体的订单-机器分配方案,同时维持产能可行性、产品-模具-机器兼容性及交付窗口合规性。调度器强制执行"每台机器每日单模具"稳定规则,避免日内模具碎片化。我们建立残差不变量并证明可靠性定理:当精化过程终止且残差履约量为零时,返回的分配方案相对于有效包络具有可执行性。该框架以高级计划与调度(APS)原型系统实现,并基于中国江苏某手机壳制造商的真实工业案例(含37种产品类型、150个订单及超过830万件需求)进行验证。所提出的稳定精化方法实现了100%准时交付、消除外协需求,并将换模引发的产能损失限制在1.9-4.6%范围内。在九种需求与换模扰动场景下,该方法保持稳健的交货性能,表明可靠包络精化是可靠制造调度的实用机制。