基于改进遗传算法的硫化加工柔性车间生产调度研究

Research on Production Scheduling of Flexible Workshop for Vulcanization Processing Based on Improved Genetic Algorithm

摘要: 随着多品种小批量生产模式在橡胶加工行业的广泛应用，换模作业成为影响生产效率和成本的关键因素，同时订单延误和能源消耗也对企业绿色发展提出新挑战。针对硫化加工柔性车间调度问题，本文构建了包含订单延期成本、换模成本及碳排放成本的多目标优化数学模型，并设计了基于双层编码和贪婪插入式解码的改进遗传算法求解方法。该算法采用工序加工顺序与机器指派的双层编码结构，引入“最早可用设备优先”解码策略，通过快速非支配排序与精英保留策略保持解的多样性与优质性，结合针对换模点的邻域搜索策略提高算法收敛效率。算例研究表明，所提方法能够在迭代200代后使总成本和能耗分别降低约96%和91%，调度方案兼顾了订单按时交付、设备负载均衡、换模次数最小化及生产连续性等目标。敏感性分析显示，成本参数的设置对调度结果有显著影响，为企业根据战略重点灵活调整决策提供了依据。研究结果为橡胶加工企业在“双碳”背景下实现经济效益与绿色发展的协同提升提供了理论支撑和决策参考。

Abstract: With the widespread application of small-batch, multi-variety production in the rubber processing industry, die changing operations have become a key factor affecting production efficiency and cost, while order delays and energy consumption also pose new challenges to enterprises’ green development. Addressing the vulcanization flexible job-shop scheduling problem, this paper constructs a multi-objective optimization mathematical model incorporating order delay cost, die changing cost, and carbon emission cost, and designs an improved genetic algorithm based on dual-layer encoding and greedy insertion decoding. The algorithm employs a dual-layer encoding structure of operation sequence and machine assignment, introduces an “earliest available equipment priority” decoding strategy, maintains solution diversity and quality through fast non-dominated sorting and elite preservation strategies, and improves convergence efficiency through neighborhood search targeting die change points. Case studies demonstrate that the proposed method can reduce total cost and energy consumption by approximately 96% and 91% respectively after 200 iterations, with scheduling solutions balancing on-time order delivery, equipment load balance, minimization of die changes, and production continuity. Sensitivity analysis shows that cost parameter settings significantly impact scheduling results, providing a basis for enterprises to flexibly adjust decisions according to strategic priorities. The research results provide theoretical support and decision-making reference for rubber processing enterprises to achieve synergistic improvement of economic benefits and green development under the “dual carbon” background.