243 lines
13 KiB
Python
243 lines
13 KiB
Python
"""康尼芜湖柔性排产 · 全流程模拟（in-process，不依赖服务端）。
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跑通 demand/ 方案的完整链路并打印可读结果：
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0 主数据与能力池概览
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1 初始排产（瓶颈锚）→ 虚拟产线组装 + 甘特文本
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2 瓶颈产能法评估（替代台账法）
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3 三种排产模式对比（正排/倒排/瓶颈锚）
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4 交期承诺模拟（询单 → 乐观/预计完工）
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5 动态调度A：紧急插单（VIP 高优先小批量）
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6 动态调度B：设备故障（压接机停机 → 产能池收缩 → 重排）
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运行： .venv\\Scripts\\python.exe scripts\\flex_simulation.py
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"""
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from __future__ import annotations
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import os
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import sys
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# 让脚本从仓库根可直接运行（把仓库根加入模块搜索路径）
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sys.path.insert(0, os.path.dirname(os.path.dirname(os.path.abspath(__file__))))
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# Windows 控制台 UTF-8（中文输出）
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try:
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sys.stdout.reconfigure(encoding="utf-8", errors="replace")
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except Exception:
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pass
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from server.aps_domain.flex import capability_pools, capacity_analysis # 领域能力
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from server.engines import PoolEngine # 柔性引擎
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from server.state.seed import seed_world # 种子（含 flex*）
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from server.timeutil import add_minutes, fmt_date, today0 # 日期工具
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# ---------------- 通用工具 ----------------
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def rule(title: str) -> None:
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"""分隔标题。"""
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print("\n" + "=" * 72)
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print(f" {title}")
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print("=" * 72)
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def sub(title: str) -> None:
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print(f"\n— {title} —")
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def counter():
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"""独立发号器（纯内存、确定性）。"""
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c: dict[str, int] = {}
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def nid(kind: str) -> int:
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c[kind] = c.get(kind, 0) + 1
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return c[kind]
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return nid
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def run_flex(world, sort_mode: str, start_date: str):
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"""在给定 world 上跑一次柔性排产（清空既有产物，隔离多次运行）。"""
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for k in ("flexScheduleVersions", "flexVirtualLines", "flexWorkOrders", "flexConflicts"):
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world[k] = []
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return PoolEngine().solve(world, counter(), sort_mode=sort_mode, start_date=start_date)
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def product_name(world, code: str) -> str:
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m = next((x for x in world["flexMaterials"] if x["code"] == code), None)
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return m["name"] if m else code
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def print_virtual_lines(world, limit_steps: bool = False) -> None:
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"""打印本版本每条虚拟产线的工序-设备-模具-时间。"""
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vls = world["flexVirtualLines"]
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wos = {(w["vlId"], w["seq"]): w for w in world["flexWorkOrders"]}
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for vl in vls:
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pname = product_name(world, vl["productCode"])
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print(f"\n ▶ {vl['vlNo']} {pname} × {vl['quantity']}套 "
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f"[{vl['plannedStart']} → {vl['plannedEnd']}] "
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f"WBS={vl.get('wbs')} 控制者={vl.get('productionController')}")
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for a in vl["assignments"]:
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w = wos.get((vl["id"], a["seq"]))
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flag = " ★瓶颈" if (w and w.get("isBottleneck")) else ""
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mold = f" 模具={a['moldCode']}" if a.get("moldCode") else ""
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extra = ""
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if w:
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extra = f"（换型{w['changeoverMin']:.0f}+移动{w['moveMin']:.0f}+加工{w['runMin']:.0f}min）"
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print(f" {a['seq']:>2} {a['operationCode']:<9} → {a['equipmentCode']:<9}"
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f"{mold:<18} {a['start']} → {a['end']} {extra}{flag}")
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def print_conflicts(world) -> None:
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cfs = world["flexConflicts"]
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if not cfs:
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print(" 冲突：无")
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return
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print(f" 冲突（{len(cfs)}）：")
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for c in cfs:
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print(f" · [{c['severity']}] {c['conflictType']} {c['description']}")
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# ============================================================
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# 主流程
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# ============================================================
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def main() -> None:
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world = seed_world()
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start = fmt_date(add_minutes(today0(), 24 * 60)) # 明天作为排产起点
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# ---------- 0 主数据与能力池概览 ----------
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rule("阶段 0 ｜ 主数据与产能池（设备虚拟化 + 产能池化）")
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print(f" 布局区域：{', '.join(z['code'] + '(' + z['name'] + ')' for z in world['flexZones'])}")
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sub("产能池（工序能力 → 设备集合；★=瓶颈工序）")
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for p in capability_pools(world):
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star = "★" if p["isBottleneck"] else " "
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eqs = ", ".join(f"{e['code']}{'(可移动)' if e['movable'] else ''}" for e in p["equipment"])
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print(f" {star} {p['operationCode']:<9} {p['operationName']:<6} 设备{p['equipmentCount']}台"
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f"（可移动{p['movableCount']}） : {eqs}")
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sub("模具（工装适配 + 寿命）")
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for m in world["flexMolds"]:
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life = f"{m['lifeUsed']}/{m['lifeTotal']}"
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print(f" {m['code']:<12} {m['name']:<10} 工序{m['operationCode']:<9} "
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f"适配{','.join(m['adaptableEquipment'])} 寿命{life} 换型{m['changeoverMin']}min")
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sub("待排订单")
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for o in world["flexOrders"]:
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print(f" {o['orderNo']:<8} {product_name(world, o['productCode']):<8} ×{o['quantity']:<4} "
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f"交期{o['dueDate']} 优先级{o['priority']} 状态{o['status']} WBS={o['wbs']}")
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# ---------- 1 初始排产（瓶颈锚） ----------
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rule("阶段 1 ｜ 初始排产：瓶颈锚模式 → 动态组装虚拟产线")
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r = run_flex(world, "BOTTLENECK", start)
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print(f" 版本 {r['versionNo']}｜模式 {r['sortMode']}｜虚拟产线 {r['vlCount']} 条｜"
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f"工单 {r['woCount']} 个｜设备平均利用率 {r['avgUtilization']*100:.1f}%｜"
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f"总延迟 {r['totalTardiness']:.1f}h")
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print(f" 识别瓶颈工序：" + "，".join(
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f"{b['operationName']}({b['operationCode']}, 池内{b['poolEquipmentCount']}台)" for b in r["bottleneck"]))
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print_virtual_lines(world)
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print()
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print_conflicts(world)
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# ---------- 2 瓶颈产能法 ----------
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rule("阶段 2 ｜ 产能评估：瓶颈产能法（替代台账法）")
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cap = capacity_analysis(world)
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print(f" {'工序池':<20}{'设备':>4}{'日可用(min)':>12}{'单件(min)':>10}{'日产能(件)':>10}{'本版工作量(折合日)':>16}")
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for p in cap["pools"]:
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star = "★" if p["isBottleneck"] else " "
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print(f" {star}{p['operationCode']+'/'+p['operationName']:<19}{p['equipmentCount']:>4}"
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f"{p['dailyMinutes']:>12}{p['stdTimePerUnit']:>10}{p['dailyCapacity']:>10}"
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f"{p['workDays']:>15.2f}天")
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bp = cap["bottleneckPool"]
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if bp:
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print(f"\n → 限制性瓶颈：{bp['operationName']}（{bp['operationCode']}），"
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f"全厂日产能上界≈{bp['dailyCapacity']}件/天。这一道最慢，产能由它决定。")
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print(f" → 对照台账法：压接池 4 台×480min÷1min＝1920件/天（虚高）；瓶颈法只认最慢的焊接池。")
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# ---------- 3 三模式对比（在压力场景下才能显出差异） ----------
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rule("阶段 3 ｜ 排产模式对比：正排 / 倒排 / 瓶颈锚（吸收《排产逻辑》PPT）")
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print(" 为显差异，统一压缩交期至 +3~+5 天制造产能压力：")
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modes = {"ASC": "正排(EDD 最早交期优先)", "DESC": "倒排(最晚交期优先)", "BOTTLENECK": "瓶颈锚(含瓶颈单优先)"}
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print(f" {'模式':<24}{'总延迟(h)':>10}{'准时单':>8}{'最晚完工':>18}{'利用率':>8}{'冲突':>6}")
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for mode, label in modes.items():
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w2 = seed_world()
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_compress_due(w2) # 压缩交期制造压力
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rr = run_flex(w2, mode, start)
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print(f" {label:<22}{rr['totalTardiness']:>10.1f}{rr['onTimeCount']:>6}/5"
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f"{(rr['makespan'] or '—'):>19}{rr['avgUtilization']*100:>7.1f}%{rr['conflictCount']:>6}")
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print(" 说明：交期宽松时三模式结果趋同；压力下正排保最早交期、倒排后置、瓶颈锚优先喂饱瓶颈。")
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# ---------- 4 交期承诺模拟 ----------
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rule("阶段 4 ｜ 交期承诺模拟：询单「PDU 500套 何时能交？」")
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# 复用 world（已含在制订单）做一次 in-process 模拟
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probe_qty = 500
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# 乐观：独占资源
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w_opt = seed_world()
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w_opt["flexOrders"] = [{"id": 99, "orderNo": "PROBE", "productCode": "PDU-UNIT", "quantity": probe_qty,
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"dueDate": "2999-12-31", "priority": 1, "wbs": None,
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"productionController": None, "status": "RELEASED"}]
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run_flex(w_opt, "BOTTLENECK", start)
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opt_vl = next((v for v in w_opt["flexVirtualLines"] if v["orderNo"] == "PROBE"), None)
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# 预计：插入现有订单集竞争资源
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w_exp = seed_world()
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w_exp["flexOrders"].append({"id": 99, "orderNo": "PROBE", "productCode": "PDU-UNIT", "quantity": probe_qty,
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"dueDate": "2999-12-31", "priority": 9, "wbs": None,
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"productionController": None, "status": "RELEASED"})
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run_flex(w_exp, "BOTTLENECK", start)
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exp_vl = next((v for v in w_exp["flexVirtualLines"] if v["orderNo"] == "PROBE"), None)
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print(f" 询单：PDU配电单元 × {probe_qty} 套")
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print(f" · 乐观（独占产能） ：最早 {opt_vl['plannedEnd'] if opt_vl else '—'} 完成")
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print(f" · 预计（与在制竞争）：预计 {exp_vl['plannedEnd'] if exp_vl else '—'} 完成")
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print(f" · 资源缺口提示：PDU 瓶颈为激光焊接（1台）；若要提前，需增焊接设备或外包焊接工序。")
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# ---------- 5 动态调度A：紧急插单 ----------
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rule("阶段 5 ｜ 动态调度A：紧急插单（VIP 高压线束 50套，交期紧）")
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w5 = seed_world()
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r5a = run_flex(w5, "BOTTLENECK", start) # 先有一版基线
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print(f" 插单前：{r5a['vlCount']} 条虚拟产线，最晚完工 {r5a['makespan']}，总延迟 {r5a['totalTardiness']:.1f}h")
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w5["flexOrders"].append({"id": 90, "orderNo": "RUSH-001", "productCode": "HV-HARNESS", "quantity": 50,
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"dueDate": fmt_date(add_minutes(today0(), 3 * 24 * 60)), "priority": 0,
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"wbs": "WBS-HV", "productionController": "李强", "status": "RELEASED"})
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r5 = run_flex(w5, "BOTTLENECK", start) # 冻结→重排（本切片=全量重排 L4）
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rush = next((v for v in w5["flexVirtualLines"] if v["orderNo"] == "RUSH-001"), None)
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print(f" 插单后：{r5['vlCount']} 条虚拟产线，最晚完工 {r5['makespan']}，"
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f"准时 {r5['onTimeCount']}/{r5['vlCount']}，总延迟 {r5['totalTardiness']:.1f}h")
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if rush:
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print(f" · 插单 RUSH-001 排入：{rush['plannedStart']} → {rush['plannedEnd']}（优先占用瓶颈压接池）")
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print_conflicts(w5)
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# ---------- 6 动态调度B：设备故障（两个对比子案例） ----------
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rule("阶段 6 ｜ 动态调度B：设备故障 → 产能池实时收缩 → 重排")
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sub("案例①：可移动压接机 PRESS-01 故障（压接池有冗余 → 影响小）")
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w6 = seed_world()
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_compress_due(w6) # 用压力场景才能看出延迟变化
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r6a = run_flex(w6, "BOTTLENECK", start)
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crimp_before = next(p for p in capacity_analysis(w6)["pools"] if p["operationCode"] == "OP-CRIMP")
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print(f" 故障前：压接池 {crimp_before['equipmentCount']} 台，日产能 {crimp_before['dailyCapacity']} 件，"
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f"总延迟 {r6a['totalTardiness']:.1f}h，准时 {r6a['onTimeCount']}/5")
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next(e for e in w6["flexEquipment"] if e["code"] == "PRESS-01")["status"] = "MAINTENANCE"
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r6b = run_flex(w6, "BOTTLENECK", start)
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crimp_after = next(p for p in capacity_analysis(w6)["pools"] if p["operationCode"] == "OP-CRIMP")
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print(f" 故障后：压接池 {crimp_after['equipmentCount']} 台，日产能 {crimp_after['dailyCapacity']} 件，"
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f"总延迟 {r6b['totalTardiness']:.1f}h，准时 {r6b['onTimeCount']}/5")
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print(f" · 池化韧性：自动剔除 PRESS-01 用剩余 {crimp_after['equipmentCount']} 台重排，"
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f"日产能降 {crimp_before['dailyCapacity']-crimp_after['dailyCapacity']} 件但仍有冗余，交期基本不受影响。")
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sub("案例②：单点瓶颈激光焊接机 WELD-01 故障（无备机 → PDU 停摆）")
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w6b = seed_world()
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run_flex(w6b, "BOTTLENECK", start)
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next(e for e in w6b["flexEquipment"] if e["code"] == "WELD-01")["status"] = "MAINTENANCE"
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r6c = run_flex(w6b, "BOTTLENECK", start)
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print(f" 故障后：虚拟产线 {r6c['vlCount']} 条（PDU 单无法组线），冲突 {r6c['conflictCount']}")
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print_conflicts(w6b)
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print(" · 单点瓶颈无冗余：系统立即暴露 NO_CAPABILITY，提示应备用焊接机 / 外包焊接工序 / 议定交期。")
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rule("模拟结束")
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print(" 全流程覆盖：设备虚拟化→产能池→虚拟产线排产→瓶颈产能评估→模式对比→交期承诺→动态重排。")
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print(" 数据口径见 docs/product/demand-data-intake.md；真实数据逐表替换 flex* 即可复跑。")
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def _compress_due(world) -> None:
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"""把订单交期压缩到 +3~+5 天，制造产能压力（用于模式对比/故障影响演示）。"""
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offs = [4, 3, 4, 5, 5]
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for o, off in zip(world["flexOrders"], offs):
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o["dueDate"] = fmt_date(add_minutes(today0(), off * 24 * 60))
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if __name__ == "__main__":
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main()
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