Disruption management in a constrained multi-product imperfect production system

Over several decades, production and inventory systems have been widely studied in different aspects, but only a few studies have considered the production disruption problem. In production systems, the production may be disrupted by priorly unknown disturbance and the entire manufacturing plan can be distorted. This research introduces a production-disruption model for a multi-product single-stage production-inventory system. First, a mathematical model for the multi-item production-inventory system is developed to maximize the total profit for a single-disruption recovery-time window. The main objective of the proposed model is to obtain the optimal manufacturing batch size for multi-item in the recovery time window so that the total profit is maximized. To maintain the matter of multi-product, budget and space constraints are used. A genetic algorithm and pattern search techniques are employed to solve this model and all randomly generated test results are compared. Some numerical examples and sensitivity analysis are given to explain the effectiveness and advantages of the proposed model. This proposed model offers a recovery plan for managers and decision-makers to make accurate and effective decisions in real time during the production disruption problems.     

An AHP based heuristic DPSO algorithm for generating multi criteria production–distribution plan

Multi-criteria integrated production–distribution problems were solved by many researchers using different optimization techniques. A novel analytic hierarchy process (AHP) based heuristic discrete particle swarm optimization (DPSO) algorithm is proposed in this research for solving difficult production–distribution problems. A bearing manufacturing industry's case is considered in this paper and the mathematical model is formulated as mixed integer linear programming (MILP) problem considering multi-period, multi-product and multi-plant scenarios. The three major objectives considered are total cost reduction, minimization of change in labor levels and percentage under-utilization. The results of the AHP based heuristic DPSO algorithm are compared with the branch and bound algorithm results generated using LINGO software. The approach gives good near optimal solutions. In addition to the bearing manufacturing industry dataset, two other test datasets are also solved.     

Churn management optimization with controllable marketing variables and associated management costs

In this paper, we propose a churn management model based on a partial least square (PLS) optimization method that explicitly considers the management costs of controllable marketing variables for a successful churn management program. A PLS prediction model is first calibrated to estimate the churn probabilities of customers. Then this PLS prediction model is transformed into a control model after relative management costs of controllable marketing variables are estimated through a triangulation method. Finally, a PLS optimization model with marketing objectives and constraints are specified and solved via a sequential quadratic programming method. In our experiments, we observe that while the training and test data sets are dramatically different in terms of churner distributions (50% vs. 1.8%), four controllable variables in three marketing strategies significantly changed through optimization process while other variables only marginally changed. We also observe that the most significant variable in a PLS prediction model does not necessarily change most significantly in our PLS optimization model due to the highest management cost associated, implying differences between a prediction and an optimization model. Finally, two marketing models designed for targeting the subsets of customers based on churn probability or management costs are presented and discussed.     

Fuzzy global optimization of complex system reliability

The problem of optimizing the reliability of complex systems has been modeled as a fuzzy multi-objective optimization problem. Three different kinds of optimization problems: reliability optimization of a complex system with constraints on cost and weight; optimal redundancy allocation in a multistage mixed system with constraints on cost and weight; and optimal reliability allocation in a multistage mixed system with constraints on cost, weight, and volume have been solved. Four numerical examples have been solved to demonstrate the effectiveness of the present methodology. The influence of various kinds of aggregators is also studied. The inefficiency of the noncompensatory min operator has been demonstrated. One of the well-known global optimization meta-heuristics, the threshold accepting, has been invoked to take care of the optimization part of the model. A software has been developed to implement the above model. The results obtained are encouraging     

Computational aspects of an extended EMQ model with variable production rate

The paper considers a generalized economic manufacturing quantity (EMQ) model with stochastic machine breakdown and repair in which the time to machine failure, corrective and preventive repair times are all assumed to be random variables. The model is formulated under general failure and general repair time distributions, treating the machine production rate (speed) as a decision variable. As the stress condition of the machine changes with the production rate, the failure rate is assumed to be dependent on the production rate. The model is further extended to the case where certain safety stocks are hold in inventory to protect against possible stockout during machine repair. The solution procedure and computational algorithms of the associated constrained optimization problems are provided. Numerical examples are taken to determine the optimal production policies by the proposed algorithms and examine the sensitivity of the model parameters.Several economic manufacturing quantity (EMQ) models for unreliable manufacturing systems have been developed in the literature even for general failure and general repair (corrective) time distributions. In these studies, preventive repair has not been considered in a general way and efforts have been made to derive the production control and maintenance policy for inflexible manufacturing systems, where the machine capacity is pre-determined. The purpose of this article is to formulate a generalized EMQ model for a flexible unreliable manufacturing system in which (i) the time to machine failure and repair (corrective and preventive) times follow general probability distributions and (ii) the machine failure rate is dependent on the production rate. Consideration of a variable production rate makes the model hard to analyze completely. So, attempt has also been made to get into its computational aspects by developing solution algorithms.     

Multi-item integrated supply chain model for deteriorating items with stock dependent demand under fuzzy random and bifuzzy environments

In this paper, we have investigated multi-item integrated production-inventory models of supplier and retailer with a constant rate of deterioration under stock dependent demand. Here we have considered supplier’s production cost as nonlinear function depending on production rate, retailers procurement cost exponentially depends on the credit period and suppliers transportation cost as a non-linear function of the amount of quantity purchased by the retailer. The models are optimized to get the value of the credit periods and total time of the supply chain cycle under the space and budget constraints. The models are also formulated under fuzzy random and bifuzzy environments. The ordering cost, procurement cost, selling price of retailer’s and holding costs, production cost, transportation cost, setup cost of the supplier’s and the total storage area and budget are taken in imprecise environments. To show the validity of the proposed models, few sensitivity analyses are also presented under the different rate of deterioration. The models are also discussed in non deteriorating items as a special case of the deteriorating items. The deterministic optimization models are formulated for minimizing the entire monetary value of the supply chain and solved using genetic algorithm (GA). A case study has been performed to illustrate those models numerically.     

Concurrent multi-scale design optimization of composite frames with manufacturing constraints

This paper presents a gradient based concurrent multi-scale design optimization method for composite frames considering specific manufacturing constraints raised from the aerospace industrial requirements. Geometrical parameters of the frame components at the macro-structural scale and the discrete fiber winding angles at the micro-material scale are introduced as the independent design variables at the two geometrical scales. The DMO (Discrete Material Optimization) approach is utilized to couple the two geometrical scales and realize the simultaneous optimization of macroscopic topology and microscopic material selection. Six kinds of manufacturing constraints are explicitly included in the optimization model as series of linear inequalities or equalities. The capabilities of the proposed optimization model are demonstrated with the example of compliance minimization, subject to constraint on the composite volume. The linear constraints and optimization problems are solved by Sequential Linear Programming (SLP) optimization algorithm with move limit strategy. Numerical results show the potential of weight saving and structural robustness design with the proposed concurrent optimization model. The multi-scale optimization model, considering specific manufacturing constraints, provides new choices for the design of the composite frame structure in aerospace and other industries.     

Optimal pricing, lot-sizing and marketing planning in a capacitated and imperfect production system

In the classical economic production quantity (EPQ) problem demand is considered to be known in advance. However, in the real-world, demand of a product is a function of factors such as product’s price, its quality, and marketing expenditures for promoting the product. Quality level of the product and specifications of the adopted manufacturing process also affect the unit product’s cost. Therefore, in this paper we consider a profit maximizing firm who wants to jointly determine the optimal lot-sizing, pricing, and marketing decisions along with manufacturing requirements in terms of flexibility and reliability of the process. Geometric programming (GP) technique is proposed to address the resulting nonlinear optimization problem. Using recent advances in optimization techniques we are able to optimally solve the developed, highly nonlinear, mathematical model. Finally, using numerical examples, we illustrate the solution approach and analyze the solution under different conditions.     

Exploiting Bivariate Dependencies to Speedup Structure Learning in Bayesian Optimization Algorithm

Bayesian optimization algorithm (BOA) is one of the successful and widely used estimation of distribution algorithms (EDAs) which have been employed to solve different optimization problems. In EDAs, a model is learned from the selected population that encodes interactions among problem variables. New individuals are generated by sampling the model and incorporated into the population. Different probabilistic models have been used in EDAs to learn interactions. Bayesian network (BN) is a well-known graphical model which is used in BOA. Learning a proper model in EDAs and particularly in BOA is distinguished as a computationally expensive task. Different methods have been proposed in the literature to improve the complexity of model building in EDAs. This paper employs bivariate dependencies to learn accurate BNs in BOA efficiently. The proposed approach extracts the bivariate dependencies using an appropriate pairwise interaction-detection metric. Due to the static structure of the underlying problems, these dependencies are used in each generation of BOA to learn an accurate network. By using this approach, the computational cost of model building is reduced dramatically. Various optimization problems are selected to be solved by the algorithm. The experimental results show that the proposed approach successfully finds the optimum in problems with different types of interactions efficiently. Significant speedups are observed in the model building procedure as well.     

Modeling and optimization of manufacturing process performance using Modelica graphical representation and process analytics formalism

This paper concerns the development of a design methodology and its demonstration through a prototype system for performance modeling and optimization of manufacturing processes. The design methodology uses a Modelica simulation tool serving as the graphical user interface for manufacturing domain users such as process engineers to formulate their problems. The Process Analytics Formalism, developed at the National Institute of Standards and Technology, serves as a bridge between the Modelica classes and a commercial optimization solver. The prototype system includes (1) manufacturing model components’ libraries created by using Modelica and the Process Analytics Formalism, and (2) a translator of the Modelica classes to Process Analytics Formalism, which are then compiled to mathematical programming models and solved using an optimization solver. This paper provides an experiment toward the goal of enabling manufacturing users to intuitively formulate process performance models, solve problems using optimization-based methods, and automatically get actionable recommendations.     

Solving a bi-objective unrelated parallel batch processing machines scheduling problem: A comparison study

Nowadays in competitive markets, production organizations are looking to increase their efficiency and optimize manufacturing operations. In addition, batch processor machines (BPMs) are faster and cheaper to carry out operations; thus the performance of manufacturing systems is increased. This paper studies a production scheduling problem on unrelated parallel BPMs with considering the release time and ready time for jobs as well as batch capacity constraints. In unrelated parallel BPMs, modern machines are used in a production line side by side with older machines that have different purchasing costs; so this factor is introduced as a novel objective to calculate the optimum cost for purchasing various machines due to the budget. Thus, a new bi-objective mathematical model is presented to minimize the makespan (i.e., C_max), tardiness/earliness penalties and the purchasing cost of machines simultaneously. The presented model is first coded and solved by the ε-constraint‌ method. Because of the complexity of the NP-hard problem, exact methods are not able to optimally solve large-sized problems in a reasonable time. Therefore, we propose a multi-objective harmony search (MOHS) algorithm. the results are compared with the multi-objective particle swarm optimization (MOPSO), non-dominated sorting genetic algorithm (NSGA-II), and multi-objective ant colony optimization algorithm (MOACO). To tune their parameters, the Taguchi method is used. The results are compared by five metrics that show the effectiveness of the proposed MOHS algorithm compared with the MOPSO, NSGA-II and MOACO. At last, the sensitivity of the model is analyzed on new parameters and impacts of each parameter are illustrated on bi- objective functions.     

Metamodeling approach in solving the machine parameters optimization problem using neural network and genetic algorithms: A case study

The use of multilayer ceramic capacitors (MLCCs) is increasing because they are surface-mountable and are used primarily in the expanding communication and computing market. In the MLCC manufacturing process, some 80% of the loss in yield is attributable to paste-printing quality problems. Improvement in the quality of MLCC screen-printing is therefore tactically and strategically important. This research extends existing MLCC screen-printing robust design results to search for a universal optimum solution. A metamodeling approach has been applied to solving a variety of optimization problems. This is an abstraction model form from a model. The abstracted model aims to reduce model complexity, and yet maintain validity. This work involved building a screen-printing quality metamodel, based upon fractional factorial experimental design data using a neural network approach—that were then solved by genetic algorithms. The empirical results are promising. The paper concludes with practical constraints and insights for management.     

Simultaneous parameter and tolerance optimization of structures via probability-interval mixed reliability model

Both structural sizes and dimensional tolerances strongly influence the manufacturing cost and the functional performance of a practical product. This paper presents an optimization method to simultaneously find the optimal combination of structural sizes and dimensional tolerances. Based on a probability-interval mixed reliability model, the imprecision of design parameters is modeled as interval uncertainties fluctuating within allowable tolerance bounds. The optimization model is defined as to minimize the total manufacturing cost under mixed reliability index constraints, which are further transformed into their equivalent formulations by using the performance measure approach. The optimization problem is then solved with the sequential approximate programming. Meanwhile, a numerically stable algorithm based on the trust region method is proposed to efficiently update the target performance points (TPPs) and the worst case points (WCPs), which shows better performance than traditional approaches for highly nonlinear problems. Numerical results reveal that reasonable dimensions and tolerances can be suggested for the minimum manufacturing cost and a desirable structural safety.     

Aggregate production planning for a continuous reconfigurable manufacturing process

Most of the research on aggregate production planning has been focused on discrete parts manufacturing models. In environments where intermediate inventory cannot be stored, and multiple products are produced simultaneously using complex configurations of production machines, these models may produce erroneous results. In this paper, we present a configuration-based formulation for one such manufacturing environment, where production may involve dissimilar machines performing similar operations at different rates and equipment can be connected together to form different production lines. The production process is continuous and no in-process inventory can be kept. We present and compare several heuristics to generate input data to solve the aggregate production-planning problems using the configuration-based formulation. Computational experiments show that large-scale real-world problems we encountered can be solved in reasonable time using our heuristics and commercial optimization software like CPLEX.     

New optimization method based on energy management in microgrids based on energy storage systems and combined heat and power

Microgrids can be assumed as a solution model for green energy sources, energy storage systems, and combined heat and power (CHP) systems. In this work, the cost and emission minimization based on a demand response (DR) program is considered an optimization problem. To solve the mentioned problem a new multiobjective optimization algorithm (improved particle swarm optimization) is proposed based on a fuzzy mechanism to select the optimal value. The microgrid system includes two CHP units, fuel cell and battery systems, and the heat buffer tank. In this problem, two different feasible operating regions have been assumed in CHPs. Accordingly, to decrease the operational cost, time-of-use, and real-time pricing DR programs have been simulated, and the impacts of the mentioned models are evaluated overload profiles. The effectiveness of proposed models has been applied on different cases studies by different scenarios. The proposed model solved the DR program, time of use-DR and real-time pricing-DR problems. The proposed model could reduce the cost about 10%.     

Firefly-inspired algorithm for discrete optimization problems: An application to manufacturing cell formation

The canonical firefly algorithm is basically developed for continuous optimization problems. However, lots of practical problems are formulated as discrete optimization problems. The main purpose of this paper is to present the discrete firefly algorithm (DFA) to solve discrete optimization problems. In the DFA, we define a firefly's position in terms of changes of probabilities that will be in one state or the other. Then by using this metaheuristic algorithm, the manufacturing cell formation problem is solved. To illustrate the behavior of the proposed model and verify the performance of the algorithm, we introduce a number of numerical examples to illustrate the use of the foregoing algorithm. The performance evaluation shows the effectiveness of the DFA. The proposed metaheuristic algorithm should thus be useful to both researchers and practitioners.     

面向制造领域人机物三元数据融合的本体自动化构建方法

当前,智能制造面临的许多问题都具有不确定性和复杂性,单纯地利用专家经验和机理模型难以有效解决.鉴于此,面向跨层跨域的复杂制造系统网络化协同控制机制,提出一种基于本体的人机物三元数据融合方法,研究复杂制造环境下的人机物三元数据融合建模.在抽取三元组时,区别于传统的流水线式抽取方式,提出一种基于实体-关系联合抽取的模型Er...     

Multi-physics bi-directional evolutionary topology optimization on GPU-architecture

Topology optimization has proven to be viable for use in the preliminary phases of real world design problems. Ultimately, the restricting factor is the computational expense since a multitude of designs need to be considered. This is especially imperative in such fields as aerospace, automotive and biomedical, where the problems involve multiple physical models, typically fluids and structures, requiring excessive computational calculations. One possible solution to this is to implement codes on massively parallel computer architectures, such as graphics processing units (GPUs). The present work investigates the feasibility of a GPU-implemented lattice Boltzmann method for multi-physics topology optimization for the first time. Noticeable differences between the GPU implementation and a central processing unit (CPU) version of the code are observed and the challenges associated with finding feasible solutions in a computational efficient manner are discussed and solved here, for the first time on a multi-physics topology optimization problem. The main goal of this paper is to speed up the topology optimization process for multi-physics problems without restricting the design domain, or sacrificing considerable performance in the objectives. Examples are compared with both standard CPU and various levels of numerical precision GPU codes to better illustrate the advantages and disadvantages of this implementation. A structural and fluid objective topology optimization problem is solved to vary the dependence of the algorithm on the GPU, extending on the previous literature that has only considered structural objectives of non-design dependent load problems. The results of this work indicate some discrepancies between GPU and CPU implementations that have not been seen before in the literature and are imperative to the speed-up of multi-physics topology optimization algorithms using GPUs.

     

Optimal policy for set-up time reduction in a multistage production inventory system

A batch production-inventory system consisting of multiple stages with an optimal policy of set-up time reduction and a fixed increment cost are discussed. The ratio of set-up time reduction as a decision variable under various cases of demand in the batch production-inventory model is considered. The ratio of set-up time reduction and lot size are solved simultaneously to obtain an optimal value of the total annual cost. A numerical example is presented to demonstrate the accuracy of the proposed method.     

Evolutionary techniques for optimization problems in integrated manufacturing system: State-of-the-art-survey

Integrated manufacturing system (IMS) is a novel manufacturing environment which has been developed for the next generation of manufacturing and processing technologies. It consists of engineering design, process planning, manufacturing, quality management, and storage and retrieval functions. Improving the decision quality in those fields give rise to complex combinatorial optimization problems, unfortunately, most of them fall into the class of NP-hard problems. Find a satisfactory solution in an acceptable time play important roles. Evolutionary techniques (ET) have turned out to be potent methods to solve such kind of optimization problems. How to adapt evolutionary technique to the IMS is very challenging but frustrating. Many efforts have been made in order to give an efficient implementation of ET to optimize the specific problems in IMS.In this paper, we address four crucial issues in IMS, including design, planning, manufacturing, and distribution. Furthermore, some hot topics in these issues are selected to demonstrate the efficiency of ET’s application, such as layout design (LD) problem, flexible job-shop scheduling problem (fJSP), multistage process planning (MPP) problem, and advanced planning and scheduling (APS) problem. First, we formulate a generalized mathematic models for all those problems; several evolutionary algorithms which adapt to the problems have been proposed; some test instances based on the practical problems demonstrate the effectiveness and efficiency of our proposed approach.