Artificial bee colony algorithm for CONWIP production control system in a multi-product multi-machine manufacturing environment

In this paper, a multi-product multi-machine serial production line operated under a constant-work-in-process protocol is considered. A mathematical model for the system is first presented, and then an artificial bee colony optimization algorithm is applied to simultaneously find the optimal work-in-process inventory level as well as job sequence order in order to minimize the overall makespan time. Unlike many existing approaches, which are based on deterministic search algorithms such as nonlinear programming and mixed integer programming, the proposed method does not use a linearized or simplified model of the system. A production line simulator implemented on MATLAB is, instead, employed to model the highly nonlinear dynamics of the production line and is used to evaluate the candidate solutions. The efficiency of the proposed approach, even for systems of large sizes, is validated via numerical simulations.     

A mathematical model on EPQ for stochastic demand in an imperfect production system

In the paper, we develop an EPQ (economic production quantity) inventory model to determine the optimal buffer inventory for stochastic demand in the market during preventive maintenance or repair of a manufacturing facility with an EPQ (economic production quantity) model in an imperfect production system. Preventive maintenance, an essential element of the just-in-time structure, may cause shortage which is reduced by buffer inventory. The products are sold with the free minimal repair warranty (FRW) policy. The production system may undergo “out-of-control” state from “in-control” state, after a certain time that follows a probability density function. The defective (non-conforming) items in “in-control” or “out-of-control” state are reworked at a cost just after the regular production time. Finally, an expected cost function regarding the inventory cost, unit production cost, preventive maintenance cost and shortage cost is minimized analytically. We develop another case where the buffer inventory as well as the production rate are decision variables and the expected unit cost considering the above cost functions is optimized also. The numerical examples are provided to illustrate the behaviour and application of the model. Sensitivity analysis of the model with respect to key parameters of the system is carried out.     

Heuristics for solving continuous berth allocation problem considering periodic balancing utilization of cranes

This study investigates a berth allocation problem considering the periodic balancing utilization of quay cranes in container terminals. The proposed model considers that the quay cranes allocated to a work shift should be fully used and other real-world considerations, such as the continuous quay line, the penalties for early arrivals and departure delays. To solve the model, several heuristics are developed: the model for large problems is decomposed into sub-models that are solved by rolling-horizon heuristics; neighborhood search heuristics are used for optimizing a berthing order of vessels; parallel computing is used to improve the algorithmic performance. The method performs well when applied to real-world large-scale instances with promising computation time that is linearly related to the number of vessels.     

Multi-objective genetic algorithm for berth allocation problem considering daytime preference

Maximization of operational efficiency and minimization of cost are pursued by terminal operators, whereas daytime preference is increasingly emphasized by governments, terminal operators and workers. Daytime preference in berth allocation schedule refers to schedule the workloads in nights as fewer as possible, which improves working comfort, safety, and green and energy-savings degrees, but may decrease the throughput and total operational efficiency. By extending existing dynamic discrete berth allocation model, a bi-objective model considering daytime preference is established to minimize the delayed workloads and the workloads in nights. Based on the well known NSGA-II algorithm, a multi-objective genetic algorithm (moGA) is developed for solving the bi-objective model by using a two-part representation scheme. The sensitivities of the algorithmic parameters and tradeoffs between daytime preference and delayed workloads are analyzed by numerical experiments. The algorithmic aspects of the proposed approach and the effects of daytime preference on solutions are all examined. Finally, the managerial implications are discussed.     

A vector space model approach to production planning for a multi-product,multi-cell and multi-stage manufacturing system

This paper develops a formal mathematical approach to aggregate production planning for a multi-product, multi-cell and multi-stage manufacturing system. The model, based upon a vector space approach, includes all the important variables relating to the demand for individual items, inventory levels, the availability of machines taking into account any breakdowns, subcontracting of orders and overtime working. The computational procedure for determining the production planning strategies, in terms of overtime/undertime working and increase/decrease in the number of orders subcontracted, are presented. Three numerical examples are presented showing the use of the model developed. This approach makes it possible to develop realistic models of practical manufacturing systems. It is particularly applicable to flexible manufacturing systems.     

A constrained multi-product pricing and inventory control problem

The aim of this article is presenting a new constrained multi-product pricing and inventory model in which perishable products are put into three categories: substitute, complementary and independent. The general demand is found by considering the relations of different products and the impact of their prices. The goal of the model is deciding on the prices as well as the inventory and production decisions in order to maximize the total profit. The derived model is a non-linear programming model and a genetic algorithm is developed for its solution. To enhance the performance of our genetic algorithm, we apply the Taguchi experimental design method to tune the parameters of the algorithm. Finally, the computational results and some recommendations for future extensions are presented.     

Beam search algorithm for capacity allocation problem in flexible manufacturing systems

This study considers the operation assignment and tool allocation problem in flexible manufacturing systems. A set of operations together with their required tools are selected so as to maximize the total weight. The machines have limited time and tool magazine capacities and the tools are available in limited quantities. We develop a beam search algorithm and obtain near optimal solutions for large size problems very quickly.     

Operation assignment and capacity allocation problem in automated manufacturing systems

We address an operation assignment and capacity allocation problem that arises in semiconductor industries and flexible manufacturing systems. We assume the automated machines have scarce time and tool magazine capacities and the tools are available in limited quantities. The aim is to select a subset of operations with maximum total weight. We show that the problem is NP-hard in the strong sense, develop two heuristics and a Tabu Search procedure. The results of our computational tests have revealed that our Tabu Search procedure produces near optimal solutions very quickly.     

Bounding approaches for operation assignment and capacity allocation problem in flexible manufacturing systems

This study considers an operation assignment and capacity allocation problem that arises in flexible manufacturing systems. Automated machines are assumed to have scarce time and tool magazine capacities and the tools are available in limited quantities. The aim is to select a subset of operations with maximum total weight. The weight of an operation may represent its profit, processing load, relative priority. Several upper bounding procedures have been taken into account. The results of computational tests have revealed that the proposed upper bounding procedures produce satisfactory solutions in reasonable CPU times. We suggest using some of the bounds when the quality of the solutions is more important than the speed of achieving them and some others when the speed is more important than the quality.     

Redundancy allocation problems considering systems with imperfect repairs using multi-objective genetic algorithms and discrete event simulation

This paper considers a multi-objective genetic algorithm (GA) coupled with discrete event simulation to solve redundancy allocation problems in systems subject to imperfect repairs. In the multi-objective formulation, system availability and cost may be maximized and minimized, respectively; the failure-repair processes of system components are modeled by Generalized Renewal Processes. The presented methodology provides a set of compromise solutions that incorporate not only system configurations, but also the number of maintenance teams. The multi-objective GA is validated via examples with analytical solutions and shows its superior performance when compared to a multi-objective Ant Colony algorithm. Moreover, an application example is presented and a return of investment analysis is suggested to aid the decision maker in choosing a solution of the obtained set.     

An optimal production lot-sizing problem for an imperfect process with imperfect maintenance and inspection time length

This article develops an integrated model in considering the situations of an imperfect process with imperfect maintenance and inspection time for the joint determination of both economic production quantity (EPQ) and preventive maintenance (PM). This imperfect process has a general deterioration distribution with increasing hazard rate. Even with periodic PM, such a production system cannot be recovered as good as new. This means that the system condition depends on how long it runs. Also, the PM level can be distinct due to the maintenance cost. For convenience, it is assumed the age of system is reduced in proportional to the PM level. Further, during a production cycle, we need an inspection to see if the process is in control. This inspection might demand a considerable amount of time. In this article, we take PM level and inspection time into consideration to optimise EPQ with two types of out-of-control states. To see how the method works, we use a Weibull shock model to show the optimal solutions for the least costs.     

Application of fuzzy sets to manufacturing/distribution planning decisions with multi-product and multi-time period in supply chains

This work applies fuzzy sets to integrating manufacturing/distribution planning decision (MDPD) problems with multi-product and multi-time period in supply chains by considering time value of money for each of the operating cost categories. The proposed fuzzy multi-objective linear programming model (FMOLP) attempts to simultaneously minimize total costs and total delivery time with reference to inventory levels, available machine capacity and labor levels at each source, as well as market demand and available warehouse space at each destination, and the constraint on total budget. An industrial case demonstrates the feasibility of applying the proposed model to a realistic MDPD problem and several significant management implications are presented based on computational analysis and comparisons with the existing MDPD methods. The main advantage of the proposed model is that it presents a systematic framework that facilitates fuzzy decision-making for solving the multi-objective MDPD problems with multi-product and multi-time period in supply chains under an uncertain environment, enabling the decision maker to adjust the search direction during the solution procedure to obtain a preferred satisfactory solution.     

A cell formation problem considering machine utilization and alternative process routes by scatter search

Cell formation (CF) is the first step in the design of cellular manufacturing systems (CMSs), which has been recognized as an effective way to enhance the productivity in a factory. There is a set of criteria on which to judge route of product, machine grouping and part family simultaneously in terms of the effective utilization of these cells. In this study, we consider four objectives simultaneously: (1) Minimizing the total fixed and variable cost including costs of purchasing, operation, and maintenance; (2) minimizing cost of intercellular movements; (3) maximizing the utilization of machines in the system; and (4) minimizing deviations among the levels of the cell utilization (i.e., balancing the workload between cells). In this paper, these objectives are first weighted by their relative importance and then a new mathematical model is presented. To solve this model, a scatter search (SS) algorithm is proposed to select a process plan for each part with the minimum cost along with forming the part family and machine grouping simultaneously. The performance of the proposed SS is compared with the Lingo 8.0 software. A number of test problems are carried out to verify the good ability of the proposed SS in terms of the solution quality and computational time. The computational results reveal that the SS finds promising results, especially in the case of large-sized problems.     

Modeling and solving a multi-objective supplier quota allocation problem considering transaction costs

Suppliers’ evaluation is a subject, which has attracted the attention of many researchers. The performance of potential suppliers is evaluated against multiple criteria rather than considering a single factor such as cost or quality. One of the major objectives of suppliers’ evaluation is to determine the optimal quota assigned to each supplier while needing to replenish an order. This problem has been studied by many researchers as a multi-objective problem. The usual objectives are minimizing the purchasing cost, rejected units, and late delivered units. However, in a few researches maximizing the evaluation scores of the selected suppliers is considered as fourth objective. In this paper, we present a model with five objectives including minimizing the transaction costs of purchasing from suppliers as well as the four addressed objectives. We convert the model to a single objective one using the well-known weighting method, solve it utilizing two meta-heuristic algorithms, and analyze the efficiency of the heuristics. The reason why we utilize the meta-heuristic algorithms is that the problem is proved to be an NP-hard one.     

A capacity allocation and expansion model for TFT-LCD multi-site manufacturing

This paper presents a capacity allocation and expansion problem of thin film transistor liquid crystal display (TFT-LCD) manufacturing in a multi-site environment. Capacity allocation and expansion decisions have become more challenging issues because of the following: (1) complex product hierarchy caused by a wide range of product types and applications, (2) coexistence of multiple generations of manufacturing technologies in the multi-stage production network, and (3) rapidly growing and changing market demands due to the replacement of the traditional cathode ray tube. Since the Array stage is the bottleneck of this production network, our research objective is to simultaneously seek an optimal capacity allocation plan and capacity expansion policy under single-stage, multi-generation, and multi-site structures. Capacity allocation determines the profitable product mixes and allocated production quantities for each product group at each production site. Capacity expansion determines timing, types, and sizes of capacity investments, especially in the acquisition of auxiliary tools. This study proposes a mixed integer linear programming to formulate the whole model of capacity allocation and expansion, which considers the practical characteristics and constraints of TFT-LCD manufacturing. Finally, an industrial case study modified from a Taiwanese TFT-LCD manufacturer is illustrated and a sensitivity analysis of some influential parameters is also addressed.     

An artificial immune system heuristic for two-stage multi-machine assembly scheduling problem to minimize total completion time

We address the two-stage multi-machine assembly scheduling problem. The first stage consists of m independently working machines where each machine produces its own component. The second stage consists of two independent and identical assembly machines. The objective is to come up with a schedule that minimizes total or mean completion time for all jobs. The problem has been addressed in the scheduling literature and several heuristics have been proposed. In this paper, we propose a new heuristic called artificial immune system (AIS). We conduct experimental analysis for comparing the newly proposed heuristic AIS with the best known heuristic in the literature. Experimental results show that our proposed heuristic AIS performs better than the best known existing heuristic. More specifically, our new heuristic AIS reduces the error of the best known heuristic by 60% while the computational times of both AIS and the best known heuristic are almost the same.     

A knowledge-based system for information management in an automated and integrated manufacturing system

In recent years there has been considerable interest in flexible automation of manufacturing processes in an effort to improve the productivity of manufacturing industry. Central to an integrated, flexible and intelligent manufacturing system is the information management function. The sharing of data is the basis of flexible and intelligent decision-making, the means of integrating the system components, the mode of synchronizing their processes and the method of maintaining the consistency of their states.

It appears that the data management and manipulation function in manufacturing systems is increasingly becoming a bottleneck for further performance improvement of manufacturing systems. New information management systems need to be developed that meet the needs of modern manufacturing systems in terms of efficiency, flexibility, reliability and intelligence. A new model for an integrated manufacturing information system is presented. A double structure of two parallel but independent system is proposed for manufacturing control and manufacturing information management. The objective is to improve service efficiency. representational adequacy, consistency of information and reliability in the information system.     

Dynamic vehicle allocation control for automated material handling system in semiconductor manufacturing

The current study examines the dynamic vehicle allocation problems of the automated material handling system (AMHS) in semiconductor manufacturing. With the uncertainty involved in wafer lot movement, dynamically allocating vehicles to each intrabay is very difficult. The cycle time and overall tool productivity of the wafer lots are affected when a vehicle takes too long to arrive. In the current study, a Markov decision model is developed to study the vehicle allocation control problem in the AMHS. The objective is to minimize the sum of the expected long-run average transport job waiting cost. An interesting exhaustive structure in the optimal vehicle allocation control is found in accordance with the Markov decision model. Based on this exhaustive structure, an efficient algorithm is then developed to solve the vehicle allocation control problem numerically. The performance of the proposed method is verified by a simulation study. Compared with other methods, the proposed method can significantly reduce the waiting cost of wafer lots for AMHS vehicle transportation.     

The order fulfillment planning problem considering multi-site order allocation and single-site shop floor scheduling

The order fulfillment planning process in the thin film transistor–liquid crystal display panel industry is analyzed in this study. A two-phase order fulfillment planning structure is proposed, including the multi-site order allocation among module factories and single-site shop floor scheduling in each factory. In the first phase, the order allocation problem is solved using a mathematical programming model considering practical characteristics, including product structures, customer preferences, alternative bill-of-material, and production constraints. In the second phase, a constraint-based simulation scheduling algorithm is developed to address the scheduling problem in each module factory for determining the ideal order release time. Since production planning and scheduling are dealt with different time scales, the major challenge for the integration lies in the large problem size of the optimization model and becomes intractable. Most of the time bucket-based planning methods in the past literature simplify their scheduling models, but in this paper the detailed shop floor operations and processing behaviors are considered, such as changeover time, processing sequence of orders, and machine characteristics. Finally, a practical case in Taiwan will be employed to testify the feasibility of the proposed order fulfillment planning process; meanwhile, through the analysis of experiments, the adaptability and comparison of different planning approaches in an environment of various market demands are discussed.     

Bi-objective optimization of the reliability-redundancy allocation problem for series-parallel system

The main objective of this paper is to solve the bi-objective reliability redundancy allocation problem for series-parallel system where reliability of the system and the corresponding designing cost are considered as two different objectives. In their formulation, reliability of each component is considered as a triangular fuzzy number. In order to solve the problem, developed fuzzy model is converted to a crisp model by using expected values of fuzzy numbers and taking into account the preference of decision maker regarding cost and reliability goals. Finally the obtained crisp optimization problem has been solved with particle swarm optimization (PSO) and compared their results with genetic algorithm (GA). Examples are shown to illustrate the method. Finally statistical simulation has been performed for supremacy the approach.