Cell formation problem with consideration of both intracellular and intercellular movements

The cellular manufacturing system (CMS) is a well-known strategy which enhances production efficiency while simultaneously cutting down the system-wide operation cost. Most of the researchers have been focused on developing different approaches in order to identify machine-cells and part-families more efficiently. In recent years, researchers have also focused their studies more scrupulously by collectively considering CMS with production volume, operation sequence, alternative routing or even more. However, very few of them have tried to investigate both the allocation sequence of machines within the cells (intra-cell layout) and the sequence of the formed cells (inter-cell layout). Solving this problem is indeed very important in reducing the total intracellular and intercellular part movements which is especially significant with large production volume.

In this paper, a two-phase approach has been proposed to tackle the cell formation problem (CFP) with consideration of both intra-cell and inter-cell part movements. In the first phase, a mathematical model with multi-objective function is formed to obtain the machine cells and part families. Afterwards, in the second phase, another mathematical model with single-objective function is presented which optimizes the total intra-cell and inter-cell part movements. In other words, the scope of problem has been identified as a CFP together with the background objective of intra-cell and inter-cell layout problems (IAECLP). The primary assumption for IAECLP is that only linear layouts will be considered for both intra-cell and inter-cell. In other words, the machine within cells and the formed cells are arranged linearly. This paper studies formation of two mathematical models and used the part-machine incidence matrix with component operational sequence.

The IAECLP is considered as a quadratic assignment problem (QAP). Since QAP and CFP are NP-hard, genetic algorithm (GA) has been employed as solving algorithm. GA is a widespread accepted heuristic search technique that has proven superior performances in complex optimization problems and further it is a popular and well-known methodology. The proposed algorithms for CFP and IAECLP have been implemented in JAVA programming language.     

A branch-and-bound algorithm for the cell formation problem

The Cell Formation Problem (CFP) is an important optimisation problem in manufacturing. It has been introduced in the Group Technology (GT) and its goal is to group machines and parts processed on them into production cells minimising the movement of parts to other cells for processing and maximising for each cell the loading of its machines with operations on its parts. We consider one of the computationally hardest formulations of this problem – the CFP with a variable number of cells and the grouping efficacy objective, which is a fractional function. The CFP literature contains many heuristic algorithms, but only a small number of exact approaches especially for this formulation. In the current paper, we present an exact branch-and-bound algorithm for the same hard CFP formulation. To linearise the fractional objective function, we apply the Dinkelbach approach. We have been able to solve 24 of the 35 instances from the well known GT benchmark. For the remaining 11 instances, the difference in the grouping efficacy with the best known solutions is less than 2.6%.     

Minimising makespan on a single batch processing machine with dynamic job arrivals and non-identical job sizes

Batch scheduling is a prevalent policy in many industries such as burn-in operations in semiconductor manufacturing and heat treatment operations in metalworking. In this paper, we consider the problem of minimising makespan on a single batch processing machine in the presence of dynamic job arrivals and non-identical job sizes. The problem under study is NP-hard. Consequently, we develop a number of efficient construction heuristics. The performance of the proposed heuristics is evaluated by comparing their results to two lower bounds, and other solution approaches published in the literature, namely the first-fit longest processing time-earliest release time (FFLPT-ERT) heuristic, hybrid genetic algorithm (HGA), joint genetic algorithm and dynamic programming (GA+DP) approach and ant colony optimisation (ACO) algorithm. The computational experiments demonstrate the superiority of the proposed heuristics with respect to solution quality, especially for the problems with small size jobs. Moreover, the computational costs of the proposed heuristics are very low.     

Cloud manufacturing resources fuzzy classification based on genetic simulated annealing algorithm

To solve the problem of fuzzy classification of manufacturing resources in a cloud manufacturing environment, a hybrid algorithm based on genetic algorithm (GA), simulated annealing (SA) and fuzzy C-means clustering algorithm (FCM) is proposed. In this hybrid algorithm, classification is based on the processing feature and attributes of the manufacturing resource; the inner and outer layers of the nested loops are solving it, GA obtains the best classification number in the outer layer; the fitness function is constructed by fuzzy clustering algorithm (FCM), carrying out the selection, crossover and mutation operation and SA cooling operation. The final classification results are obtained in the inner layer. Using the hybrid algorithm to solve 45 kinds of manufacturing resources, the optimal classification number is 9 and the corresponding classification results are obtained, proving that the algorithm is effective.     

Scheduling a batch processing machine with non-identical job sizes: a clustering perspective

Batch processing machines that process a group of jobs simultaneously are often encountered in semiconductor manufacturing and metal heat treatment. This paper considered the problem of scheduling a batch processing machine from a clustering perspective. We first demonstrated that minimising makespan on a single batching machine with non-identical job sizes can be regarded as a special clustering problem, providing a novel insight into scheduling with batching. The definition of WRB (waste ratio of batch) was then presented, and the objective function of minimising makespan was transformed into minimising weighted WRB so as to define the distance measure between batches in a more understandable way. The equivalence of the two objective functions was also proved. In addition, a clustering algorithm CACB (constrained agglomerative clustering of batches) was proposed based on the definition of WRB. To test the effectiveness of the proposed algorithm, the results obtained from CACB were compared with those from the previous methods, including BFLPT (best-fit longest processing time) heuristic and GA (genetic algorithm). CACB outperforms BFLPT and GA especially for large-scale problems.     

Minimising material handling cost in cell formation with alternative processing routes by grouping genetic algorithm

The alternative processing route is one of the important design factors for the cell formation problem (CFP) in cellular manufacturing systems (CMSs). Genetic algorithm (GA) is a popular method for solving the CFPs, because GA is capable of searching large regions of the solution's space while being less susceptible to getting trapped in local optima. However, the disadvantage of classical GAs is that the number of manufacturing cells should be known in advance. Knowing the actual number of manufacturing cells is relatively difficult before the CMS design is determined. Grouping genetic algorithm (GGA) is capable of solving CFP without predetermination of the number of cells, which is introduced by Falkenauer's GGA (1998 Falkenauer, E. 1998. Genetic Algorithms for Grouping Problem, New York: Wiley.  [Google Scholar]). In order to adopt the GGA on CFP with alternative processing routes, we develop a new chromosome representation, a local optimisation algorithm for crossover operator and special mutation operators. These efforts ensure the efficiency of our method and are indicated in the numerical examples, and improved solutions are also obtained in the numerical examples.     

Converting functional manufacturing systems into focused machine cells— a bicriterion approach

The main purpose of adopting cellular manufacturing (CM) is to achieve a preferred compromise between flow-line efficiency and job-shop flexibility. This paper presents a bicriterion approach to seek such a preferred design compromise in converting functional manufacturing systems into focused CM systems. The problem is formulated as a bicriterion nonlinear-integer programming model. The number of part types accommodated into the focused cells is employed as a measure of system flexibility and the average system similarity level is used as a measure of system efficiency. A heuristic algorithm, consisting of seeding, grouping, and inserting modules, is then proposed to solve the model. Finally, an example problem is included to illustrate the application of the model and solution procedure.     

Multi-product continuous plant scheduling: combination of decomposition,genetic algorithm,and constructive heuristic

We propose a polylithic method for medium-term scheduling of a large-scale industrial plant operating in a continuous mode. The method combines a decomposition approach, a genetic algorithm (GA) and a constructive MILP-based heuristic. In the decomposition, decisions are made at two levels, using the rolling horizon approach. At the upper level, a reduced set of products and the time period is chosen to be considered in the lower level. At the lower level, a short-term scheduling MILP-model with event-based representation is used. A heuristic solution to the lower level problem is found using a constructive Moving Window heuristic guided by a genetic algorithm. The GA is applied for finding efficient utilisation of critical units in the lower level problem. For solving the one unit scheduling problem, a parallel dynamic programming algorithm is proposed. Implementation of the dynamic programming algorithm for a graphics processing unit (GPU) is incorporated in the GA for improving its performance. The experimental study of the proposed method on a real case of a large-scale plant shows a significant improvement of the solution quality and the solving time comparing to the pure decomposition algorithm proposed in the earlier study, and confirmed suitability of the proposed approach for the real-life production scheduling. In particular, the reduction of the number of changeovers and their duration in the obtained solution as well as the CPU time of solving the problem was about 60% using the new approach.     

A parallel genetic algorithm for dynamic cell formation in cellular manufacturing systems

Instead of using expensive multiprocessor supercomputers, parallel computing can be implemented on a cluster of inexpensive personal computers. Commercial accesses to high performance parallel computing are also available on the pay-per-use basis. However, literature on the use of parallel computing in production research is limited. In this paper, we present a dynamic cell formation problem in manufacturing systems solved by a parallel genetic algorithm approach. This method improves our previous work on the use of sequential genetic algorithm (GA). Six parallel GAs for the dynamic cell formation problem were developed and tested. The parallel GAs are all based on the island model using migration of individuals but are different in their connection topologies. The performance of the parallel GA approach was evaluated against a sequential GA as well as the off-shelf optimization software. The results are very encouraging. The considered dynamic manufacturing cell formation problem incorporates several design factors. They include dynamic cell configuration, alternative routings, sequence of operations, multiple units of identical machines, machine capacity, workload balancing, production cost and other practical constraints.     

Developing a method to generate semi-distributed layouts by genetic algorithm

Recent research in industries shows that existing layout configurations do not satisfy the needs of multi-product enterprises in turbulent environments but within new layout strategies, distributed layouts have deserved more attention in most manufacturing environments and have a promising potential to cope with demand disturbances. This study is an attempt to design weighted distributed layouts via considering machine independent capabilities by a resource elements (REs) approach, which has caused generation of a new type of distributed layout named semi-distributed layout. REs are used to define processing requirements of parts and processing capabilities of machines. Another contribution of this paper is applying genetic algorithms (GAs) to distribute REs to find the optimal assignment of machines to available locations in such a way the travelled distances of parts are minimised and the accessibility of them to the required machines are maximised. The methodology of this paper is illustrated using a two-phase procedure. First, all machining facilities are divided into a set of REs based on their capabilities and second, the weighted connections among REs are considered to distribute them over the floor through implementing the developed GA. To evaluate the methodology, the proposed algorithm is tested with three illustrative examples obtained from the literature, in which two of them are comparable with outputs of simulated annealing (SA). The comparison between the outputs of the GA and the SA on the same cases presents that for large size problems, the GA significantly outperforms the SA.     

A new paradigm for rule-based scheduling in the wafer probe centre

This paper addresses the scheduling problem in the wafer probe centre. The proposed approach is based on the dispatching rule, which is popularly used in the semiconductor manufacturing industry. Instead of designing new rules, this paper proposes a new paradigm to utilize these rules. The proposed paradigm formulates the dispatching process as a 2-D assignment problem with the consideration of information from multiple lots and multiple pieces of equipment in an integrated manner. Then, the dispatching decisions are made by maximizing the gains of multiple possible decisions simultaneously. Besides, we develop a genetic algorithm (GA) for generating good dispatching rules through combining multiple rules with linear weighted summation. The benefits of the proposed paradigm and GA are verified with a comprehensive simulation study on three due-date-based performance measures. The experimental results show that under the proposed paradigm, the dispatching rules and GA can perform much better than under the traditional paradigm.     

Optimisation for multi-part flow-line configuration of reconfigurable manufacturing system using GA

To facilitate the configuration selection of reconfigurable manufacturing systems (RMS) at the beginning of every demand period, it needs to generate K (predefined number) best configurations as candidates. This paper presents a GA-based approach for optimising multi-part flow-line (MPFL) configurations of RMS for a part family. The parameters of the MPFL configuration comprise the number of workstations, the number of paralleling machines and machine type as well as assigned operation setups (OSs) for each workstation. Input requirements include an operation precedence graph for each part, relationships between operations and OSs as well as machine options for each OS. The objective is to minimise the capital cost of MPFL configurations. A 0-1 nonlinear programming model is developed to handle sharing machine utilisation over consecutive OSs for each part which is ignored in the existing approach. Then a novel GA-based approach is proposed to identify K economical solutions within a refined solution space comprising the optimal configurations associated with all feasible OS assignments. A case study shows that the best solution found by GA is better than the optimum obtained by the existing approach. The solution comparisons between the proposed GA and a particle swarm optimisation algorithm further illustrate the effectiveness and efficiency of the proposed GA approach.     

An integrated model for assembly line re-balancing problem

In this paper, an integrated approach for assembly line rebalancing problem (IALRP) is proposed to quickly react and find an optimal rebalancing of the line when disruptive event occurs because of product demand changes. This model is motivated by real-life application of an automotive cable manufacturer which provides more realistic constraints. To solve the problem, we propose a genetic algorithm (GA) hybridised with a heuristic priority rule-based procedure. This hybridisation is used to add more rich seeds to the initial population and consequently to improve the convergence capability and performance of the GA. After the disturbance, we aim to find a rebalance with the proposed approach to maximise the line efficiency and distributing the idle time across the workstations as equally as possible. To evaluate the efficiency of the proposed algorithm, set of samples collected from the literature are used. The real case study and the experiment results show the proposed approach is very effective and competitive.     

Manufacturing cell design: an integer programming model employing genetic algorithms

The design of a cellular manufacturing system requires that a part population, at least minimally described by its use of process technology (part/machine incidence matrix), be partitioned into part families and that the associated plant equipment be partitioned into machine cells. At the highest level, the objective is to form a set of completely autonomous units such that inter-cell movement of parts is minimized. We present an integer program that is solved using a genetic algorithm (GA) to assist in the design of cellular manufacturing systems. The formulation uses a unique representation scheme for individuals (part/machine partitions) that reduces the size of the cell formation problem and increases the scale of problems that can be solved. This approach offers improved design flexibility by allowing a variety of evaluation functions to be employed and by incorporating design constraints during cell formation. The effectiveness of the GA approach is demonstrated on several problems from the literature.     

Towards a psychologically consistent cellular manufacturing system

In cellular manufacturing systems (CMSs), an operator plays an important role. Because operators work for long-time periods in a production area, an increase in job satisfaction and system productivity occurs if the consistency of operators’ personal characteristics are considered in the design of CMSs. In a CMS, a cell formation problem (CFP) focuses on grouping and allocating machines, part families and operators to manufacturing cells. This paper considers a decision-making style (DMS) as an operator’s personal characteristic index in a CFP for designing a psychologically consistent CMS. DMS influences not only the interaction between two operators, but also the work that operator does on a machine. Hence, this paper develops a novel multi-objective mathematical model for the CFP considering consistency between each two operators in each cell and consistency between operator and his/her assigned machine(s). Because of possibility of a change in the primary DMS of a person to the backup one, this paper tackles this issue by applying a probabilistic procedure. Two hybrid meta-heuristic algorithms are developed for the large-sized test problems. In addition, the PROMETHEE-II method is applied to select the best Pareto solution. Finally, a real case study is presented to show the applicability of the developed approach.     

Effective hybrid genetic algorithm for minimizing makespan on a single-batch-processing machine with non-identical job sizes

The paper addresses minimizing makespan by a genetic algorithm (GA) for scheduling jobs with non-identical sizes on a single-batch-processing machine. A batch-processing machine can process up to B jobs simultaneously. The processing time of a batch is equal to the longest processing time among all jobs in the batch. Two different GAs are proposed based on different encoding schemes. The first is a sequence-based GA (SGA) that generates random sequences of jobs using GA operators and applies the batch first fit heuristic to group the jobs. The second is a batch-based hybrid GA (BHGA) that generates random batches of jobs using GA operators and ensures feasibility by using knowledge of the problem based on a heuristic procedure. A greedy local search heuristic based on the problem characteristics is hybridized with a BHGA that has the ability of steering efficiently the search toward the optimal or near-optimal schedules. The performance of proposed GAs is compared with a simulated annealing (SA) approach proposed by Melouk et al. (Melouk, S., Damodaran, P. and Chang, P.Y., Minimizing makespan for single machine batch processing with non-identical job sizes using simulated annealing. Int. J. Prod. Econ., 2004, 87, 141–147) and also against a modified lower bound proposed for the problem. Computational results show that BHGA performs considerably well compared with the modified lower bound and significantly outperforms the SGA and SA in terms of both quality of solutions and required runtimes.     

Multiprocessor task scheduling in multistage hybrid flow-shops: an ant colony system approach

The hybrid flow-shop scheduling problem (HFSP) has been of continuing interest for researchers and practitioners since its advent. This paper considers the multistage HFSP with multiprocessor tasks, a core topic for numerous industrial applications. A novel ant colony system (ACS) heuristic is proposed to solve the problem. To verify the developed heuristic, computational experiments are conducted on two well-known benchmark problem sets and the results are compared with genetic algorithm (GA) and tabu search (TS) from the relevant literature. Computational results demonstrate that the proposed ACS heuristic outperforms the existing GA and TS algorithms for the current problem. Since the proposed ACS heuristic is comprehensible and effective, this study successfully develops a near-optimal approach which will hopefully encourage practitioners to apply it to real-world problems.     

Designing group layout of unequal-area facilities in a dynamic cellular manufacturing system with variability in number and shape of cells

This paper presents a new mixed-integer non-linear programming model for designing the group layout (GL) of unequal-area facilities in a cellular manufacturing system (CMS) under a dynamic environment. There are some features that make the presented model different from the previous studies. These include: (1) manufacturing cells with variable numbers and shapes, (2) machine depot keeping idle machines, (3) machines of unequal-areas, (4) manufacturing cells with rectangle regular shapes established on the continuous shop floor and (5) integration of cell formation and GL as interrelated decisions involved in the design of a CMS in a dynamic environment. The objective function is to minimises the total costs of intra- and inter-cell material handling, machine overhead, machine relocation, machine processing, purchasing machines and forming cells. Since the problem is NP-hard, an efficient simulated annealing (SA) algorithm is developed to solve the presented model. The performance of this model is illustrated by two numerical examples. It is then tested using several test problems with different sizes and settings to verify the computational efficiency of the developed algorithm in comparison to the classical genetic algorithm (GA). The obtained results show that the quality of the solutions obtained by SA is better than GA.     

Real-coded genetic algorithm and fuzzy logic approach for real-time tuning of proportional-integral?derivative controller in automatic voltage regulator system

Optimal tuning of proportional?integral?derivative (PID) controller parameters is necessary for the satisfactory operation of automatic voltage regulator (AVR) system. This study presents a combined genetic algorithm (GA) and fuzzy logic approach to determine the optimal PID controller parameters in AVR system. The problem of obtaining the optimal PID controller parameters is formulated as an optimisation problem and a real-coded genetic algorithm (RGA) is applied to solve the optimisation problem. In the proposed RGA, the optimisation variables are represented as floating point numbers in the genetic population. Further, for effective genetic operation, the crossover and mutation operators which can deal directly with the floating point numbers are used. The proposed approach has resulted in PID controller with good transient response. The optimal PID gains obtained by the proposed GA for various operating conditions are used to develop the rule base of the Sugeno fuzzy system. The developed fuzzy system can give the PID parameters on-line for different operating conditions. The suitability of the proposed approach for PID controller tuning has been demonstrated through computer simulations in an AVR system.     

Minimisation of total tardiness for identical parallel machine scheduling using genetic algorithm

In recent years research on parallel machine scheduling has received an increased attention. This paper considers minimisation of total tardiness for scheduling of n jobs on a set of m parallel machines. A spread-sheet-based genetic algorithm (GA) approach is proposed for the problem. The proposed approach is a domain-independent general purpose approach, which has been effectively used to solve this class of problem. The performance of GA is compared with branch and bound and particle swarm optimisation approaches. Two set of problems having 20 and 25 jobs with number of parallel machines equal to 2, 4, 6, 8 and 10 are solved with the proposed approach. Each combination of number of jobs and machines consists of 125 benchmark problems; thus a total for 2250 problems are solved. The results obtained by the proposed approach are comparable with two earlier approaches. It is also demonstrated that a simple GA can be used to produce results that are comparable with problem-specific approach. The proposed approach can also be used to optimise any objective function without changing the basic GA routine.