Methods for activating the decision-making process that is used for controlling flexible manufacturing systems

This paper deals with controlling flexible manufacturing systems (FMS) operating in volatile production environments. Shnits et al. (Shnits, B., Rubinovitz, J., and Sinreich, D., 2004. Multicriteria dynamic scheduling methodology for controlling a flexible manufacturing system. International Journal of Production Research, 42 (17), 3457–3472.) and Shnits and Sinreich (Shnits, B. and Sinreich, D., 2006. Controlling flexible manufacturing systems based on a dynamic selection of an appropriate operational criteria and scheduling policy. International Journal of Flexible Manufacturing Systems, 18 (1), 1–27.) developed a multi-criteria dynamic scheduling mechanism for controlling an FMS that can cope with such environments. An important part of this mechanism functioning, which impinges directly on its performance, is the activation of its decision-making process. This study continues the research presented in the above-mentioned papers and proposes different triggering methods for activating the control system decision-making process. The operational conditions for each suggested triggering method were analysed and a comparative analysis between these methods was performed. It was revealed that the highly dynamic triggering method, which activates the decision-making process right before a resource becomes available, outperformed the triggering methods that use a predefined scheduling period.     

A constructive heuristic algorithm for concurrently selecting and sequencing jobs in an FMS environment

This paper deals with the concurrent solution of the loading and scheduling problems in a flexible manufacturing system ( FMS) environment. It is assumed that the FMS environment has production planned periodically and each job in the system has a number of operations to be processed on flexible machines. A heuristic approach using a constructive scheduling method is developed to solve the FMS loading and scheduling problems concurrently. The computational results are compared to an existing procedure that considers a hierarchical approach with a similar problem environment. The comparison study shows a significant improvement over the existing hierarchical procedure. This experiment indicates that a concurrent solution approach can solve the FMS loading and scheduling problems very effectively.     

A loading and dispatching problem in a random flexible manufacturing system

A scheduling problem in a flexible manufacturing system (FMS) is considered to be a composite of two interdependent tasks: loading and sequencing. Formulations are presented for the loading problem with two objectives:

(i) minimization of the system workload unbalance, and

(ii) minimization of system unbalance and the number of late jobs;

including constraints such as the number of tools slots with duplications, unique job routing, nonsplitting of jobs and machine capacity. For both the objectives, heuristic methods are developed and performance is compared with the exact mixed integer programming solutions. A simulation model is developed for investigating the system performance for the problem of minimizing the system unbalance using heuristic and sequential loading methods in conjunction with four—FIFO, SPT, LPT and MOPR—dispatching rules.     

Effects of loading and routeing decisions on performance of flexible manufacturing systems

Research has found that while flexibility is purported to be a prime advantage of flexible manufacturing systems (FMS), it has not yet become a major competitive priority for American and European manufacturers. Moreover, many installed systems either are not very flexible or do not use the available flexibility to the best advantages. We suspect that inappropriate application of the conventional production management concepts to FMS is one of the major factors that hinders current FMSs from capturing their key advantage: flexibility. This paper takes a first step to examine why the conventional job shop loading and fixed routeing concepts fail to capture the flexibility of FMS. Once problems are identified we suggest ways to exploit the FMS flexibility. We further conduct an experiment to investigate FMS performance under different manufacturing policies and operating conditions. The results indicate that the performance of an FMS greatly diminishes when the conventional job shop loading and fixed routeing concepts are applied. This is because the inherent flexibility of the FMS is not fully utilized. Moreover, the operating conditions such as tooling duplication levels and operation processing time variation could also significantly affect the FMS performance.     

Celeritas: a coloured Petri net approach to simulation and control of flexible manufacturing systems

In many areas of computerization today, the capabilities of hardware systems far exceed the sophistication of software systems needed for optimum control. This research is an attempt to advance software control capabilities of flexible manufacturing systems (FMSs). To this end, an FMS controller architecture, called Celeritas, has been designed and a software system conforming to this architecture has been designed and implemented. Celeritas is a generic, data-configurable FMS controller designed using the coloured Petri nets (CP-nets) modelling paradigm augmented with decision support software to provide both FMS simulation and control. Formalisms of the CP-net paradigm provide straightforward representation of both the inherent concurrency and resource conflicts present in such a complex system. Augmentations provide user-defined routines for real-time interfaces to this information which is utilized to provide resource arbitration services among jobs competing for scarce resources and overall job scheduling.     

Fuzzy logic-based FMEA robust design: a quantitative approach for robustness against groupthink in group/team decision-making

Group/team decision-making is an integral part of almost all failure mode and effects analysis (FMEA) projects. A dysfunctional aspect of this decision-making fashion in fuzzy FMEA is that group/team members’ designs for membership functions and IF-THEN rules may be overshadowed by a member’s design. This problem is caused by groupthink, a pitfall known by the Organisational Behaviour science. This study aims to develop a fuzzy FMEA approach which is robust to the problem. We applied the Taguchi’s robust parameter design and investigated the effects of various control parameters namely Defuzzification, Aggregation, And and Implication operators for the fuzzy inference system (FIS). Our experiments illustrate that the control parameters, in the above-mentioned order, have the most effect on the signal-to-noise ratio (SNR). These factors’ optimal setting consists of the Centroid, Sum, Minimum and Minimum levels, respectively.     

FMS Scheduling Simulation Based on an Evolution Algorithm

A FMS（flexible manufacturing system) scheduling algorithm based on an evolution algorithm (EA) is developed by intensively analyzing and researching the scheduling method in this paper.Many factors related to FMS scheduling are considered sufficiently.New explanations for a common kind of the encoding model are given.The rationality of encoding model is ensured by designing a set of new encoding methods,while the simulation experiment is performed.The results show that a FMS scheduling optimum problem with multi-constraint conditions can be effectively solved by a FMS scheduling simulation model based on EA.Comparing this method with others,this algorithm has the advantage of good stability and quick convergence.     

An experimental study of human decision-making in computer-based scheduling of flexible manufacturing system

This paper describes a study which explores human decision-making abilities in scheduling and dispatching of a flexible manufacturing system (FMS) An experiment is described, using an FMS, in which subjects make scheduling and dispatching decisions using a real-time interactive computer-simulation based system. The experimental results demonstrate that human decision-making is superior to general dispatching rules. An explanation of these results and an analysis of subjects' behaviour is presented in the light of information obtained from verbal protocol data     

Scheduling of machines and automated guided vehicles in FMS using differential evolution

This paper addresses the problem of simultaneous scheduling of machines and two identical automated guided vehicles (AGVs) in a flexible manufacturing system (FMS). For solving this problem, a new meta-heuristic differential evolution (DE) algorithm is proposed. The problem consists of two interrelated problems, scheduling of machines and scheduling of AGVs. A simultaneous scheduling of these, in order to minimise the makespan will result in a FMS being able to complete all the jobs assigned to it at the earliest time possible, thus saving resources. An increase in the performance of the FMS under consideration would be expected as a result of making the scheduling of AGVs as an integral part of the overall scheduling activity. The algorithm is tested by using problems generated by various researchers and the makespan obtained by the algorithm is compared with that obtained by other researchers and analysed.     

A novel hybrid meta-heuristic algorithm for a no-wait flexible flow shop scheduling problem with sequence dependent setup times

In this paper, we contemplate the problem of scheduling a set of n jobs in a no-wait flexible flow shop manufacturing system with sequence dependent setup times to minimising the maximum completion time. With respect to NP-hardness of the considered problem, there seems to be no avoiding application of metaheuristic approaches to achieve near-optimal solutions for this problem. For this reason, three novel metaheuristic algorithms, namely population based simulated annealing (PBSA), adapted imperialist competitive algorithm (AICA) and hybridisation of adapted imperialist competitive algorithm and population based simulated annealing (AICA?+?PBSA), are developed to solve the addressed problem. Because of the sensitivity of our proposed algorithm to parameter's values, we employed the Taguchi method as an optimisation technique to extensively tune different parameters of our algorithm to enhance solutions accuracy. These proposed algorithms were coded and tested on randomly generated instances, then to validate the effectiveness of them computational results are examined in terms of relative percentage deviation. Moreover, some sensitive analyses are carried out for appraising the behaviour of algorithms versus different conditions. The computational evaluations manifestly support the high performance of our proposed novel hybrid algorithm against other algorithms which were applied in literature for related production scheduling problems.     

Mitigating supply and production uncertainties with dynamic scheduling using real-time transport information

Supply and production uncertainties can affect the scheduling and inventory performance of final production systems. Facing such uncertainties, production managers normally choose to maintain the original production schedule, or follow the first-in-first-out policy. This paper develops a new, dynamic algorithm policy that considers scheduling and inventory problems, by taking advantage of real-time shipping information enabled by today’s advanced technology. Simulation models based on the industrial example of a chemical company and the Taguchi’s method are used to test these three policies under 81 experiments with varying supply and production lead times and uncertainties. Simulation results show that the proposed dynamic algorithm outperforms the other two policies for supply chain cost. Results from Taguchi’s method show that companies should focus their long-term effort on the reduction of supply lead times, which positively affects the mitigation of supply uncertainty.     

A comparison of tool management strategies and part selection rules for a flexible manufacturing system

An important element in the successful operation of flexible manufacturing systems (FMS) is the management of the tooling component. This paper reports on one aspect of tool management for FMS operations. Four tool allocation and scheduling strategies are compared in the presence of three part selection rules through a simulation study of a five-machine FMS with an automated tool handling system. The tool allocation strategies are similar to those used in industry while the part selection rules are synthesized from the literature on FMS scheduling under tooling constraints. The use of different tooling strategies produces significantly different outcomes in FMS performance.     

Intelligent decision support system for the adaptive control of a flexible manufacturing system with machine and tool flexibility

This paper describes an intelligent decision support system (IDSS) for real time control of a flexible manufacturing system (FMS). The controller is capable of classifying symptoms in developing the control policies on FMSs with flexibility in operation assignment and scheduling of multi-purpose machining centres which have different tools with their own efficiency. The proposed system is implemented by coupling of rule-based IDSS, simulation block and centralised simulation optimiser for elicitation of shop floor control knowledge. This posteriori adaptive controller uses a new bilateral mechanism in simulation optimiser block for offline training of IDSS based on multi-performance criteria simulation optimisation. The proposed intelligent controller receives online information of the FMS current state and trigger appropriate control rule within real-time simulation data exchange. Finally the FMS intelligent controller is validated by a benchmark test problem. Application of this adaptive controller showed that it could be an effective approach for real time control of various flexible manufacturing systems.     

Making full use of taguchi's orthogonal arrays

Taguchi¹ has provided 18 orthogonal arrays which have been widely touted as useful frameworks for planning experiments. Thirteen of these are ‘saturated designs’, that is, they are appropriate for investigating (N - 1) factors in N runs, thus using the full capacity of the design. Here, the other five ‘non-saturated’ designs are discussed. By creating additional, orthogonal columns which provide estimates of interaction effects, we can essentially wring out some additional information over and above that suggested by Taguchi, without additional cost. In particular, if only the linear effect is of interest for any specific factor, one can accommodate more factors than the number suggested by Taguchi. An example is given for illustration.     

Experimental investigation of flexible manufacturing system scheduling decision rules

This paper reports the results of an experimental investigation of scheduling decision rules for a dedicated flexible manufacturing system. A simulation model of an existing flexible manufacturing system (FMS) comprised of 16 computer numerical controlled machines (CNC) was constructed using actual operation routings and machining times to evaluate the performance of various part loading and routing procedures. The results indicate that FMS performance is significantly affected by the choice of heuristic parts scheduling rules.     

Identification of preferred combination of factors in manufacturing bioepoxy/clay nanocomposites

The current study aims to identify the preferred combination of factors for manufacturing bioepoxy/clay nanocomposites based on epoxidised soybean oil (ESO), including material formulation and manufacturing parameters for maximising tensile strengths of nanocomposites according to Taguchi design of experiments (DoEs). A Taguchi mixed-level DoEs with an L ₁₆ orthogonal array was selected. The response was set to achieve the maximum tensile strengths of nanocomposites with a preferred combination of factors determined by the Pareto analysis of variance (ANOVA). The associated results revealed that the ESO content was found to be the most significant factor with a contribution percentage of 66.63% amongst nine factors investigated. This result was followed by two less significant factors, namely mechanical mixing speed and clay content with contribution percentages of 19.09 and 7.01%, respectively. However, other factors of clay type, curing agent type, mechanical mixing temperature and time, as well as sonication frequency and time, were categorised as non-significant factors from the manufacturing and economical point of view. A confirmation test was conducted based on the preferred combination of factors showing good agreement with statistically predicted results.     

Robust design and optimization of material handling in an FMS

Although a significant amount of simulation research has been carried out for design and analysis of flexible manufacturing systems (FMS), it does not provide optimal solutions. In this research, we employ two optimum-seeking methods to design and optimize a manufacturing system. The first method is a Taguchi approach, which uses robust design concept to reduce the output variation. The second method is the response surface methodology (RSM), which combines mathematical and statistical techniques to study the geography of the response surface. The results show that throughput of a selected FMS system can be maximized when both methods are employed.     

Solving the n-job 3-stage flexible flowshop scheduling problem using an agent-based approach

In this paper, a general methodology of agent-based manufacturing systems scheduling, incorporating game theoretic analysis of agent cooperation is presented to solve the n-job 3-stage flexible flowshop scheduling problem. The flowshops are flexible in the sense that a job can be processed by any of the identical machines at each stage. Our objective is to schedule a set of n jobs so as to minimize the makespan. We perform error bound analysis using the lower bound estimates developed in the literature as a datum for comparing the agent-based scheduling solutions with other heuristic solutions. The results of the evaluation show that the agent-based scheduling approach outperforms existing heuristics for the majority of the testing problems.     

Development of a simulation-based optimisation for controlling operation allocation and material handling equipment selection in FMS

Flexible manufacturing system (FMS) is described as a set of computerised numerical controlled machines, input–output buffers interconnected by automated material handling devices. This paper develops a bi-objective operation allocation and material handling equipment selection problem in FMS with the aim of minimising the machine operation, material handling and machine setup costs and maximising the machine utilisation. The proposed model is solved by a modified chaotic ant swarm simulation based optimisation (CAS²O) while applying pre-selection and discrete recombination operators is surveyed a capable method to simulate different experiments of FMS problems. A test problem is selected from the literature to evaluate the performance of the proposed approach. The results validate the effectiveness of the proposed method to solve the FMS scheduling problem.     

A scheduling approach for a flexible manufacturing system

This paper discusses the scheduling problem of a particular flexible manufacturing system (FMS). The two main components of the FMS are a CNC turret lathe and a CNC machining centre. In the system a wide range of different jobs has to be processed. Each job consists of one or more processing operations on one or both machines. Important characteristics of the scheduling problem are sequence-dependent change-over times (on the turret lathe) and transfer times (on both machines and between the machines). The change-over times are caused by the need to exchange tools in the turret when a new part is going to be processed. The transfer times reflect the time needed to perform manual transportation and clamping activities between two subsequent processing (machining) operations of a part. In this paper a branch and bound algorithm is described based on an active schedule strategy. Solutions are compared to results obtained by a simple dispatching rule