A hybrid heuristic to solve the parallel machines job-shop scheduling problem

This paper presents an advanced software system for solving the flexible manufacturing systems (FMS) scheduling in a job-shop environment with routing flexibility, where the assignment of operations to identical parallel machines has to be managed, in addition to the traditional sequencing problem. Two of the most promising heuristics from nature for a wide class of combinatorial optimization problems, genetic algorithms (GA) and ant colony optimization (ACO), share data structures and co-evolve in parallel in order to improve the performance of the constituent algorithms. A modular approach is also adopted in order to obtain an easy scalable parallel evolutionary-ant colony framework. The performance of the proposed framework on properly designed benchmark problems is compared with effective GA and ACO approaches taken as algorithm components.     

Solving Part-Type Selection and Operation Allocation Problems in an FMS: An Approach Using Constraints-Based Fast Simulated Annealing Algorithm

Production planning of a flexible manufacturing system (FMS) is plagued by two interrelated problems, namely 1) part-type selection and 2) operation allocation on machines. The combination of these problems is termed a machine loading problem, which is treated as a strongly NP-hard problem. In this paper, the machine loading problem has been modeled by taking into account objective functions and several constraints related to the flexibility of machines, availability of machining time, tool slots, etc. Minimization of system unbalance (SU), maximization of system throughput (TH), and the combination of SU and TH are the three objectives of this paper, whereas two main constraints to be satisfied are related to time and tool slots available on machines. Solutions for such problems even for a moderate number of part types and machines are marked by excessive computational complexities and thus entail the application of some random search optimization techniques to resolve the same. In this paper, a new algorithm termed as constraints-based fast simulated annealing (SA) is proposed to address a well-known machine loading problem available in the literature. The proposed algorithm enjoys the merits of simple SA and simple genetic algorithm and is designed to be free from some of their drawbacks. The enticing feature of the algorithm is that it provides more opportunity to escape from the local minimum. The application of the algorithm is tested on standard data sets, and superiority of the same is witnessed. Intensive experimentations were carried out to evaluate the effectiveness of the proposed algorithm, and the efficacy of the same is authenticated by efficiently testing the performance of algorithm over well-known functions     

A modeling technique for loading and scheduling problems in FMS

In recent years, due to highly competitive market conditions, it has become necessary for manufacturing systems to have quick response times and high flexibility. Flexible manufacturing systems (FMS's) have gained attention in response to this challenge. FMS has the ability to produce a variety of parts using the same system. However this flexibility comes at the price, which is the development of efficient and effective methods for integrated production planning, and control.In this paper, we analyze the production planning problem in flexible manufacturing systems. We address the problems of part loading, tool loading, and part scheduling. We assume that there is a set of tools with known life and a set of machines that can produce a variety of parts. A batch of various part types is routed through this system with the assumption that the processing time and cost vary with the assignment of parts to different machines and assignment of various tool sets to machines. We developed a mathematical model to select machines and assign operations and the required tools to machines in order to minimize the summation of maximum completion time, material handling time, and total processing time.We first integrate and formulate loading, and routing, two of the most important FMS planning problems, as a 0–1 mixed integer programming problem. We then take the output from the integrated planning model and generate a detailed operations schedule. The results reported in this paper demonstrate the model efficiency and examine the performance of the system with respect to measures such as production rate and utilization.     

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.     

A heuristic based on multi-stage programming approach for machine-loading problem in a flexible manufacturing system

Manufacturing industries are rapidly changing from economies of scale to economies of scope, characterized by short product life cycles and increased product varieties. This implies a need to improve the efficiency of job shops while still maintaining their flexibility. These objectives are achieved by Flexible manufacturing systems (FMS). The basic aim of FMS is to bring together the productivity of flow lines and the flexibility of job shops. This duality of objectives makes the management of an FMS complex. In this article, the loading problem in random type FMS, which is viewed as selecting a subset of jobs from the job pool and allocating them among available machines, is considered. A heuristic based on multi-stage programming approach is proposed to solve this problem. The objective considered is to minimize the system unbalance while satisfying the technological constraints such as availability of machining time and tool slots. The performance of the proposed heuristic is tested on 10 sample problems available in FMS literature and compared with existing solution methods. It has been found that the proposed heuristic gives good results.     

Multi-period part selection and loading problems in flexible manufacturing systems

We consider multi-period part selection and loading problems in flexible manufacturing systems with the objective of minimizing subcontracting costs. The part selection problem is to select sets of part types and to determine their quantities to be produced during the upcoming planning horizon while satisfying due dates of all orders for the parts, and the loading problem involves allocation of operations and required tools to machines. Production demands should be satisfied for periods through subcontracting if production demands cannot be satisfied by the system due to machine capacity or tool magazine capacity constraints. For the part selection and loading problems, we develop three iterative algorithms, called the forward algorithm, the backward algorithm and the capacity approximation algorithm, that solve the part selection and loading problems iteratively for each period. To compare the three algorithms, a series of computational experiments is done on randomly generated test problems.     

A novel 0-1 linear integer programming model for dynamic machine-tool selection and operation allocation in a flexible manufacturing system

This paper considers a problem of dynamic machine-tool selection and operation allocation with part and tool movement policies in a flexible manufacturing system (FMS) environment. For this purpose, a novel 0-1 linear integer programming model is presented in such a way that each part and each tool can move during the production phase. It is assumed that there are a given set of tools and machines that can produce different kinds of orders (or part types). The objective of this model is to determine a machine-tool combination for each operation of the part type by minimizing some production costs, such as machining costs, setup costs, material handling costs and tool movement costs. In addition, due to the NP-hard nature of the problem, a new heuristic method based on five simple procedures (FSP) is proposed for solving the given problem, whose performance is tested on a number of randomly generated problems. The related results are compared with results obtained by a branch-and-bound method. It has been found that the proposed heuristic method gives good results in terms of objective function values and CPU times.     

Application of genetic algorithm to computer-aided process planning in preliminary and detailed planning

Computer-aided process planning (CAPP) is an important interface between computer-aided design (CAD) and computer-aided manufacturing (CAM) in the computer integrated manufacturing (CIM) environment. A good process plan of a part is built up based on two elements: (1) optimized sequence of the operations of the part; and (2) optimized selection of the machine, cutting tool and tool access direction (TAD) for each operation. On the other hand, two levels of planning in the process planning is suggested: (1) preliminary and (2) secondary and detailed planning. In this paper for the preliminary stage, the feasible sequences of operations are generated based on the analysis of constraints and using a genetic algorithm (GA). Then in the detailed planning stage, using a genetic algorithm again which prunes the initial feasible sequences, the optimized operations sequence and the optimized selection of the machine, cutting tool, and TAD for each operation are obtained. By applying the proposed GA in two levels of planning, the CAPP system can generate optimal or near-optimal process plans based on a selected criterion. A number of case studies are carried out to demonstrate the feasibility and robustness of the proposed algorithm. This algorithm performs well on all the test problems, exceeding or matching the solution quality of the results reported in the literature for most problems. The main contribution of this work is to emerge the preliminary and detailed planning, implementation of compulsive and additive constraints, optimization sequence of the operations of the part, and optimization selection of machine, cutting tool and TAD for each operation using the proposed GA, simultaneously.     

A parametric fuzzy logic approach to dynamic part routing under full routing flexibility

Manufacturing flexibility is a competitive weapon for surviving today’s highly variable and volatile markets. It is critical therefore, to select the appropriate type of flexibility for a given manufacturing system, and to design effective strategies for using this flexibility in a way to improve the system performance. This study focuses on full routing flexibility which includes not only alternative machines for operations but also alternative sequences of operations for producing the same work piece. Upon completion of an operation, an on-line dispatching decision called part routing is required to choose one of the alternatives as the next step. This study introduces three new approaches, including a fuzzy logic approach, for dynamic part routing. The fuzzy part routing system adapts itself to the characteristics of a given flexible manufacturing system (FMS) installation by setting the key parameters of the membership functions as well as its Takagi-Sugeno type rule base, in such a way to capture the bottlenecks in the environment. Thus, the model does not require a search or training for the parameter set. The proposed approaches are tested against several crisp and fuzzy routing algorithms taken from the literature, by means of extensive simulation experiments in hypothetical FMS environments under variable system configurations. The results show that the proposed fuzzy approach remains robust across different system configurations and flexibility levels, and performs favourably compared to the other algorithms. The results also reveal important characteristic behaviour regarding routing flexibility.     

A genetic algorithm approach to the multiple machine tool selection problem

A number of earlier researches have emphasized the on-the-job scheduling problems that occur with a single flexible machine. Two solutions to the problem have generally been considered; namely minimization of tool switches and minimization of tool switching instances. Methods used to solve the problems have included KTNS heuristic, dual-based relaxation heuristic, and non-LP-based branch-and-bound methods. However, scant literature has considered the case of job scheduling on multiple parallel machines which invokes another problem involving machine assignment. This paper addresses the problem of job scheduling and machine assignment on a flexible machining workstation (FMW) equipped with multiple parallel machines in a tool-sharing environment. Under these circumstances, the authors have attempted to model the problem with the objective of simultaneously minimizing both the number of tool switches and the number of tool switching instances. Furthermore, a set of realistic constraints has been included in the investigation. A novel genetic algorithm (GA) heuristic has been developed to solve the problem, and performance results show that GA is an appropriate solution.     

Ant colony optimization approach to a fuzzy goal programming model for a machine tool selection and operation allocation problem in an FMS

Due to the global competition in manufacturing environment, firms are forced to consider increasing the quality and responsiveness to customization, while decreasing costs. The evolution of flexible manufacturing systems (FMSs) offers great potential for increasing flexibility and changing the basis of competition by ensuring both cost effective and customized manufacturing at the same time. Some of the important planning problems that need realistic modelling and quicker solution especially in automated manufacturing systems have assumed greater significance in the recent past. The language used by the industrial workers is fuzzy in nature, which results in failure of the models considering deterministic situations. The situation in the real life shop floor demands to adopt fuzzy-based multi-objective goals to express the target set by the management. This paper presents a fuzzy goal programming approach to model the machine tool selection and operation allocation problem of FMS. An ant colony optimization (ACO)-based approach is applied to optimize the model and the results of the computational experiments are reported.     

FMS scheduling with knowledge based genetic algorithm approach

In this paper a complex scheduling problem in flexible manufacturing system (FMS) has been addressed with a novel approach called knowledge based genetic algorithm (KBGA). The literature review indicates that meta-heuristics may be used for combinatorial decision-making problem in FMS and simple genetic algorithm (SGA) is one of the meta-heuristics that has attracted many researchers. This novel approach combines KB (which uses the power of tacit and implicit expert knowledge) and inherent quality of SGA for searching the optima simultaneously. In this novel approach, the knowledge has been used on four different stages of SGA: initialization, selection, crossover, and mutation. Two objective functions known as throughput and mean flow time, have been taken to measure the performance of the FMS. The usefulness of the algorithm has been measured on the basis of number of generations used for achieving better results than SGA. To show the efficacy of the proposed algorithm, a numerical example of scheduling data set has been tested. The KBGA was also tested on 10 different moderate size of data set to show its robustness for large sized problems involving flexibility (that offers multiple options) in FMS.     

A computer simulation model for studying the performance of coordinate measuring machines

The increasing trend toward computer-integrated manufacturing (CIM) in today's industry created a need for an effective process control. The objective of the inspection process is not only preventing shipment of defective parts but also providing a feedback to keep the manufacturing process in control. Through data processing capability, speed, and flexibility of operation, coordinate measuring machines (CMMs) play an important role for computer-integrated manufacturing (CIM). This paper introduces coordinate measuring machines and studies their performance. A computer simulation method for studying the performance of such machines working in a production line is developed. In this paper, CMM performance is measured by its speed and flexibility in performing measurements. In flexible manufacturing systems (FMS), CMMs serve as the inspection work station where arrival time of parts to be measured vary according to the flow of operations. The developed simulation model provides information about the machine, scheduled time for parts to be measured, and delay time for the measuring process.     

Simulation modelling and analysis of part and tool flow control decisions in a flexible manufacturing system

This paper presents the details of a simulation study carried out for analyzing the impact of scheduling rules that control part launching and tool request selection decisions of a flexible manufacturing system (FMS) operating under tool movement along with part movement policy. Two different scenarios have been investigated with respect to the operation of FMS. In scenario 1, the facilities such as machines, tool transporter and part transporter are assumed to be continuously available without breakdowns, whereas in scenario 2, these facilities are prone to failures. For each of these scenarios, a discrete-event simulation model is developed for the purpose of experimentation. A number of scheduling rules are incorporated in the simulation models for the part launching and tool request selection decisions. The performance measures evaluated are mean flow time, mean tardiness, mean waiting time for tool and percentage of tardy parts. The results obtained through the simulation have been statistically analyzed. The best possible scheduling rule combinations for part launching and tool request selection have been identified for the chosen FMS.     

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.     

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.     

Tool allocation in flexible manufacturing systems with tool alternatives

In this paper, a heuristic approach for tool selection in flexible manufacturing systems (FMS) is presented. The proposed approach utilizes the ratio of tool life over tool size (L/S) for tool selection and allocation. The proposed method selects tool types with high L/S ratios by considering tool alternatives for the operations assigned to each machine. The performance of the method is demonstrated in sample problems as static examples, as well as in a simulation study for further analysis. This study also presents a survey of several approaches related to loading and tool allocation problems in FMS, highlights the importance of tooling, and discusses the practical aspects of tool-oriented decision-making. An extended framework, which expands on the L/S concept, is also presented.     

An improved adaptive genetic algorithm based on hormone modulation mechanism for job-shop scheduling problem

An improved adaptive genetic algorithm (IAGA) for solving the minimum makespan problem of job-shop scheduling problem (JSP) is presented. Though the traditional genetic algorithm (GA) exhibits implicit parallelism and can retain useful redundant information about what is learned from previous searches by its representation in individuals in the population, yet GA may lose solutions and substructures due to the disruptive effects of genetic operators and is not easy to regulate GA’s convergence. The proposed IAGA is inspired from hormone modulation mechanism, and then the adaptive crossover probability and adaptive mutation probability are designed. The proposed IAGA is characterized by simplifying operations, high search precision, overcoming premature phenomenon and slow evolution. The proposed method by employing operation-based encoding is effectively applied to solve a dynamic job-shop scheduling problem (DJSP) and a complicated contrastive experiment of JSP in manufacturing system. Meanwhile, in order to ensure to create a feasible solution, a new method for crossover operation is adopted, named, partheno-genetic operation (PGO). The computational results validate the effectiveness of the proposed IAGA, which can not only find optimal or close-to-optimal solutions but can also obtain both better and more robust results than the existing genetic algorithms reported recently in the literature. By employing IAGA, machines can be used more efficiently, which means that tasks can be allocated appropriately, production efficiency can be improved, and the production cycle can be shortened efficiently.     

A problem space genetic algorithm in multiobjective optimization

In this study, a problem space genetic algorithm (PSGA) is used to solve bicriteria tool management and scheduling problems simultaneously in flexible manufacturing systems. The PSGA is used to generate approximately efficient solutions minimizing both the manufacturing cost and total weighted tardiness. This is the first implementation of PSGA to solve a multiobjective optimization problem (MOP). In multiobjective search, the key issues are guiding the search towards the global Pareto-optimal set and maintaining diversity. A new fitness assignment method, which is used in PSGA, is proposed to find a well-diversified, uniformly distributed set of solutions that are close to the global Pareto set. The proposed fitness assignment method is a combination of a nondominated sorting based method which is most commonly used in multiobjective optimization literature and aggregation of objectives method which is popular in the operations research literature. The quality of the Pareto-optimal set is evaluated by using the performance measures developed for multiobjective optimization problems.     

Drilling reconfigurable machine tool selection and process parameters optimization as a function of product demand

Special purpose machines (SPMs) are customized machine tools that perform specific machining operations in a variety of production contexts, including drilling-related operations. This research investigates the effect of optimal process parameters and SPM configuration on the machine tool selection problem versus product demand changes. A review of previous studies suggests that the application of optimization in the feasibility analysis stage of machine tool selection has received less attention by researchers. In this study, a simulated model using genetic algorithm is proposed to find the optimal process parameters and machine tool configuration. During the decision-making phase of machine tool selection, unit profit is targeted as high as possible and is given by the value of the following variables: SPM configuration selection, machining unit assignment to each operation group, and feed and cutting speed of all operations. The newly developed model generates any random chromosome characterized by feasible values for process parameters. Having shown how the problem is formulated, the research presents a case study which exemplifies the operation of the proposed model. The results show that the optimization results can provide critical information for making logical, accurate, and reliable decisions when selecting SPMs.