A genetic algorithm based heuristic for scheduling of virtual manufacturing cells (VMCs)

We present a genetic algorithm (GA) based heuristic approach for job scheduling in virtual manufacturing cells (VMCs). In a VMC, machines are dedicated to a part as in a regular cell, but machines are not physically relocated in a contiguous area. Cell configurations are therefore temporary, and assignments are made to optimize the scheduling objective under changing demand conditions. We consider the case where there are multiple jobs with different processing routes. There are multiple machine types with several identical machines in each type and are located in different locations in the shop floor. Scheduling objective is weighted makespan and total traveling distance minimization. The scheduling decisions are the (i) assignment of jobs to the machines, and (ii) the job start time at each machine. To evaluate the effectiveness of the GA heuristic we compare it with a mixed integer programming (MIP) solution. This is done on a wide range of benchmark problem. Computational results show that GA is promising in finding good solutions in very shorter times and can be substituted in the place of MIP model.     

Optimum loading of machines in a flexible manufacturing system using a mixed-integer linear mathematical programming model and genetic algorithm

Machine loading problem in a flexible manufacturing system (FMS) encompasses various types of flexibility aspects pertaining to part selection and operation assignments. The evolution of flexible manufacturing systems offers great potential for increasing flexibility by ensuring both cost-effectiveness and customized manufacturing at the same time. This paper proposes a linear mathematical programming model with both continuous and zero-one variables for job selection and operation allocation problems in an FMS to maximize profitability and utilization of system. The proposed model assigns operations to different machines considering capacity of machines, batch-sizes, processing time of operations, machine costs, tool requirements, and capacity of tool magazine. A genetic algorithm (GA) is then proposed to solve the formulated problem. Performance of the proposed GA is evaluated based on some benchmark problems adopted from the literature. A statistical test is conducted which implies that the proposed algorithm is robust in finding near-optimal solutions. Comparison of the results with those published in the literature indicates supremacy of the solutions obtained by the proposed algorithm for attempted model.     

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.     

带不相关并行机和有限缓冲MHFS调度的混合启发式算法

研究每阶段含不相关并行机的多阶段混合流水车间问题(MHFSP),工件的加工时间取决于所分配的机器,相邻阶段之间缓冲区能力有限.鉴于直接求解该NP-hard问题较为困难,将其转化为带阻塞和不相关并行机的MHFSP (BMHFSP-UPM),建立整数规划模型,基于遗传算法(GA)和禁忌搜索(TS)提出一种混合启发式算法(HHGA&TS)进行求解.在该算法中,设计基于多阶段并行加工的二维矩阵编码方案,继而基于二维矩阵元胞组的初始解群体表述设计参数自适应策略;引入基于工件位-基因位的单点倒置交叉以及基于机器号的单点变异过程,利用GA求解机制完成解更新过程;设计机器号次序交换(MNE)、工件位置交换(JNE)、工件工序变异(JNM)三种邻域解移动规则,从而完成基于MNE-JNE-JNM的TS二次优化.仿真实验测试了多达120个工件的720组不同规模实例,结果表明,相较于GA、TS及NEH-IGA,所提出的混合启发式算法在解的质量方面表现更佳.     

Capacitated lot sizing and sequence dependent setup scheduling: an iterative approach for integration

We consider here the lot sizing and scheduling problem in single-level manufacturing systems. The shop floor is composed of unrelated parallel machines with sequence dependent setup times. We propose an integer programming model embedding precise capacity information due to scheduling constraints in a classical lot-sizing model. We also propose an iterative approach to generate a production plan taking into account scheduling constraints due to changeover setup times. The procedure executes two decision modules per iteration: a lot-sizing module and a scheduling module. The capacitated lot-sizing problem is solved to optimality considering estimated data and aggregate information, and the scheduling problem is solved by a GRASP heuristic. In the proposed scheme the information flow connecting the two levels is managed in each iteration. We report a set of computational experiments and discuss future work.     

Scheduling of Virtual Cellular Manufacturing Systems: A Biogeography-Based Optimization Algorithm

Virtual cellular manufacturing system (VCMS) is one of the modern strategies in the production facilities layout, which has attracted considerable attention in recent years. In this system, machines are located in different positions on the shop floor and virtual cells are a logical grouping of machines, jobs, and workers from the viewpoint of the production control system. These features not only enhance the system’s agility but also allow a dynamic reassignment of cells as demand changes. This paper addresses the VCMS scheduling problems where the jobs have different orders on machines and the objective is to simultaneously minimize the weighted sum of the makespan and total traveling distance in order to create a balance between criteria. The research methodology firstly consists of a mathematical programming model with regard to the production constraints in order to describe the characteristics of the VCMS. Secondly, a basic genetic algorithm (GA), a biogeography-based optimization (BBO) algorithm, an algorithm based on hybridization of BBO and GA, and the BBO algorithm accompanied by restart phase are developed to solve the VCMS scheduling problems. The developed algorithms have been compared to each other and their performance are evaluated in terms of their best solution and computational time as effectiveness and efficiency criteria, respectively. Consequently, the performance of the best algorithm has been evaluated by the state-of-the-art algorithm, GA, in the literature. The results show that the best algorithm based on BBO could find solutions at least as good as the last famous algorithm, GA, in the literature.     

An efficient hybrid self-learning method for stochastic cellular manufacturing problem: A queuing-based analysis

This paper addresses a new version of Stochastic Mixed-Integer model to design cellular manufacturing systems (CMSs) under random parameters described by continues distributions. In an uncertain environment processing time, part demand, product mix, inter-arrival time and etc. may change over the period of time. Thus, during planning horizon since any of the parameters of the problem may vary widely, design decisions may be in effect. So, in this research to overcome such drawback, it’s assumed that processing time for parts on machines and arrival time for parts to cells are stochastic and described by continues distribution which yields more flexibility to analyze manufacturing framework. In such case, there are some approaches such as stochastic programming (SP), robust optimization (RO) and queuing theory which can formulate and analyze this problem. In this paper, it’s assumed that each machine works as a server and each part is a customer where servers should service to customers. Therefore, formed cells define a queue system which can be optimized by queuing theory. In this way, by optimizing a desired queue system measurement such as maximizing the probability that a server is busy, the optimal cells and part families will be formed. To solve such a stochastic and non-linear model, an efficient hybrid method based on new combination of genetic algorithm (GA) and simulated annealing (SA) algorithm will be proposed where SA is a sub-ordinate part of GA under a self-learning rule (SLR) criterion. This integrative combination algorithm is compared against global solutions obtained from branch-and-bound algorithm and a benchmark heuristic algorithm existing in the literature. Also, sensitivity analysis will be performed to illustrate behavior of the model.     

Solving a group layout design model of a dynamic cellular manufacturing system with alternative process routings,lot splitting and flexible reconfiguration by simulated annealing

This paper presents a novel mixed-integer non-linear programming model for the layout design of a dynamic cellular manufacturing system (DCMS). In a dynamic environment, the product mix and part demands are varying during a multi-period planning horizon. As a result, the best cell configuration for one period may not be efficient for successive periods, and thus it necessitates reconfigurations. Three major and interrelated decisions are involved in the design of a CMS; namely cell formation (CF), group layout (GL) and group scheduling (GS). A novel aspect of this model is concurrently making the CF and GL decisions in a dynamic environment. The proposed model integrating the CF and GL decisions can be used by researchers and practitioners to design GL in practical and dynamic cell formation problems. Another compromising aspect of this model is the utilization of multi-rows layout to locate machines in the cells configured with flexible shapes. Such a DCMS model with an extensive coverage of important manufacturing features has not been proposed before and incorporates several design features including alternate process routings, operation sequence, processing time, production volume of parts, purchasing machine, duplicate machines, machine capacity, lot splitting, intra-cell layout, inter-cell layout, multi-rows layout of equal area facilities and flexible reconfiguration. The objective of the integrated model is to minimize the total costs of intra and inter-cell material handling, machine relocation, purchasing new machines, machine overhead and machine processing. Linearization procedures are used to transform the presented non-linear programming model into a linearized formulation. Two numerical examples taken from the literature are solved by the Lingo software using a branch-and-bound method to illustrate the performance of this model. An efficient simulated annealing (SA) algorithm with elaborately designed solution representation and neighborhood generation is extended to solve the proposed model because of its NP-hardness. It is then tested using several problems with different sizes and settings to verify the computational efficiency of the developed algorithm in comparison with the Lingo software. The obtained results show that the proposed SA is able to find the near-optimal solutions in computational time, approximately 100 times less than Lingo. Also, the computational results show that the proposed model to some extent overcomes common disadvantages in the existing dynamic cell formation models that have not yet considered layout problems.     

A simulated annealing algorithm for the job shop cell scheduling problem with intercellular moves and reentrant parts

This paper addresses the problem of scheduling parts in job shop cellular manufacturing systems by considering exceptional parts that need to visit machines in different cells and reentrant parts which need to visit some machines more than once in non-consecutive manner. Initially, an integer linear programming (ILP) model is presented for the problem to minimize the makespan, which considers intercellular moves and non-consecutive multiple processing of parts on a machine. Due to the complexity of the model, a simulated annealing (SA) based solution approach is developed to solve the problem. To increase the efficiency of the search algorithm, a neighborhood structure based on the concept of blocks is applied. Subsequently, the efficiency of the ILP model and the performance of the proposed SA are assessed over a set of problem instances taken from the literature. The proposed ILP model was coded in Lingo 8.0 and the solution obtained by the proposed SA was compared to the optimal values. The computational results demonstrate that the proposed ILP model and SA algorithm are effective and efficient for this problem.     

Multi-item dynamic production-distribution planning in process industries with divergent finishing stages

This paper examines a multi-item dynamic production-distribution planning problem between a manufacturing location and a distribution center. Transportation costs between the manufacturing location and the distribution center offer economies of scale and can be represented by general piecewise linear functions. The production system at the manufacturing location is a serial process with a multiple parallel machines bottleneck stage and divergent finishing stages. A predetermined production sequence must be maintained on the bottleneck machines. A tight mixed-integer programming model of the production process is proposed, as well as three different formulations to represent general piecewise linear functions. These formulations are then used to develop three equivalent mathematical programming models of the manufacturer-distributor flow planning problem. Valid inequalities to strengthen these formulations are proposed and the strategy of adding extra 0–1 variables to improve the branching process is examined. Tests are performed to compare the computational efficiency of these models. Finally, it is shown that by adding valid inequalities and extra 0–1 variables, major computational improvements can be achieved.     

The economic lot scheduling problem in limited-buffer flexible flow shops: Mathematical models and a discrete fruit fly algorithm

This paper considers the lot scheduling problem in the flexible flow shop with limited intermediate buffers to minimize total cost which includes the inventory holding and setup costs. The single available mathematical model by Akrami et al. (2006) for this problem suffers from not only being non-linear but also high size-complexity. In this paper, two new mixed integer linear programming models are developed for the problem. Moreover, a fruit fly optimization algorithm is developed to effectively solve the large problems. For model’s evaluation, this paper experimentally compares the proposed models with the available model. Moreover, the proposed algorithm is also evaluated by comparing with two well-known algorithms (tabu search and genetic algorithm) in the literature and adaption of three recent algorithms for the flexible flow shop problem. All the results and analyses show the high performance of the proposed mathematical models as well as fruit fly optimization algorithm.     

A new approach to scheduling in manufacturing for power consumption and carbon footprint reduction

Manufacturing scheduling strategies have historically emphasized cycle time; in almost all cases, energy and environmental factors have not been considered in scheduling. This paper presents a new mathematical programming model of the flow shop scheduling problem that considers peak power load, energy consumption, and associated carbon footprint in addition to cycle time. The new model is demonstrated using a simple case study: a flow shop where two machines are employed to produce a variety of parts. In addition to the processing order of the jobs, the proposed scheduling problem considers the operation speed as an independent variable, which can be changed to affect the peak load and energy consumption. Even with a single objective, finding an optimal schedule is notoriously difficult, so directly applying commercial software to this multi-objective scheduling problem requires significant computation time. This paper calls for the development of more specialized algorithms for this new scheduling problem and examines computationally tractable approaches for finding near-optimal schedules.     

Scheduling optimization of a stochastic flexible job-shop system with time-varying machine failure rate

Due to environmental circumstances encountered in manufacturing processes, operating machines need to be maintained preventively, so as to ensure satisfactory operating condition. This paper investigates a scheduling problem in a flexible job-shop system with maintenance considerations where each operation can be processed by a machine out of a set of capable machines, and so, jobs may have alternative routes. Machine failure rates are assumed to be time-varying. This is a real assumption comes from a fact in realistic environments, where failure rate of a machine is variable when environmental situations like shop temperature, shop light, shop humidity or even worker skill change significantly. Moreover, in order to more close the addressed problem into the situations encountered in real world, the processing times and due dates are considered to be stochastic parameters. A mixed integer linear programming (MILP) model is constructed for addressed problem with the objective of number of tardy jobs and a minimum total availability constraint. Then a simulation-optimization framework based on a simulated annealing (SA) optimizer and Monte Carlo (MC) simulator is presented to solve the problem.     

A simulated annealing algorithm approach to hybrid flow shop scheduling with sequence-dependent setup times

One of the scheduling problems with various applications in industries is hybrid flow shop. In hybrid flow shop, a series of n jobs are processed at a series of g workshops with several parallel machines in each workshop. To simplify the model construction in most research on hybrid flow shop scheduling problems, the setup times of operations have been ignored, combined with their corresponding processing times, or considered non sequence-dependent. However, in most real industries such as chemical, textile, metallurgical, printed circuit board, and automobile manufacturing, hybrid flow shop problems have sequence-dependent setup times (SDST). In this research, the problem of SDST hybrid flow shop scheduling with parallel identical machines to minimize the makespan is studied. A novel simulated annealing (NSA) algorithm is developed to produce a reasonable manufacturing schedule within an acceptable computational time. In this study, the proposed NSA uses a well combination of two moving operators for generating new solutions. The obtained results are compared with those computed by Random Key Genetic Algorithm (RKGA) and Immune Algorithm (IA) which are proposed previously. The results show that NSA outperforms both RKGA and IA.     

Robust manufacturing system design using multi objective genetic algorithms,Petri nets and Bayesian uncertainty representation

Decisions involving robust manufacturing system configuration design are often costly and involve long term allocation of resources. These decisions typically remain fixed for future planning horizons and failure to design a robust manufacturing system configuration can lead to high production and inventory costs, and lost sales costs. The designers need to find optimal design configurations by evaluating multiple decision variables (such as makespan and WIP) and considering different forms of manufacturing uncertainties (such as uncertainties in processing times and product demand). This paper presents a novel approach using multi objective genetic algorithms (GA), Petri nets and Bayesian model averaging (BMA) for robust design of manufacturing systems. The proposed approach is demonstrated on a manufacturing system configuration design problem to find optimal number of machines in different manufacturing cells for a manufacturing system producing multiple products. The objective function aims at minimizing makespan, mean WIP and number of machines, while considering uncertainties in processing times, equipment failure and repairs, and product demand. The integrated multi objective GA and Petri net based modeling framework coupled with Bayesian methods of uncertainty representation provides a single tool to design, analyze and simulate candidate models while considering distribution model and parameter uncertainties.     

基于数字化人的生产现场信息化研究

针对目前车间生产现场数字化制造所存在的信息化盲区问题,利用移动通讯技术的优势,提出了数字化人的概念,给出了理论模型,探讨了数字化人一人和人一机的协同关系及数字化人实现的关键技术,最后建立了基于数字化人的车间生产现场的信息化系统结构,给出了运行实例。     

基于数字化人的生产现场信息化研究

针对目前车间生产现场数字化制造所存在的信息化盲区问题,利用移动通讯技术的优势,提出了数字化人的概念,给出了理论模型,探讨了数字化人-人和人-机的协同关系及数字化人实现的关键技术,最后建立了基于数字化人的车间生产现场的信息化系统结构,给出了运行实例。     

Effective selection and allocation of material handling equipment for stochastic production material demand problems using genetic algorithm

This paper addresses the stochastic production demand problem in a manufacturing company. The objective of this research is to minimize the waiting time of production workstations and reduce stochastic production material problems through coordinating pickup and delivery orders in a warehouse. RFID technology is adopted to visualize the actual status of operations in production and warehouse environments. A mathematical model is developed to address this problem and a meta-heuristic algorithm using genetic algorithm (GA) is also developed to improve performance. Computational experiments are undertaken to examine the performance of the algorithm when dealing with congestion in cases of heavy and normal demand for production material. The overall result shows that the algorithm efficiently minimizes the total makespan of the production shop floor.     

Minimizing makespan and flowtime in a parallel multi-stage cellular manufacturing company

This study proposes a 3-phase solution approach for a multi-product parallel multi-stage cellular manufacturing company. The study focuses on a case study involving a shoe manufacturing plant in which products are produced according to their due dates. The investigated manufacturing process has three stages, namely lasting cells, rotary injection molding cells, finishing-packaging cells. System performance is measured based on total flowtime and makespan. We propose a 3-phase solution approach to tackle the problem; 1) the first phase of the proposed approach allocates manpower to operations in the lasting cells and finishing-packaging cells, independently. The objective is to maximize the production rates in these cells. 2) The second phase includes cell loading to determine product families based on a similarity coefficient using mathematical modeling and genetic algorithms (GA). The proposed GA algorithm for cell loading performs mutation prior to crossover, breaking from traditional genetic algorithm flow. The performance measures flow time and makespan are considered in this phase. 3) Flow shop scheduling is then performed to determine the product sequence in each (lasting, rotary injection molding, finishing-packaging) cell group. This 3-phase solution approached is repeated with alternative manpower level allocation to lasting and finishing-packaging cells where the total manpower level remains the same.     

Parallel-identical-machine job-shop scheduling with different stage-dependent buffering requirements

The neglect of buffering requirements in a classical job shop scheduling system often results in inapplicability in many complex real-world applications. To overcome this inapplicability, a new and more generalised scheduling problem is proposed under different stage-dependent buffering requirements and parallel use of identical-function machine units at each processing stage in job shop environments. The problem is formulated as a mixed integer programming model that can be exactly solved by ILOG-CPEX for small-size instances. Moreover, a hybrid metaheuristic algorithm embedded with a state-of-the-art constructive algorithm is developed. The computational experiment shows that the proposed metaheuristic can efficiently solve large-size instances. The result analysis indicates that the proposed approach can provide better configuration of real-world scheduling systems. The proposed DBPMJSS methodology has a potential to analyse, model and solve many industrial systems with the requirements of buffering conditions, particularly for manufacturing, railway, healthcare and mining industries.