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.     

Composite platinum group metals: A new structural material for glass handling equipment and laboratory apparatus

The cost of platinum and platinum-rich alloys inevitably leads to attempts to find cheaper alternative materials, particularly for applications where they are used for structural purposes. Previous work has generally been centred on coating base metals with platinum or on the development of palladium-rich alloys. However, both of these approaches have limitations particularly with regard to strength, corrosion resistance and reliability. The application of zirconia grain stablised technology to this problem has now resulted in the production of a composite trimetallic material, designated ZGS Platinum “TriM”. This largely overcomes the problems associated with earlier materials and dramatically reduces material costs.     

Decentralized autonomous AGV system for material handling

Decentralized control of an autonomous automated guided vehicle system (AGVS) used for material handling is expected to lead to high system flexibility and robustness. A complete control methodology for decentralized autonomous AGVS control was developed and implemented in a computer-integrated manufacturing environment. The methodology addresses all aspects of AGVS functionality: system management, navigation and load transfer. Hierarchical fuzzy behaviour-based control, a reactive navigation scheme, was expanded to multirobot control in semistructured environments by incorporating a priori path optimization and right-of-the-way determination.     

Advances in discrete material handling system design

The paper presents an outline of the research done in the area of facility layout and discrete material handling system design. The objective of this paper is to observe the trend in the literature in the area of manufacturing system design and predict the direction of future research in this area. The paper attempts to link the areas of facility layout design and material flow network design. A methodology for solving the integrated design problem is presented. An algorithm which aids in solving the combined pick-up/drop-off point location and material handling flowpath problem is outlined.     

A performance analytical model of automated material handling system for semiconductor wafer fabrication system

To effectively analyse and evaluate the performances of closed-loop automated material handling system (AMHS) with shortcut and blocking in semiconductor wafer fabrication system, a modified Markov chain model (MMCM) has been proposed. The system characteristics, such as vehicle blockage and system’s shortcut configuration, are well considered in the MMCM. The state space explosion problem and computational challenge due to the increase of AMHS scale can be effectively eliminated. With production data from Interbay material handling system of a 300-mm semiconductor wafer fabrication line, the proposed MMCM is compared with simulation analysis model. The results demonstrate that the proposed MMCM is an effective modelling methodology for AMHS’s performance analysis at system design stage.     

A system for computer-aided thermal design

A systems approach and design unification are used in a method of automating the thermal design of electronic devices.     

Design and operation of single-loop dual-rail inter-bay material handling system

Asynchronized automated material handling systems, e.g. automated electrified monorail systems and automated guided vehicle systems, have been playing important roles in manufacturing. Reliability becomes a critical issue as manufacturing enterprises are moving toward automation. In the past, reliability tissue has not been analysed explicitly for these types of systems. In this research, a new measure was proposed to specify reliability. A mixed integer programming model was developed to design flow paths for a special class of material handling systems, i.e. single-loop dual-rail systems. The model can be used to design systems with higher reliability. The model and application procedure in design and analysis were demonstrated through two case studies.     

An integrated approach to the facilities and material handling system design

The facility layout problem involves the optimal location of manufacturing facilities into a workshop. The classical approach to the layout design is carried out in two separate steps: the first step is the construction of the block layout, i.e. the location of the departments into the workshop, and the second step is the design of the material handling system. The separate optimization of these two aspects of the problem leads to solutions that can be far from the total optimum. In this paper, an integrated approach to the facilities and material handling system design is proposed. Referring to a physical model, named the bay structure , and to a unidirectional AGV system, a genetic approach is proposed to individuate the locations of the departments, the positions of the pickup/delivery stations and the direction of the flow-path. The minimization of material handling cost is adopted as optimality criterion.     

Design of an automated guided vehicle-based material handling system for a flexible manufacturing system

Automated guided vehicle (AGV)-based material handling systems (MHSs), which are widely used in several flexible manufacturing system (FMS) installations, require a number of decisions to be made. These include the number of vehicles required, the track layout, traffic pattern along the AGV tracks, and solving traffic control problems. This paper addresses the key issues involved in the design and operation of AGV-based material handling systems for an FMS. The problems arising from multi-vehicle systems are analysed, and strategies for resolving them are examined using analytical and simulation models.     

A hybrid modelling approach to the design of an AGV-based material handling system for an FMS

The problem of organizing and controlling the material handling activity in an AGV-based material handling system for a flexible manufacturing system involves several decisions such as the number of vehicles required for the system, the layout of the tracks, the dispatching rules for the vehicles and the provision of control zones and buffers. This paper demonstrates the use of a two-stage approach for solving the problem. The required number of vehicles is estimated using an analytical model in the first stage. In the next stage, the effects of AGV failures and AGV dispatching rules on the system performance are observed through simulation studies based on which the AGV dispatching rule can be chosen.     

Minimization of acquisition and operational costs in horizontal material handling system design

This paper considers the problem of minimizing the fixed cost of acquiring material handling transporter:; and the operational cost of material transfer in a manufacturing system. This decision problem, which arises during manufacturing facility design, is modeled using an integer programming formulation. Since the problem is NP-complete, two efficient heuristics are developed to solve it. Computational complexity, worst-case performance analysis, and extensive computational tests are provided for both heuristics. The results indicate that the proposed methods are well suited for large-scale manufacturing applications.     

An automated system for selection of a constructional material

A method for comparison of different materials is proposed. The use of any, including difficult to compare criteria such as strength, production properties, cost etc. is allowed as the criteria to be compared. All of the information for comparison is arranged in the form of material-properties stable matrices. Each line of the matrix describes a single material with certain of its properties. The material for replacement is selected by cluster analysis using a coalescence algorithm.Selection of the information for filling the original material-properties table is made under automated conditions with use of a data bank of physicomechanical properties of materials. A problem of transfer of original data from a general-purpose information base to applied user programs is solved. A system for replacement of a constructional material is developed and examples of its functioning are given.Translated from Problemy Prochnosti, No. 12, pp. 67–73, December, 1990.     

The effect of sudden material handling system breakdown on the performance of a JIT system

In this paper we explore the impact of sudden breakdown of the material handling system on the performance of a traditional kanban system (TKS). TKS, which is an element of the just-in-time system, is designed to operate in an ideal environment such as constant processing times and uninterrupted processing. However, in a real life environment, the TKS could be subjected to various unpredictable factors including stochastic processing times and process interruption due to equipment failure. These factors would seriously strain the performance of TKS. We consider a TKS in which some stations are dependent on a material handling system to move parts between them. We study the effect of a sudden breakdown of such a material handling system on the performance of the TKS. In addition, we also study a newly developed kanban system (which dynamically and systematically manipulates the number of kanbans in order to offset the blocking and starvation caused by these factors during a production cycle) under the same conditions. We refer to the new system as the 'flexible kanban system' (FKS). We compare the overall performances of the TKS and FKS by considering a variety of cases. We present the solution procedure, results and discussion for these cases.     

Extended range tactility in material handling

Optical fibres sensitized to their geometric curvature are arranged in loops around an autonomous guided vehicle (AGV) in order to extend the vehicle's tactile sensing range and allow larger speeds that require larger stopping distances. When the AGV approaches other objects (obstacles) within this range, fibre optic loops deform and sense the gradual change in their curvature. No intermediate mechanical elements are used to either transfer the impact loads onto the sensitive element or to provide compliance to it. Optical fibres themselves achieve these two functions simultaneously. As a result, tactility is achieved within a comparatively large position range extending over 15 cm. Throughout this range, virtually no reaction forces are generated with the impacting body. The range mentioned is on top of the one provided by the more traditional elastic bumper on which the optical fibres are mounted. Obstacle avoidance and wall-following AGV guidance can readily be achieved with such loops of optical fibre. A high degree of reactive capability and safety is hence provided in the system. With similar advantages, the method can likewise be applied to fixed or mobile material-handling robots.     

A comprehensive VIKOR method for material selection

In engineering design, material alternatives evaluate according to different criteria depending on the objectives of the problem. Performance ratings for different criteria are measured by different units, but in the decision matrix in order to have a valid comparison all the elements must be dimensionless. However, a lot of normalization methods have been developed for cost and benefit criteria, not only there has not been enough attention for engineering design situations in which approaching the target values are desirable but also the available methods have shortcomings. A new version of VIKOR method, which covers all types of criteria with emphasize on compromise solution, is proposed in this paper. The proposed comprehensive version of VIKOR also overcomes the main error of traditional VIKOR by a simpler approach. Suggested method can enhance exactness of material selection results in different applications, especially in biomedical application where the implant materials should possess similar properties to those of human tissues. Five examples are included to illustrate and justify the suggested method.     

A computer-aided EDM electrode design system for mold manufacturing

A large number of EDM electrodes are used in plastic injection mold manufacturing. However, electrode design is very time-consuming. This paper introduces a computer-aided electrode design system for plastic injection mold manufacturing. An algorithm to detect sharp corner uncut for electrode design is introduced in the paper. Through this algorithm, sharp corner uncut can be detected by calculating the surface angles at their common edges. Using this system, when electrode boundaries are identified either by the user or through detected sharp corner edges, the electrode tool, its holder and a working coordinate system (WCS) for electrode setting are created automatically. The system has been tested and has proved to be able to shorten the electrode design lead-time significantly.     

A selection of material using a novel type decision-making method: Preference selection index method

The aim of the current study is to implement a novel tool to help the decision-maker for selection of a proper material that will meet all the requirements of the design engineers. Preference selection index (PSI) method is a novel tool to select best alternative from given alternatives without deciding relative importance between attributes. In the present study, three different types of material selection problems are examined. A validation and consistency test of preference selection index method is performed in present work by comparing results of PSI method with published results of graph theory and matrix approach (GTMA), and technique for order preference by similarity to ideal solution (TOPSIS) method, respectively. The research has concluded that the PSI method is logical and more appropriate for the material selection problems.     

Marginal analysis guided design justification: a material handling example

The design and justification of an integrated manufacturing system and all of the supporting sub-systems (e.g. material handling system) is a difficult task. One of the most difficult aspects in the design process is determining how and where to proceed. This paper proposes the use of a marginal analysis-directed branch and bound approach as the basis for directing the design process so that a combined economic and performance justification path results. The background and rationale for a marginal analysis guided design approach is given and an example of a material handling system design is presented to illustrate the development of a design justification decision path.     

A reallocation-based heuristic to solve a machine loading problem with material handling constraint in a flexible manufacturing system

In this research, a comprehensive heuristic solution is evolved to include all the three segments of a machine loading problem of flexible manufacturing systems. These are part type sequence determination, operation allocation on machines and reallocation of part types. The machine loading problem has been formulated keeping in view two well-known objective functions, namely minimization of system unbalance and maximization of throughput. In addition to constraints related to machine time and tool slots availability, this research considers one more constraint related to material handling, i.e. number of AGVs available in the system. The part type sequence determination has been carried out by evaluating the contribution of part type to characteristics such as batch size, total processing time, and the AGV movement. Decisions pertaining to operation allocation are taken based on the enumeration of priority index. An iterative reallocation procedure has been devised to ensure minimum positive system unbalance and maximum throughput. A test problem is simulated to represent the real shop floor environment and the same has been solved using various steps of the proposed algorithm. Extensive computational experiments have been carried out to assess the performance of the proposed heuristic and validate its relevance to solve the real shop floor problems.     

Determination of unit load sizes in an AGV-based material handling system for an FMS

Unit load size is a key factor in an automated guided vehicle based material handling system for a flexible manufacturing system. Highlighting this aspect and its importance at the design stage, this paper presents an integer programming formulation of the problem of finding the optimal unit load size. Using an existing analytical model to decide the number of AGVs required, an algorithm based on branching and implicit enumeration and a heuristic have been developed. Revised computations due to dynamic system conditions such as changes in part mix are also possible with the proposed algorithms. The methodologies have been demonstrated using numerical examples.