A kanban-based simulation study of a mixed model just-in-time manufacturing line

The kanban-based operation of a mixed model manufacturing line is studied. Features of the hypothetical manufacturing line modelled are presented in terms of general structure, major components and operational characteristics. Simulation model developed is described and parameters of the base model are given. Experimental design features are discussed with respect to simulation related issues, performance measures, statistical analysis and experimental design clusters. Statistical findings are summarized in tabular format. Non-intuitive behaviour observed in each experiment set is interpreted.     

A branch-and-bound approach for machine selection in just-in-time manufacturing systems

Equipment selection issues are very important in the early stages of implementation of just-in-time (JIT) manufacturing systems. This paper addresses the problem of determining the number of machines for each stage of a JIT system by minimizing production, imbalance and investment costs. The problem is modelled as a mixed-integer nonlinear optimization program and a branch-and-bound algorithm is developed for its solution. This algorithm guarantees the global optimum of the problem and is enhanced by simple, yet very effective, upper bounding heuristics. The solutions obtained by the developed branch-and-bound approach are compared to solutions that have appeared in the literature using heuristic approaches. The comparisons indicate that the proposed algorithm leads to significant economic savings, averaging 17% on a set of problems from the literature. The paper also considers the application of the algorithm to large-scale, industrially-relevant, problems with up to 10 stages and 200 products. Even for the largest of these problems, the search for the integer optimum requires modest computational times. This demonstrates the potential practical impact of the proposed methodology.     

Tolerancing for manufacturing: A three-dimensional model

This paper proposes a three-dimensional (3D) model on manufacturing tolerancing for mechanical parts. The work presented relies on research conducted at the LURPA on the computation of 3D tolerance chains for mechanisms. Starting from these works, the authors propose a formalization of the problem within the more specific context of manufacturing tolerances. Models of the workpiece, the set-ups and the machining operations are provided. The main originality is to model the machining set-up as a mechanism. The concept of the small displacements torsor (SDT) is used to model the process planning. It opens up the way for the 3D integration product/process because of the similarities between the concepts used in both points of view. The first part recalls the principle of the modelling of surface variations with SDT as well as its application to the modelling of mechanisms. The second part introduces the use of the concept in the case of manufacturing tolerancing. A third part shows the modelling of the problem with the help of an example. At last, a detailed computer implementation is described.     

Optimization-based planning for the stochastic lot-scheduling problem

We describe a finite-horizon stochastic optimization model for the stochastic lot-scheduling problem and procedures for finding near-optimal solutions. Several different products are produced by a single-stage process with significant changeover times and costs, and the demand for these products is random. The deterministic version of this problem, the economic lot-scheduling problem, is the subject of a great deal of research. However, the problem with random demand for the products is commonly found in practice but is not as well researched. The models developed in this paper address the problem of dynamically planning the timing and size of production runs in this kind of production environment. We also report some computational results that indicate the quality of the resulting production schedules.     

A model for labour pooling in batch manufacturing

Cross-training workers to perform multi-skilled jobs is one of the modern trends in job design. As companies engage in downsizing, the remaining workforce is expected to do more and different tasks. This paper presents a formal definition and a practical solution for optimizing the size and cost of the pool of multi-skilled workers for production units operated under batch manufacturing. The pool size is optimized through a search procedure applied separately to just-in-time (JIT) and level production plans, which are derived from the stones heuristic. The method allows direct calculation of the cost savings from labour pooling. This paper was inspired by consulting in the food industry, where implementation of these results has significantly reduced labour costs.     

A capacitated vehicle routing problem for just-in-time delivery

This paper focuses on the formulation and solution of the problem of planning vehicle routes for material delivery within the premises of a plant working under a just-in-time production system. The unique characteristic of this problem is that the quantity to be delivered at each of the demand nodes is a function of the route taken by the vehicle assigned to serve that node. The problem is modeled by adding a non-linear capacity constraint to the standard vehicle routing model, such that vehicle idle times and inventories at the customer locations are minimized. A heuristic solution procedure is outlined, and the formulation of a lower-bound relaxation is suggested. The performance of the heuristic solution procedure is evaluated in comparison to the lower-bound relaxation, and the heuristic procedure is shown to provide generally good results.     

Hybrid genetic algorithm for the economic lot-scheduling problem

The economic lot-scheduling problem (ELSP) is an important production scheduling problem that has been intensively studied over 40 years. Numerous heuristic algorithms have been developed since the problem is NP-hard. Dobson's heuristic has been regarded as the best in its performance. The present paper provides a hybrid genetic algorithm based on the time-varying lot sizes approach in the ELSP literature. Numerical experiments show that the hybrid genetic algorithm outperforms Dobson's heuristic.     

A simple non-associated flow model for sand

 This paper proposes a simple non-associated plasticity model for sand. The yield surface is taken to be a member of a recently derived family of yield loci, requiring the specification of a single parameter in addition to the stress ratio at the peak value of deviatoric stress on the yield surface in deviatoric:mean effective stress space. This simple equation, can easily be fitted to given sand data. The flow rule also has a simple equation, such that the critical state is not at the top of the yield locus in stress space. The equation of the flow rule requires the specification of the critical state dissipation constant, plus one additional parameter. This permits realistic modelling of the undrained behaviour of sand in states looser and denser than critical. The parameter controlling the flow rule can, for convenience, be taken to be equal to the parameter governing the shape of the yield surface. However, since the two parameters are not required to be equal, the flow rule can easily be adjusted to model more accurately the rate of change of direction of the plastic strain increment vector with changing stress ratio around the yield surface. The model resembles more complex models based on the mathematical theory of envelopes, but the equations of the yield loci and flow rules are much simpler. The contribution in this paper is therefore to provide a model similar to those derived based on micro mechanical considerations, but which is more useful to geotechnical engineers, in that the number of parameters is kept to a minimum, the constitutive equations are simple, and the flow rule can easily be controlled. The model is easy to apply in geotechnical analysis, and would be easy to implement in a finite element program. Received: 11 January 2002     

A topological model of limitations in design for manufacturing

Design for manufacturing (DFM) is a methodology that requires the use of specific manufacturing information at all stages of design. The method relies on a collection of informal and often controversial principles that seem to have eluded the benefits of formal analysis. The transition from design to manufacturing can be modeled as a mathematical mapping, and it has been previously shown how the discontinuity of this mapping formally captures the folklore that small design changes can lead to significantly increased manufacturing cost. We study the properties of the transition map in the presence of design and manufacturing variations, and show that its continuity is closely related to the structure of design and manufacturing topological spaces. The main result of this paper establishes conditions on these spaces under which design for manufacturing cannot be described by any continuous transition map. In practical terms, our study reveals the limitations of many DFM systems and approaches in their ability to relate design and manufacturing knowledge, and explains these limitations in terms of a basic incompatibility between the underlying design and manufacturing representations. We discuss how our model applies to DFM relative to traditional manufacturing methods (such as casting and stamping) and we speculate what changes might occur for alternative manufacturing technologies (such as electrical discharge machining (EDM), stereolithography, laser machining, and particle deposition).     

A simple ballistic material model for soda-lime glass

Various open-literature experimental findings pertaining to the ballistic behavior of glass are used to construct a simple, physically based, high strain-rate, high-pressure, large-strain constitutive model for this material. The basic components of the model are constructed in such a way that the model is suitable for direct incorporation into standard commercial transient non-linear dynamics finite-element based software packages like ANSYS/Autodyn [ANSYS/Autodyn version 11.0, User documentation, Century Dynamics Inc. a subsidiary of ANSYS Inc.; 2007.] or ABAQUS/Explicit [ABAQUS version 6.7, User documentation, Dessault systems, 2007.]. To validate the material model, a set of finite element analyses of the Edge-on-Impact (EOI) tests is carried out and the results compared with their experimental counterparts obtained in the recent work of Strassburger et al. [Strassburger E, Patel P, McCauley JW, Kovalchick C, Ramesh KT, Templeton DW. High-speed transmission shadowgraphic and dynamic photoelasticity study of stress wave and impact damage propagation in transparent materials and laminates using the edge-on impact method. In: Proceedings of the twenty-third international symposium on ballistics. Spain: April 2007, and Strassburger E, Patel P, McCauley W, Templeton DW. Visualization of wave propagation and impact damage in a polycrystalline transparent ceramic-AlON. In: Proceedings of the twenty-second international symposium on ballistics. Vancouver, Canada: November 2005.]. Overall, a good agreement is found between the computational and the experimental results pertaining to: (a) the front-shapes and propagation velocities of the longitudinal and transverse waves generated in the target during impact; (b) the front-shapes and propagation velocities of the “coherent-damage” zone (a zone surrounding the projectile/target contact surface which consists of numerous micron- and sub-micron-size cracks); and (c) the formation of “crack centers”, i.e. isolated cracks nucleated ahead of the advancing coherent-damage zone front. Relatively minor discrepancies between the computational and the experimental results are attributed to the effects of damage-promoting target-fixturing induced stresses and cutting/grinding-induced flaws located along the narrow faces of the target and the surrounding regions.     

A model for co-evolution in manufacturing based on biological analogy

Manufacturing systems continue to adapt in order to survive the changing and challenging markets and global competition. Product and manufacturing design and capabilities are configured to allow the needed adaptation through innovative design, improved system paradigms, intelligent design and optimisation models, and product grouping to increase efficiency. In this research, it is hypothesised that the evolution and co-evolution of products and the machines used to manufacture them is akin to that observed in the adaptation of biological species. The symbiosis between products and manufacturing capabilities is studied using real examples, and a new model that establishes the symbiotic relationship between their evolution paths and observed co-evolution trends based on available historical information is proposed. Dual cladograms are used to track their evolution and detect useful potential development and plausible future evolution trends. When a state of co-evolution equilibrium is reached, a stimulus for more abrupt changes would be needed to cause further evolution on both sides. The co-evolution model has been applied to an example based on analysing the history of machine tools development and data from a major machine tools manufacturer. The evolution and co-evolution hypotheses of machined parts and machine tools were charted up to the currently observed state of equilibrium in this application field. This innovative model of co-evolution in manufacturing can help improve the utility of manufacturing resources and prolong the life of manufacturing systems beyond a single product generation and its variants.     

Optimizing production smoothing decisions via batch selection for mixed-model just-in-time manufacturing systems with arbitrary setup and processing times

This paper is concerned with the production smoothing problem that arises in the context of just-in-time manufacturing systems. The production smoothing problem can be solved by employing a two-phase solution methodology, where optimal batch sizes for the products and a sequence for these batches are specified in the first and second phases, respectively. In this paper, we focus on the problem of selecting optimal batch sizes for the products. We propose a dynamic programming (DP) algorithm for the exact solution of the problem. Our computational experiments demonstrate that the DP approach requires significant computational effort, rendering its use in a real environment impractical. We develop three meta-heuristics for the near-optimal solution of the problem, namely strategic oscillation, scatter search and path relinking. The efficiency and efficacy of the methods are tested via a computational study. The computational results show that the meta-heuristic methods considered in this paper provide near-optimal solutions for the problem within several minutes. In particular, the path relinking method can be used for the planning of mixed-model manufacturing systems in real time with its negligible computational requirement and high solution quality.     

A simple model of elastoplasticity for nonproportional cyclic loading

On the basis of the analysis of experimental data, we formulate requirements to the constitutive relations of plasticity under the conditions of complex cyclic loading. We propose a version of constitutive relations obtained by a simple generalization of the Mazing model to the three-dimensional case and introduction of a function of cyclic hardening. We also suggest a procedure for the identification of this function. According to the results of numerical analysis, this model adequately describes the main effects of cyclic plasticity for austenitic stainless steels. Perm State Technical University, Perm, Russia. Translated from Problemy Prochnosti, No. 1, pp. 15 – 24, January – February, 1998.     

具有简单孔洞结构柔性体的力/触觉框架模型

针对具有简单孔洞的柔性体提出了一种基于框架结构的力/触觉变形模型。此模型以外力接触端为公共端,根据内部孔的位置和形状构建框架。整体框架由一个或多个钢架组成,每根钢架可为单杆件或多杆件结构。当外力作用时,运用虚功原理和Bernoulli-Euler定理求得钢架节点和虚拟固定端的变形位移,从而得到框架的变形,通过框架变形插值求解柔性体全局变形。实验结果表明,该模型方法简单,实时性好,在具体的虚拟建模力反馈工作中可操作性强。     

A simple general model for echelon overhaul and repair

In echelon overhaul and repair, failed or time-expired machines are removed and replaced by overhauled ones. The removed machines are sent to the rear echelon, typically the maker's works, to be overhauled to ‘good-as-new’. The paper presents a simple model for determining economic overhaul intervals in the presence of minor and major failures, PM and inspection of accessible and inaccessible components, and then goes on to consider how many machines should, for maximum long-term economy, be owned by the operator. The economic implications of an echelon policy for both the owners and the makers are briefly discussed. It is argued that simple models promply applied are often adequate for comparing competing systems and policies. An example involving gas-turbines in off-shore oil-rigs demonstrates the method generally, and in particular shows that the advantages may be dissipated if the overhaulers take too long to process overhauled machines.     

A simple model for elastic fracture in thin films

A simple model for the cracking of thin films has been developed and investigated. The film is represented by a network of bonds and nodes which initially form a triangular lattice in which each node is at the junction of six bonds. The nodes are also attached to a rigid substrate by bonds which are not broken but have a relatively small force constant. Cracking is simulated by a sequence of thermally activated bond breaking events followed by mechanical relaxation. If the stretching force constant associated with the bonds in the surface layer is large, linear cracks propagate rapidly and, at a later stage, are connected by secondary cracks which become less and less linear as the strain in the surface layer is relaxed by the cracking process. Many of our simulations exhibit a distint “initiation” period in which the bond breaking rate is low, followed by a period of rapid crack propagation in which a large fraction of the surface strain energy is released. This period is then followed by a second period of relatively slow bond breaking. During the first period isolated defects are formed, followed by linear cracks in the second period. During the third period non-linear cracks connect the linear cracks, and structures which resemble shear bands are formed. Results for the effects of finite relaxation rates for the elastic network (visco-elastic effects) are also presented.     

A simple unified physical model for a reluctance accelerator

In this paper, we develop an illustrative, physically unified model for treating a solenoidal reluctance linear accelerator. A simplified field-based physical model is developed from basic principles and cast in a variational (Lagrangian) form. The equations of motion are presented in a convenient form for computation, from which a fast and compact numerical model is constructed that also accounts for the effects of core saturation as well as the energy exchange between the field and armature motion. The results of this model are then compared with experimental results obtained from a small-scale mass launcher apparatus. Good agreement between experimental and computed behavior has been observed.     

A production planning model for cellular manufacturing systems with refixturing considerations

In this paper we consider the problem of assigning operations of part types to one or more machines in a cellular manufacturing system. We develop a mixed integer linear model considering trade-off between refixturing and material handling movement. Examples are included to illustrate the applications of the models developed.     

A queueing network model for flexible manufacturing systems with tool management

The analytical model in this paper allows the evaluation of the performance of a flexible manufacturing system (FMS) with a tool management system. Design parameters such as the transportation time for tools to machines, as well as the number of transportation vehicles for tools, are explicitly considered. The part and the tool transportation system are modeled as two interacting closed queueing networks. The classical convolution algorithm is used to evaluate the part transportation system and mean value analysis approximation is applied to evaluate the tool transportation system. The resulting set of nonlinear equations allows then to estimate important system parameters such as the throughput of parts, the utilization of the tool transportation vehicles and the service interruptions caused by a tool supply order.