HEURISTIC APPROACHES FOR LOADING PROBLEMS IN FLEXIBLE MANUFACTURING SYSTEMS

Flexible manufacturing systems (FMSs) are able to process a wide variety of operations, but the specific mix of operations that can be performed at any point in time depends upon the combination of tools loaded onto the machines. The machines have tool magazines with finite capacities. We consider the problem of assigning operations and their associated tools to machines (or groups of machines) to maximize the throughput for a specified steady-state mix of orders. Since this objective is difficult to deal with directly, we use an intermediate objective of meeting workload targets for each machine group as closely as possible. A certain form of this intermediate objective has been shown to correlate highly with the original objective.

Since it is computationally intractable to find optimal solutions for problems with more than 20 operations, fast heuristic algorithms are developed. These algorithms are adapted from multi-dimensional bin-packing algorithms. Computational results are reported.     

PRODUCTION PLANNING DECISIONS IN FLEXIBLE MANUFACTURING SYSTEMS WITH RANDOM MATERIAL FLOWS

In this paper, we consider the FMS planning problem of determining optimal machine workload assignments in order to rninimize mean part flow time. We decompose this problem into the subproblems of first forming machine groups and next assigning operations to these groups. Three types of grouping configurations—no grouping, partial grouping and total grouping—are considered. In both no grouping and partial grouping, each machine is tooled differently. While each operation is assigned to only one machine in no grouping, partial grouping permits multiple operation assignments. On the other hand, total grouping partitions the machines into groups of identically-tooled machines; each machine within a group is capable of performing the same set of operations. Within this grouping framework, we consider three machine loading objectives—minimizing the total deviation from the optimal group utilization levels, minimizing part travel and maximizing routing flexibility, for generating a variety of system configurations.

A queueing network model of an FMS is used to determine the optimal configurations and machine workload assignments for the no grouping and total grouping cases. It is shown that under total grouping, the configuration of M machines into G groups that minimizes flow time is one in which the sizes of the machine groups are maximally unbalanced and the workload per machine in the larger groups is higher. This extends previous results on the optimality of unbalancing both machine group sizes and machine workload to the mean flow time criterion.

A simulation experiment is next conducted to evaluate the alternative machine configurations to understand how their relative performance depends upon the underlying system characteristics, such as system utilization level and variation among operation processing times. We also investigate the robustness of these configurations against disruptions, such as machine unreliability and variation in processing batch sizes. While different configurations minimize mean flow time under different parameter values, partial grouping with state-dependent part routing performs well across a wide range of these values. Experimental results also show that the impact of disruptions can be reduced by several means, such as aggregating operations of a part to be performed at the same machine, in addition to providing routing flexibility.     

ROBOT TASK SCHEDULING IN A FLEXIBLE MANUFACTURING CELL

Effective sequencing and scheduling of the material handling system can have a major impact on the productivity of the manufacturing system. This is especially true in the case where material handling times are on par with machine processing times. In a dynamic, real-time environment, the optimal solution of this scheduling problem may be computationally infeasible.

In this paper, we develop a branch and bound approach which is coupled with quick, effective bounds to optimize the movement of a robot which serves the material handling requirements within a manufacturing cell. Computational results are given which explore the tradeoff between computation time and deviation from optimal for different scenarios.     

PRODUCTION SCHEDULING IN A FLEXIBLE MANUFACTURING SYSTEM WITH SETUPS

A model is presented for the planning and scheduling of production batches in a flexible manufacturing system environment in which setup costs and times are nonnegligible and alternate routings are possible. The formulation is an integer program with a multicommodity flow network structure. A heuristic procedure based on price-directive decompostion using column generation is used to obtain solutions. Numerical experimentation is performed to assess die quality of the heuristic versus optimal solutions, and to determine the impact of routing flexibility on total cost, inventory levels, bottlenecks, capacity utilization, throughput time, number of setups and split lots. Important cost-benefit trade-off implications are shown for the design of flexible manufacturing systems.     

TRIP-BASED MATERIAL HANDLING SYSTEMS: THROUGHPUT CAPACITY ANALYSIS

In this paper we present a general-purpose analytical model to compute die approximate throughput capacity of a trip-based material handling system used in a manufacturing setting. A wide variety of handling systems, including freight elevators, cranes, microload automated storage/retrieval (AS/R) systems, industrial lift trucks, and automated guided vehicle (AGV) systems can be modeled as trip-based handling systems. To our knowledge, this model is one of the few analytical models that explicitly considers an empty device dispatching rule. The model is first developed for a single-device system (such as a crane) and subsequently, with a simple modification, it is extended to multiple-device systems (such as lift trucks and AGVs). Using this model one can rapidly evaluate a wide range of handling and layout alternatives for given flow data. Hence, die model would be most effective when used early in the design phase to narrow down die set of alternative handling systems and configurations prior to simulation.     

FLEXIBLE INSPECTION SYSTEMS FOR SERIAL MULTI-STAGE PRODUCTION SYSTEMS

An FIS is defined as an Inspection System where the inspection routines are determined just prior to performing the inspection. The goal is to determine the inspection routine so as to optimize global objectives (such as cost minimization) subject to global and local constraints (such as total inspection time available). The concept of an FIS provides the basis for the development of intelligent automated inspection systems. In this paper, the concept of a Flexible Inspection System (FIS) for Serial Multistage production lines is introduced, the modelling implications discussed, and numerical examples are presented.     

多柔体系统动力学碰撞研究中的若干基本问题

本文针对多柔体系统动力碰撞研究中的几个基本问题进行了全面的分析和评述,包括多柔体系统动力学方程的描述,碰撞模型的简化和处理,铰接间隙引起的碰撞问题,数值算法,实验研究,控制等几个方面,并根据目前的发现现状和研究中的存在的问题,指出了今后多柔体系统动力学碰撞研究中的发展方向。     

ECONOMIC PRODUCTION QUOTAS FOR PULL MANUFACTURING SYSTEMS

We consider the problem of using “safety capacity” to ensure due date integrity in a pull manufacturing system and quantify the basic tradeoff between lost revenue opportunity and overtime costs. In this context, we address the question of when it is economically attractive to use “under capacity scheduling” and the problem of setting economic production quotas.

We develop four models for addressing the quota setting problem. The first three assume that quota shortfalls cannot be carried over to the next regular time production period. Models 1 and 3 assume that these shortages are made up on overtime and incur fixed or fixed plus variable costs. Model 2 does not use a capacity buffer and treats shortages as lost sales. Finally, Model 4 assumes that shortages can be backlogged to the next regular time production period at a cost. For this model, we compute both an optimal quota and an overtime “trigger,” which represents the minimum shortage for which overtime is used. We give computational results that illustrate and contrast the various models.     

三维柔性多体梁系统非线性动力响应分析

研究了三维柔性多体梁系统的非线性动力响应问题。将空间柔性梁的变形分解为轴向变形以及在x-y平面的弯曲变形和在x-z平面的弯曲变形，引用各自的精确振动模态描述变形场，利用拉格朗日乘子法建立起柔性多体梁系统约束非线性动力学方程。结合Newmark直接积分法和Newton-Raphson迭代法，导出了求解该非线性代数一微分方程组的数值方法。仿真算例证明了该方法的正确性和有效性。     

MODELING OF INTEGRATED MANUFACTURING SYSTEMS USING AN OBJECT-ORIENTED APPROACH

Traditional approaches to the modeling of complex manufacturing systems are expensive, time consuming, and of limited value. Recent developments in several areas (i.e., knowledge engineering, software engineering, modeling formalisms, engineering workstations, and database systems) are now to the point that a meaningful convergence can be crafted to yield a modeling environment far superior to any we have known in the past. Fundamental to this new approach to modeling are the recent developments in object-oriented programming and related technologies. A research team at Oklahoma State University has been exploring alternative approaches to the modeling and simulation of complex manufacturing systems since 1985. This paper argues for a fundamental paradigm shift in the development and utilization of models within a CEM framework.     

DESIGNING CELLULAR MANUFACTURING SYSTEMS: BRANCH-AND-BOUND AND A* APPROACHES

In this paper, heuristic and optimal algorithms for solving the group technology problem are presented. The heuristic algorithm is based on a branch-and-bound concept. A quadratic programming model for the machine grouping problem is formulated. The A* algorithm is developed for optimal solving of the machine grouping problem. The performance of the heuristic branch-and-bound method and the A* algorithm is compared with several existing heuristics.     

RESEARCH DIRECTIONS IN ELECTRONICS MANUFACTURING

The Workshop on Electronics Manufacturing Research was held in College Station, Texas, on February 24-26, 1992. It focused on the Industrial Engineering/Operations Research/Management Science disciplines and their capabilities in modeling, analysis, and manufacturing technology. The primary goal was to identify the critical research needs in electronics manufacturing and assembly that can be addressed by these disciplines and the means of accomplishing them.

Sponsors included the Production Systems Program of the National Science Foundation (NSF), three organizations at Texas A&M University (the Department of Industrial Engineering, the Texas Engineering Experiment Station, and the Institute of Manufacturing Systems), and SEMATECH. In addition. Ford Electronics, IBM, and INTEL each sponsored one representative.

Individuals recognized for their research accomplishments in the electronics industry were invited to participate. Representing ongoing programs across the United States and Mexico in industry, government, and academia, the group identified fertile research directions as a guide for the research community and sponsoring agencies. Interacting tracks dealt with semiconductor manufacturing and circuit card (and higher level) assembly. This paper documents the important research themes identified relative to three topic areas: integrating systems, models for design and operation of production/assembly systems, and assurance sciences. It also summarizes a lively discussion which sought ways to improve the effectiveness of university/industry partnering relationships. This paper includes essential recommendations that resulted from the Workshop, but the interested reader can obtain a somewhat more detailed Final Report from Dr. Wilbert E. Wilhelm, the Principal Investigator for the Workshop project.     

A TORSIONAL SPRING-LIKE BEAM ELEMENT FOR THE DYNAMIC ANALYSIS OF FLEXIBLE MULTIBODY SYSTEMS

A new finite element beam formulation for modelling flexible multibody systems undergoing large rigid-body motion and large deflections is developed. In this formulation, the motion of the ‘nodes’ is referred to a global inertial reference frame. Only Cartesian position co-ordinates are used as degrees of freedom. The beam element is divided into two subelements. The first element is a truss element which gives the axial response. The second element is a torsional spring-like bending element which gives the transverse bending response. D'Alembert principle is directly used to derive the system's equations of motion by invoking the equilibrium, at the nodes, of inertia forces, structural (internal) forces and externally applied forces. Structural forces on a node are calculated from the state of deformation of the elements surrounding that node. Each element has a convected frame which translates and rotates with it. This frame is used to determine the flexible deformations of the element and to extract those deformations from the total element motion. The equations of motion are solved along with constraint equations using a direct iterative integration scheme. Two numerical examples which were presented in earlier literature are solved to demonstrate the features and accuracy of the new method.     

变长度柔性提升系统纵向-横向受迫耦合振动分析

以任意变长度柔性提升系统的纵向-横向耦合振动为研究对象,采用Hamilton原理建立了在受到外界横向激励情况下柔性部件的振动和振动能量的偏微分方程,并使用Galerkin方法对运动方程进行离散化求解。最后,以电梯悬挂提升系统为例对所建模型进行验算。数值结果表明:高速电梯系统在受到一定的横向扰动(激励)时,柔性部件在以横向振动为主的耦合振动状态下运动,并且在上行阶段存在一定的不稳定区域。这一现象与实际当中的发现所一致。     

DECISION INTEGRATION FUNDAMENTALS IN DISTRIBUTED MANUFACTURING TOPOLOGIES

Advances in control, communications, computer science and engineering have made it possible to design and implement large scale systems, where the decision making, control and information processing are distributed. This research effort attempts to establish the theoretical foundation of operational decision integration for such systems. Decision integration is a method to improve the quality of decision making. The basic elements of the integration process are defined. A simple distributed hypothesis testing model is employed to demonstrate that properly designed integration always improves the quality of the decisions. The problem of organizing decision making agents into architectures of integration (parallel versus hierarchical) is addressed. Several elementary decision architectures for small organizations are analyzed, and their performance is compared. The results are also extended for the case of flexible architectures with adaptive topology. The implications of integration are discussed with respect to the overall performance of an organization.     

柔性构件多次撞击力的计算方法

研究目的是精确计算多次撞击过程中的撞击力。通过研究柔性构件中的瞬态波传播理论,提出了计算多次撞击力的瞬态波效应法,避免了求解具有未知奇异载荷项的非线性方程问题。通过双柔性杆轴向多次撞击的实例分析,研究了初始撞击速度,杆长比对撞击力和撞击发生时间的影响,表明瞬态波效应法可以计算多次撞击力,并可以研究"次撞击"现象。