Design of robust cellular manufacturing system for dynamic part population considering multiple processing routes using genetic algorithm

In this paper, a comprehensive mathematical model is proposed for designing robust machine cells for dynamic part production. The proposed model incorporates machine cell configuration design problem bridged with the machines allocation problem, the dynamic production problem and the part routing problem. Multiple process plans for each part and alternatives process routes for each of those plans are considered. The design of robust cell configurations is based on the selected best part process route from user specified multiple process routes for each part type considering average product demand during the planning horizon. The dynamic part demand can be satisfied from internal production having limited capacity and/or through subcontracting part operation without affecting the machine cell configuration in successive period segments of the planning horizon. A genetic algorithm based heuristic is proposed to solve the model for minimization of the overall cost considering various manufacturing aspects such as production volume, multiple process route, machine capacity, material handling and subcontracting part operation.     

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.     

Joint optimization of job scheduling and maintenance planning for a two-machine flow shop considering job-dependent operating condition

Two-machine flow shops are widely adopted in manufacturing systems. To minimize the makespan of a sequence of jobs, joint optimization of job scheduling and preventive maintenance (PM) planning has been extensively studied for such systems. In practice, the operating condition (OC) of the two machines usually varies from one job to another because of different processing covariates, which directly affects the machines’ failure rates, PM plans, and expected job completion times. This fact is common in many real systems, but it is often overlooked in the related literature. In this study, we propose a joint decision-making strategy for a two-machine flow shop with resumable jobs. The objective is to minimize the expected makespan by taking into account job-dependent OC. We consider two situations. In the first situation, where the failure rate of a machine under a fixed OC is constant, a hybrid processing time model is proposed to obtain the optimal job sequence based on the Johnson's law. For the second situation, where the failure rate of a machine is time-varying, the job sequence and PM plan are jointly optimized. An enumeration method is adopted to find the optimal job sequence and PM plan for a small-scale problem, and a genetic algorithm-based method is proposed to solve a large-scale problem. Numerical examples are provided to demonstrate the necessity of considering the effect of job-dependent OC and the effectiveness of the proposed method in handing such joint decision-making problems in manufacturing systems.     

Computation of the makespan in a transfer line with station breakdowns using stochastic petri nets

In this paper the authors developed a Petri net model of a transfer line, whose machines are subject to failure, considering both blocking and rerouting of workpieces when a machine fails. The introduction in the net of the marked token is shown to allow the computation of the makespan of the system.     

Stochastic cellular manufacturing system design subject to maximum acceptable risk level

In this study, a non-linear mathematical model is proposed to solve the stochastic cellular manufacturing system (CMS) design problem. The problem is observed in both machine and labor-intensive cells, where operation times are probabilistic in addition to uncertain customer demand. We assume that processing times and customer demand are normally distributed. The objective is to design a CMS with product families that are formed with most similar products and minimum number of cells and machines for a specified risk level. Various experiments are carried out to study the impact of risk level on CMS design. As the risk level increases, lower number of cells and product families are formed and average cell utilization increases. However, this leads to poor performance in cells, where standard deviations of capacity requirements are high. Later, the deterministic approach proposed by Suer, Huang, and Sripathi (2010) and the proposed stochastic model with various risk levels are compared. Both of the models’ results are simulated with Arena Simulation Software. Simulation is performed to validate models and assess the performance of designed CMSs with respect to following measures: cell utilization, WIP, total waiting time and total number waiting. Stochastic CMS design with 10% risk formed a better CMS in all of the performance measures according to the results obtained from simulation experiments.     

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.     

Robust design of flexible manufacturing systems using, colored Petri net and genetic algorithm

A method is presented for the robust design of flexible manufacturing systems (FMS) that undergo the forecasted product plan variations. The resource allocation and the operation schedule of a FMS are modeled as a colored Petri net and an associated transition firing sequence. The robust design of the colored Petri net model is formulated as a multi-objective optimization problem that simultaneously minimizes the production costs under multiple production plans (batch sizes for all jobs), and the reconfiguration cost due to production plan changes. A genetic algorithm, coupled with the shortest imminent operation time (SIO) dispatching rule, is used to simultaneously find the near-optimal resource allocation and the event-driven schedule of a colored Petri net. The resulting Petri net is then compared with the Petri nets optimized for a particular production plan in order to address the effectiveness of the robustness optimization. The simulation results suggest that the proposed robustness optimization scheme should be considered when the products are moderately different in their job specifications so that optimizing for a particular production plan creates inevitably bottlenecks in product flow and/or deadlock under other production plans.     

A hybrid flowshop scheduling model considering dedicated machines and lot-splitting for the solar cell industry

This paper studies a solar cell industry scheduling problem, which is similar to traditional hybrid flowshop scheduling (HFS). In a typical HFS problem, the allocation of machine resources for each order should be scheduled in advance. However, the challenge in solar cell manufacturing is the number of machines that can be adjusted dynamically to complete the job. An optimal production scheduling model is developed to explore these issues, considering the practical characteristics, such as hybrid flowshop, parallel machine system, dedicated machines, sequence independent job setup times and sequence dependent job setup times. The objective of this model is to minimise the makespan and to decide the processing sequence of the orders/lots in each stage, lot-splitting decisions for the orders and the number of machines used to satisfy the demands in each stage. From the experimental results, lot-splitting has significant effect on shortening the makespan, and the improvement effect is influenced by the processing time and the setup time of orders. Therefore, the threshold point to improve the makespan can be identified. In addition, the model also indicates that more lot-splitting approaches, that is, the flexibility of allocating orders/lots to machines is larger, will result in a better scheduling performance.     

Stochastic cellular manufacturing system design subject to maximum acceptable risk level

In this study, a non-linear mathematical model is proposed to solve the stochastic cellular manufacturing system (CMS) design problem. The problem is observed in both machine and labor-intensive cells, where operation times are probabilistic in addition to uncertain customer demand. We assume that processing times and customer demand are normally distributed. The objective is to design a CMS with product families that are formed with most similar products and minimum number of cells and machines for a specified risk level. Various experiments are carried out to study the impact of risk level on CMS design. As the risk level increases, lower number of cells and product families are formed and average cell utilization increases. However, this leads to poor performance in cells, where standard deviations of capacity requirements are high. Later, the deterministic approach proposed by Suer, Huang, and Sripathi (2010) and the proposed stochastic model with various risk levels are compared. Both of the models’ results are simulated with Arena Simulation Software. Simulation is performed to validate models and assess the performance of designed CMSs with respect to following measures: cell utilization, WIP, total waiting time and total number waiting. Stochastic CMS design with 10% risk formed a better CMS in all of the performance measures according to the results obtained from simulation experiments.     

Solving facilities location problem in the presence of alternative processing routes using a genetic algorithm

Facilities location problem deals with the optimization of location of manufacturing facilities like machines, departments, etc. in the shop floor. This problem greatly affects performance of a manufacturing system. It is assumed in this paper that there are multiple products to be produced on several machines. Alternative processing routes are considered for each product and the problem is to determine the processing route of each product and the location of each machine to minimize the total distance traveled by the materials within the shop floor. This paper presents a mixed-integer non-linear mathematical programming formulation to find optimal solution of this problem. A technique is used to linearize the formulated non-linear model. However, due to the NP-hardness of this problem, even the linearized model cannot be optimally solved by the conventional mathematical programming methods in a reasonable time. Therefore, a genetic algorithm is proposed to solve the linearized model. The effectiveness of the GA approach is evaluated with numerical examples. The results show that the proposed GA is both effective and efficient in solving the attempted problem.     

Genetic algorithm for rotary machine scheduling with dependent processing times

This paper focuses on scheduling a rotary injection molding machine with dependent processing times. The injection machine has n pairs of positions to process n pairs of shoes. It is rotated after every cycle time. Cycle time is the maximum injection time of the jobs currently loaded in the machine. Thus, for all practical purposes, the processing time of a job depends on the combination of the jobs currently assigned to the machine. The uncertainty of processing time makes this problem more complicated than traditional parallel machine scheduling problems. Additionally, since switching jobs leads to mold changes, set-up time is also included in the analysis. We develop a Sequential Genetic Algorithm (SGA) to identify the best schedule with regard to makespan. In this approach, multiple GA evolvers are connected by using a feeding strategy, where each GA evolver identifies the best schedule with minimum makespan for the corresponding product family. A multi-segment (product lines) chromosome representation is applied to represent the product line sequence as well as the job sequence within a product family. Furthermore, an adaptive feeding strategy is also proposed to improve results and reduce computation times. Besides SGA, we also improve the performance of a traditional heuristic procedure by proposing a minimum ΔIT heuristic approach. The experimentation is performed by using four experimental data sets with different demand patterns and nine data sets from a shoe manufacturing plant. The results indicate that our SGA provides better schedule with respect to makespan value, while heuristic procedures take insignificant time to obtain results. Another observation is that adaptive feeding strategy helps to find good results in a shorter time.     

A two-stage hybrid flowshop scheduling problem with a function constraint and unrelated alternative machines

This article addresses a two-stage hybrid flowshop scheduling problem with unrelated alternative machines. The problem to be studied has m unrelated alternative machines at the first machine center followed by a second machine center with a common processing machine in the system. The objective is to minimize the makespan of the system. For the processing of any job, it is assumed that the operation can be partially substituted by other machines in the first center, depending on its machining constraints. Such scheduling problems occur in certain practical applications such as semiconductors, electronics manufacturing, airplane engine production, and petrochemical production. We demonstrate that the addressed problem is NP-hard and then provide some heuristic algorithms to solve the problem efficiently. The experimental results show that the combination of the modified Johnson's rule and the First-Fit rule provides the best solutions within all proposed heuristics.Scope and purpose     

CONWIP based control of a lamp assembly production line

Efficient and effective production control systems are very important for manufacturing plants. CONWIP, one of these production control systems, has a high potential of becoming the best one available because it suits a variety of production environments and is easy to implement. In the following paper, we compare the single-loop and multi-loop CONWIP production control systems for an actual lamp assembly production line producing different kinds of products with discrete distribution processing time and demand. A model is formulated with respect to total cost and service level. A novel rule-based genetic algorithm (GA) approach is proposed for the multi-loop CONWIP system to find the optimum parameter setting. The results have shown that the single-loop CONWIP production control system is more efficient than the multi-loop system. It can greatly decrease the total cost and the WIP (Work-In-Process) with zero shortage probability.     

Genetic algorithms in integrated process planning and scheduling

Process planning and scheduling are actually interrelated and should be solved simultaneously. Most integrated process planning and scheduling methods only consider the time aspects of the alternative machines when constructing schedules. The initial part of this paper describes a genetic algorithm (GA) based algorithm that only considers the time aspect of the alternative machines. The scope of consideration is then further extended to include the processing capabilities of alternative machines, with different tolerance limits and processing costs. In the proposed method based on GAs, the processing capabilities of the machines, including processing costs as well as number of rejects produced in alternative machine are considered simultaneously with the scheduling of jobs. The formulation is based on multi-objective weighted-sums optimization, which are to minimize makespan, to minimize total rejects produced and to minimize the total cost of production. A comparison is done w ith the traditional sequential method and the multi-objective genetic algorithm (MOGA) approach, based on the Pareto optimal concept.     

Intra-cell manpower transfers and cell loading in labor-intensive manufacturing cells

Labor-intensive manufacturing cells consist of simple machines and equipment that require continuous operator attendance and involvement. Operators are often re-assigned to different machines when a new product is released to the cell. The main reason for this re-assignment is to maximize the output rate of the cell by balancing the flow of products through several machines with varying capacities. In this paper, first a product-sequencing problem with the objective of minimizing the total intra-cell manpower transfers is introduced. A three-phase hierarchical methodology is proposed to solve the problem optimally. Next, manpower transfer matrix values are modified considering the distances traveled among machines. In the second part of the paper, a machine-level-based similarity coefficient that uses the number of machines as a similarity measure is discussed. Later, these coefficients are used during the cell loading process to minimize makespan and also machine and space requirements. Manpower allocation decisions are made along with scheduling decisions that are critical in most labor-intensive manufacturing cells and both approaches are illustrated with an example problem.     

Scheduling unrelated parallel batch processing machines with non-identical job sizes

Scheduling unrelated parallel batch processing machines to minimize makespan is studied in this paper. Jobs with non-identical sizes are scheduled on batch processing machines that can process several jobs as a batch as long as the machine capacity is not violated. Several heuristics based on best fit longest processing time (BFLPT) in two groups are proposed to solve the problem. A lower bound is also proved to evaluate the quality of the heuristics. Computational experiments were undertaken. These showed that J_SC-BFLPT, considering both load balance of machines and job processing times, was robust and outperformed other heuristics for most of the problem categories.     

Solving a multi-floor layout design model of a dynamic cellular manufacturing system by an efficient genetic algorithm

This paper presents a mixed-integer programming model for a multi-floor layout design of cellular manufacturing systems (CMSs) in a dynamic environment. A novel aspect of this model is to concurrently determine the cell formation (CF) and group layout (GL) as the interrelated decisions involved in the design of a CMS in order to achieve an optimal (or near-optimal) design solution for a multi-floor factory in a multi-period planning horizon. Other design aspects are to design a multi-floor layout to form cells in different floors, a multi-rows layout of equal area facilities in each cell, flexible reconfigurations of cells during successive periods, distance-based material handling cost, and machine depot keeping idle machines. This model incorporates with an extensive coverage of important manufacturing features used in the design of CMSs. The objective is to minimize the total costs of intra-cell, inter-cell, and inter-floor material handling, purchasing machines, machine processing, machine overhead, and machine relocation. Two numerical examples are solved by the CPLEX software to verify the performance of the presented model and illustrate the model features. Since this model belongs to NP-hard class, an efficient genetic algorithm (GA) with a matrix-based chromosome structure is proposed to derive near-optimal solutions. To verify its computational efficiency in comparison to the CPLEX software, several test problems with different sizes and settings are implemented. The efficiency of the proposed GA in terms of the objective function value and computational time is proved by the obtained results.     

Design synthesis of machining systems using co-platforming

Modern manufacturing environment is characterized by frequent product design changes in order to satisfy evolving customer requirements. Various strategies are implemented in order to efficiently manage the consequences arising from the product design changes starting from product design to planning and manufacturing. This paper focuses on synthesizing manufacturing system using the co-platforming concept which maps product platform features and components to the manufacturing system candidate platform machines. A matrix-based mapping model is proposed in order to determine the candidate platform and non-platform machines. Product-related characteristics including manufacturing features, feature orientation, dimensional and geometrical tolerance, cutting power requirements, workpiece volume and surface finish are considered. Characteristics of machines in the manufacturing system include machining axes, accuracy, working envelop and available power. A case study adopted from an automotive engine cylinder block manufacturer is used for demonstrating synthesizing manufacturing systems, based on co-platforming, which are capable of adapting to new products variants without changes to the platform machines. This prolongs the life of the manufacturing system and reduces costs associated with retooling and replacing it.     

A two-stage-priority-rule-based algorithm for robust resource-constrained project scheduling

Traditionally, the resource-constrained project scheduling problem (RCPSP) is modeled as a static and deterministic problem and is solved with the objective of makespan minimization. However, many uncertainties, such as unpredictable increases in processing times caused by rework or supplier delays, random transportation and/or setup, may render the proposed solution obsolete. In this paper, we present a two-stage algorithm for robust resource-constrained project scheduling. The first stage of the algorithm solves the RCPSP for minimizing the makespan only using a priority-rule-based heuristic, namely an enhanced multi-pass random-biased serial schedule generation scheme. The problem is then similarly solved for maximizing the schedule robustness while considering the makespan obtained in the first stage as an acceptance threshold. Selection of the best schedule in this phase is based on one out of 12 alternative robustness predictive indicators formulated for the maximization purpose. Extensive simulation testing of the generated schedules provides strong evidence of the benefits of considering robustness of the schedules in addition to their makespans. For illustration purposes, for 10 problems from the well-known standard set J30, both robust and non-robust schedules are executed with a 10% duration increase that is applied to the same randomly picked 20% of the project activities. Over 1000 iterations per instance problem, the robust schedules display a shorter makespan in 55% of the times while the non-robust schedules are shown to be the best performing ones in only 6% of the times.