A novel methodology to measure the responsiveness of RMTs in reconfigurable manufacturing system

Reconfigurable manufacturing systems are designed to deliver exact functionality and capacity that is needed, when it is needed. The reconfigurable machine tool (RMT) plays a pivotal role in the accomplishment of this objective through their built in modular structure consisting of basic and auxiliary modules along with the open architecture software.     

Simultaneous optimal selection of design and manufacturing tolerances with alternative manufacturing process selection

Tolerance specification is an important part of mechanical design. Design tolerances strongly influence the functional performance and manufacturing cost of a mechanical product. Tighter tolerances normally produce superior components, better performing mechanical systems and good assemblability with assured exchangeability at the assembly line. However, unnecessarily tight tolerances lead to excessive manufacturing costs for a given application. The balancing of performance and manufacturing cost through identification of optimal design tolerances is a major concern in modern design. Traditionally, design tolerances are specified based on the designer’s experience. Computer-aided (or software-based) tolerance synthesis and alternative manufacturing process selection programs allow a designer to verify the relations between all design tolerances to produce a consistent and feasible design. In this paper, a general new methodology using intelligent algorithms viz., Elitist Non-dominated Sorting Genetic Algorithm (NSGA-II) and Multi Objective Particle Swarm Optimization (MOPSO) for simultaneous optimal selection of design and manufacturing tolerances with alternative manufacturing process selection is presented. The problem has a multi-criterion character in which 3 objective functions, 3 constraints and 5 variables are considered. The average fitness factor method and normalized weighted objective functions method are separately used to select the best optimal solution from Pareto optimal fronts. Two multi-objective performance measures namely solution spread measure and ratio of non-dominated individuals are used to evaluate the strength of Pareto optimal fronts. Two more multi-objective performance measures namely optimiser overhead and algorithm effort are used to find the computational effort of NSGA-II and MOPSO algorithms. The Pareto optimal fronts and results obtained from various techniques are compared and analysed.     

RMS中的基于时间的设备选择方法研究

根据生产需求快速确定制造资源是可重组制造系统高效快速响应市场变化的关键功能之一。文中提出了以系统整体加工时间消耗最少为目标的时间虚负荷矩阵算法,这种算法通过矩阵进行运算,计算简单直观,在计算过程中同时实现设备优化选择和工序分配,这种算法还可应用于车间作业调度。     

Simulated annealing with auxiliary knowledge for process planning optimization in reconfigurable manufacturing

In this paper, three simulated annealing based algorithms that exploit auxiliary knowledge in different ways are devised and employed to handle a manufacturing process planning problem for reconfigurable manufacturing. These algorithms are configured based on a generic combination of the simulated annealing technique with; (a) heuristic knowledge, and (b) metaknowledge. Capabilities of the implemented algorithms are tested and their performances compared against a basic simulated annealing algorithm. Computational and optimization performances of the implemented algorithms are investigated and analyzed for two problem sizes. Each problem size consists of five different forms of a manufacturing process planning problem. The five forms are differentiated by five alternative objective functions. Experimental results show that the implemented simulated annealing algorithms are able to converge to good solutions in reasonable time. A computational analysis indicates that significant improvements towards a better optimal solution can be gained by implementing simulated annealing based algorithms that are supported by auxiliary knowledge.     

A virtual prototyping system with reconfigurable actuators for multi-material layered manufacturing

Proliferation of layered manufacturing (LM) in various sectors has been calling for fabrication of large, complex products with more materials and efficiency. We address this issue by integrating reconfigurable manufacturing (RM) with LM. This paper first analyses the benefits of such integration, and then presents a virtual prototyping system with reconfigurable actuators (VPRA) that can increase the number of materials, speed, and build volume to improve the efficiency and flexibility of multi-material layered manufacturing (MMLM). The VPRA system offers a test bed for design, visualization, and validation of MMLM facilities and processes. It takes advantage of the convenient graphics platform of SolidWorks™ for constructing a virtual MMLM facility by selecting reconfigurable actuators from predefined templates. The characteristics, including the dimensions and relative spatial constraints, of the actuators can be conveniently configured to suit design requirements. The mechanism and the operation process of the resulting MMLM facility can then be simulated and validated through digital fabrication of complex objects. Case studies are presented to demonstrate some possible applications of the VPRA system. Overall, the VPRA system gives insights into the characteristics of a reconfigurable MMLM system, which can be subsequently materialized for physical fabrication of multi-material objects. This approach highlights a possible direction for development of MMLM technology.     

敏捷制造中制造资源选择问题的遗传算法

对敏捷制造系统重构中的制造资源选择问题进行了分析,建立了数学模型,提出了一种适合求解该问题的遗传算法。该算法与解决同类问题的已有算法相比,编码方案和遗传算子均比较简单。实验结果表明,遗传算法在解的质量、稳定性和收敛速度方面具有优良性能。     

Trends and perspectives in flexible and reconfigurable manufacturing systems

To better understand future needs in manufacturing and their enabling technologies, a survey of experts in manufacturing has been conducted. The survey instrument (i.e., questionnaire) tries to assess the experience to date with the use of flexible manufacturing systems (FMS) and to examine the potential roles and enabling technologies for reconfigurable manufacturing systems (RMS). The results show that two-thirds of respondents stated that FMSs are not living up to their full potential, and well over half reported purchasing FMS with excess capacity (which was eventually used) and excess features (which in many cases were not eventually used). They identified a variety of problems associated with FMS, including training, reconfigurability, reliability and maintenance, software and communications, and initial cost. However, despite these issues, nearly 75% of respondent expressed their desire to purchase additional, or expand existing FMSs. The experts agreed that RMS (which can provide exactly the capacity and functionality needed, exactly when needed) is a desirable next step in the evolution of production systems. The key enabling technologies for RMS were identified as modular machines, open-architecture controls, high-speed machining, and methods, training and education for the operation of manufacturing systems.     

Near optimal process plan selection for multiple jobs in networked based manufacturing using multi-objective evolutionary algorithms

The networked manufacturing offers several advantages in current competitive atmosphere by way of reducing the manufacturing cycle time and maintenance of the production flexibility, thereby achieving several feasible process plans. In this paper, we have addressed a Multi Objective Problem (MOP) which covers-minimize the makespan and to maximize the machine utilization while generating the feasible process plans for multiple jobs in the context of network based manufacturing system. A new multi-objective based Territory Defining Evolutionary Algorithm (TDEA) to resolve the above computationally challenge problem have been developed. In particular, with two powerful Multi-Objective Evolutionary Algorithms (MOEAs), viz. Non-dominated Sorting Genetic Algorithm (NSGA-II) and Controlled Elitist-NSGA-II (CE-NSGA-II) the performance of the proposed TDEA has been compared. An illustrative example along with three complex scenarios is presented to demonstrate the feasibility of the approach. The proposed algorithm is validated and the results are analyzed and compared.     

A dynamic multi-objective approach for the reconfigurable multi-facility layout problem

The multi-facility layout problem involves the physical organization of departments inside several facilities, to allow flexible and efficient operations. This work studies the facility layout problem in a new perspective, considering a group of facilities, and two different concerns: the location of departments within a group of facilities, and the location of departments inside each facility itself. The problem is formulated as a Quadratic Programming Problem with multiple objectives and unequal areas, allowing layout reconfigurations in each planning period. The objectives of the model are: the minimization of costs (material handling inside facilities and between facilities, and re-layout); the maximization of adjacency between departments; and the minimization of the “unsuitability” of department positions and locations. This unsuitability measure is a new objective proposed in this work, to combine the characteristics of existing locations with the requirements of departments. The model was tested with data from the literature as well as with a problem inspired in a first tier supplier in the automotive industry. Preliminary results show that this work can be viewed as an innovative and promising integrated approach for tackling real, complex facility layout problems.     

A genetic algorithm based approach to optimal fixture configuration

In this paper the application of genetic algorithms (GAs) to the fixture configuration optimisation problem is presented. A general purpose fixturing verification system has been developed to check the validity of individual fixture configurations by analysing various contact types in the workpiece-fixture system. Based on the information provided by the verification system, a genetic algorithm based approach carries out the evaluation process to determine the most statically stable fixture configuration among a large number of candidates. The preliminary implementation is introduced to demonstrate the ability of GAs and two different coding schemes are tested to explain their influence on the performance of GAs.     

An optimal image watermarking approach based on a multi-objective genetic algorithm

In accordance with the multi-objective nature of image watermarking, an optimal image watermarking approach using a multi-objective genetic algorithm is presented in this paper. Both watermarking parameters and embedding positions are often important factors affecting the performance of watermarking systems. The proposed multi-objective watermarking method can automatically optimize system parameters, and a variable-length mechanism is specially designed to search the most suitable positions for embedding watermarks. The method can also remove the difficult issue of determining optimal watermarking parameters from previous watermarking algorithms. The proposed multi-objective watermarking method directly deals with the problem of optimizing watermarking under non-dominated meaning, thus it can effectively avoid the difficulty of determining the optimally weighted factor in existing single-objective watermarking schemes. In addition, a Pareto-optimal set generated by multi-objective optimization can provide flexibility in selecting the most suitable watermarking parameters according to practical requirements.     

An evolutionary algorithm approach to generate distinct sets of non-dominated solutions for wicked problems

Many engineering design problems must optimize multiple objectives. While many objectives are explicit and can be mathematically modeled, some goals are subjective and cannot be included in a mathematical model of the optimization problem. A set of alternative non-dominated fronts that represent multiple optima for problem solution can be identified to provide insight about the decision space and to provide options and alternatives for decision-making. This paper presents a new algorithm, the Multi-objective Niching Co-evolutionary Algorithm (MNCA) that identifies distinct sets of non-dominated solutions which are maximally different in their decision vectors and are located in the same non-inferior regions of a Pareto front. MNCA is demonstrated to identify a set of non-dominated fronts with maximum difference in decision vectors for a set of real-valued problems.     

A multi-objective genetic algorithm approach to rule mining for affective product design

A novel multi-objective genetic algorithm (GA)-based rule-mining method for affective product design is proposed to discover a set of rules relating design attributes with customer evaluation based on survey data. The proposed method can generate approximate rules to consider the ambiguity of customer assessments. The generated rules can be used to determine the lower and upper limits of the affective effect of design patterns. For a rule-mining problem, the proposed multi-objective GA approach could simultaneously consider the accuracy, comprehensibility, and definability of approximate rules. In addition, the proposed approach can deal with categorical attributes and quantitative attributes, and determine the interval of quantitative attributes. Categorical and quantitative attributes in affective product design should be considered because they are commonly used to define the design profile of a product. In this paper, a two-stage rule-mining approach is proposed to generate rules with a simple chromosome design in the first stage of rule mining. In the second stage of rule mining, entire rule sets are refined to determine solutions considering rule interaction. A case study on mobile phones is used to demonstrate and validate the performance of the proposed rule-mining method. The method can discover rule sets with good support and coverage rates from the survey data.     

A decision support system for material and manufacturing process selection

The material and manufacturing process selection problem is a multi-attribute decision-making problem. These decisions are made during the preliminary design stages in an environment characterized by imprecise and uncertain requirements, parameters, and relationships. Material and process selection decisions must occur before design for manufacturing can begin. This paper describes a prototype material and manufacturing process selection system called MAMPS that integrates a formal multi-attribute decision model with a relational database. The decision model enables the representation of the designer's preferences over the decision factors. A compatibility rating between the product profile requirements and the alternatives stored in the database for each decision criteria is generated using possibility theory. The vector of compatibility ratings are aggregated into a single rating of that alternative's compatibility. A ranked set of compatible material and manufacturing process alternatives is output by the system. This approach has advantages over existing systems that either do not have a decision module or are not integrated with a database.     

An approach to partner selection in agile manufacturing

It is believed that agile manufacturing is the twenty-first century manufacturing enterprise strategy and should be realized by agile virtual enterprise (AVE) which is dynamically configured for the manufacturing of one or more products. Agile manufacturing creates a significant challenge for the partner selection in configuring an AVE. This paper presents a brief introduction to the task decomposition for the manufacturing of a product in multisite environment. A bidding process should be carried out for each task so as to get the information necessary for the configuration of AVE. To minimize the manufacturing cost, an integer programming (IP) formulation is presented for the partner selection problem. The IP formulation is then transformed into a graph-theoretical formulation by taking the advantage of the precedence relationship between the tasks. The graph obtained turns out to be a directed multipartite graph. Based on the graph-theoretical formulation, an efficient solution algorithm is proposed for the problem. It is shown that the algorithm is polynomial bounded. Therefore, it is applicable to large practical problems.     

基于模糊控制及遗传算法的反向选择算法

针对基于人工免疫的入侵检测技术中所使用的传统反向选择算法,在面对大量的网络通信数据或具有多个分离特征区间网络通信数据时的无效性,提出了基于模糊控制及遗传算法的反向选择算法.在利用反向选择算法生成抗体时,首先利用模糊控制原理来确定抗体的数量,使得计算机中抗体的数量处于最优,然后为了达到在一定数量抗体时种群的总体免疫力最大,引入了遗传算法来进化种群,最终使得在计算机中抗体的数量得到控制,同时在该数量下种群具有最大的免疫力.     

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.     

A hybrid multi-objective approach based on the genetic algorithm and neural network to design an incremental cellular manufacturing system

One important issue related to the implementation of cellular manufacturing systems (CMSs) is to decide whether to convert an existing job shop into a CMS comprehensively in a single run, or in stages incrementally by forming cells one after the other, taking the advantage of the experiences of implementation. This paper presents a new multi-objective nonlinear programming model in a dynamic environment. Furthermore, a novel hybrid multi-objective approach based on the genetic algorithm and artificial neural network is proposed to solve the presented model. From the computational analyses, the proposed algorithm is found much more efficient than the fast non-dominated sorting genetic algorithm (NSGA-II) in generating Pareto optimal fronts.     

Multi-period part selection and loading problems in flexible manufacturing systems

We consider multi-period part selection and loading problems in flexible manufacturing systems with the objective of minimizing subcontracting costs. The part selection problem is to select sets of part types and to determine their quantities to be produced during the upcoming planning horizon while satisfying due dates of all orders for the parts, and the loading problem involves allocation of operations and required tools to machines. Production demands should be satisfied for periods through subcontracting if production demands cannot be satisfied by the system due to machine capacity or tool magazine capacity constraints. For the part selection and loading problems, we develop three iterative algorithms, called the forward algorithm, the backward algorithm and the capacity approximation algorithm, that solve the part selection and loading problems iteratively for each period. To compare the three algorithms, a series of computational experiments is done on randomly generated test problems.     

A decision support system for the selection of computer-integrated manufacturing technologies

The adoption of computer-integrated manufacturing (CIM) offers manufacturing organizations many tangible and intangible benefits which enable them to produce products of high quality at low costs. However, the selection and evaluation of CIM is a complex process as it involves the consideration of many parameters to ensure that the selected technology meets the requirements of individual companies. This paper describes the development of a quantitative/qualitative decision support system for the evaluation of CIM which takes into consideration the objectives and operating characteristics of a company, thus ensuring that the selected technology matches the individual needs of that company. The methodology used in the decision support system is based on a combination of the analytical hierarchy process (AHP) and database technology. The AHP provides a means to consider both the tangible and the intangible benefits of CIM while databases are used to store the knowledge about the various benefits that CIM may offer. The system has been implemented in EXCEL, which fully automates the evaluation process. A case study is also presented to illustrate the capability of the proposed decision support system.