Robotic disassembly sequence planning using enhanced discrete bees algorithm in remanufacturing

Increasing attention is being paid to remanufacturing due to environmental protection and resource saving. Disassembly, as an essential step of remanufacturing, is always manually finished which is time-consuming while robotic disassembly can improve disassembly efficiency. Before the execution of disassembly, generating optimal disassembly sequence plays a vital role in improving disassembly efficiency. In this paper, to minimise the total disassembly time, an enhanced discrete Bees algorithm (EDBA) is proposed to solve robotic disassembly sequence planning (RDSP) problem. Firstly, the modified feasible solution generation (MFSG) method is used to build the disassembly model. After that, the evaluation criterions for RDSP are proposed to describe the total disassembly time of a disassembly sequence. Then, with the help of mutation operator, EDBA is proposed to determine the optimal disassembly sequence of RDSP. Finally, case studies based on two gear pumps are used to verify the effectiveness of the proposed method. The performance of EDBA is analysed under different parameters and compared with existing optimisation algorithms used in disassembly sequence planning (DSP). The result shows the proposed method is more suitable for robotic disassembly than the traditional method and EDBA generates better quality of solutions compared with the other optimisation algorithms.     

Discrete harmony search algorithm for scheduling and rescheduling the reprocessing problems in remanufacturing: a case study

In this article, scheduling and rescheduling problems with increasing processing time and new job insertion are studied for reprocessing problems in the remanufacturing process. To handle the unpredictability of reprocessing time, an experience-based strategy is used. Rescheduling strategies are applied for considering the effect of increasing reprocessing time and the new subassembly insertion. To optimize the scheduling and rescheduling objective, a discrete harmony search (DHS) algorithm is proposed. To speed up the convergence rate, a local search method is designed. The DHS is applied to two real-life cases for minimizing the maximum completion time and the mean of earliness and tardiness (E/T). These two objectives are also considered together as a bi-objective problem. Computational optimization results and comparisons show that the proposed DHS is able to solve the scheduling and rescheduling problems effectively and productively. Using the proposed approach, satisfactory optimization results can be achieved for scheduling and rescheduling on a real-life shop floor.     

Heuristics for integrated job assignment and scheduling in the multi-plant remanufacturing system

We consider a multi-plant remanufacturing system where decisions have to be made on the choice of plant to perform the remanufacturing and the remanufacturing options. Each plant is in different geographical locations and differs in technological capability, labour cost, distance from customers, taxes and duties. There are three options of remanufacture: replacement, repair and recondition. Furthermore, the probability that each remanufacture job needs to be reworked depends on the remanufacturing option selected. We show the interdependencies among the plant selection, remanufacturing option and job scheduling when subject to resource constraints, which motivate the integrated solution proposed in this paper. The solution method is composed of the linear physical programming and the multi-level encoding genetic algorithm (GA). By performing a case study, we illustrate the use of the model and we present the resulting managerial insights. The results show that the proposed integrated approach performs better compared with the regular GA in terms of makespan.     

Hybrid manufacturing/remanufacturing lot-sizing and supplier selection with returns,under carbon emission constraint

This paper addresses a lot-sizing problem in manufacturing/remanufacturing systems. The studied system is a single manufacturing line where both regular manufacturing and returns remanufacturing processes are carried out, with different set-up costs for each process. We consider also a returns collection phase from customers/distributors with deterministic returns quantities at each period of the planning horizon. The environmental aspect is assumed in this study by considering a carbon emission constraint for the manufacturing, remanufacturing and transportation activities. A mixed integer programming model to minimise the management cost and meet the customer’s needs under different manufacturing constraints is proposed. Otherwise, An adaptation of the well-known Silver and Meal (SM) heuristic and two hybrid method approaches (HM1 and HM2) providing approximates solutions are developed. The mixed integer model was tested on Cplex (Software optimizer), and the obtained results were compared with the ones provided by the adapted heuristic SM and the hybrid methods. The numerical analyses show that hybrid methods provide good-quality solutions in a moderate computational time. The proposed model establishes a collegial and an integrated process that sets values, goals, decisions and priorities along the considered supply chain while taking into account the environmental aspect.     

特殊工艺约束下并行机多目标调度问题

针对并行机多目标调度问题的特点,提出了一个多目标调度模型,设计了一个基于向量组编码的遗传算法,并对其初始种群、选择、交叉和变异等方法进行了研究。此算法的编码方法能有效地反映实际调度方案,并引入免疫算子,保证了种群的多样性和种群的质量,加快了收敛速度。仿真结果表明,此算法是有效的,优于没引入免疫算子的遗传算法。     

Deadlock-free genetic scheduling for flexible manufacturing systems using Petri nets and deadlock controllers

In this paper, a new deadlock-free scheduling method based on genetic algorithm and Petri net models of flexible manufacturing systems is proposed. The optimisation criterion is to minimise the makespan. In the proposed genetic scheduling algorithm, a candidate schedule is represented by a chromosome that consists of two sections: route selection and operation sequence. With the support of a deadlock controller, a repairing algorithm is proposed to check the feasibility of each chromosome and fix infeasible chromosomes to feasible ones. A feasible chromosome can be easily decoded to a deadlock-free schedule, which is a sequence of transitions without deadlocks. Different kinds of crossover and mutation operations are performed on two sections of the chromosome, respectively, to improve the performance of the presented algorithm. Computational results show that the proposed algorithm can get better schedules. Furthermore, the proposed scheduling method provides a new approach to evaluate the performance of different deadlock controllers.     

A multi-objective optimisation model to integrating flexible process planning and scheduling based on hybrid multi-objective simulated annealing

Process planning and production scheduling play important roles in manufacturing systems. In this paper we present a mixed integer linear programming (MILP) scheduling model, that is to say a slot-based multi-objective multi-product, that readily accounts for sequence-dependent preparation times (transition and set up times or machine changeover time). The proposed scheduling model becomes computationally expensive to solve for long time horizons. The aim is to find a set of high-quality trade-off solutions. This is a combinatorial optimisation problem with substantially large solution space, suggesting that it is highly difficult to find the best solutions with the exact search method. To account for this, the hybrid multi-objective simulated annealing algorithm (MOHSA) is proposed by fully utilising the capability of the exploration search and fast convergence. Two numerical experiments have been performed to demonstrate the effectiveness and robustness of the proposed algorithm.     

Power distribution network expansion scheduling using dynamic programming genetic algorithm

A genetic algorithm that is dedicated to the expansion planning of electric distribution systems is presented, with incremental expansion scheduling along a time horizon of several years and treated as a dynamic programming problem. Such a genetic algorithm (called dynamic programming genetic algorithm) is endowed with problem-specific crossover and mutation operators, dealing with the problem through a heuristic search in the space of dynamic programming variables. Numerical tests have shown that the proposed algorithm has found good solutions that considerably enhance the solutions found by non-dynamic programming methods. The algorithm has also shown to work for problem sizes that would be computationally infeasible for exact dynamic programming techniques.     

混合工作日历下批量生产柔性作业车间多目标调度方法

提出了一种混合工作日历下批量生产柔性作业车间多目标调度方法。考虑设备的混合工作日历约束,构建了以生产周期最短、制造成本最低为优化目标的批量生产柔性作业车间多目标调度模型。设计了一种带精英策略的非支配排序遗传算法(NSGA II)求解该模型。算法中,采用“基于工序和设备的分段编码”方式分别对工序和设备进行编码;采用“基于工序和设备的分段交叉和变异方式”进行交叉和变异操作,采用“遗传算子改进策略”保证交叉、变异后子代个体的可行性;解码操作采用“基于平顺移动的原理”和“基于工作日历的时间推算技术”推算工序的调整开始、调整结束、加工开始和加工结束时刻。最后,通过案例分析验证了所提方法的有效性。     

Heuristic algorithms for maximising the total profit of end-of-life computer remanufacturing

Recently the optimisation of end-of-life (EOL) computer remanufacturing has been highlighted since a big amount of used computers have been disposed of every year. Each part inspected after disassembling EOL computers can have various EOL options such as reuse, repair, reconditioning and so on. Depending on EOL options, recovered values and costs of parts will be different. Hence, in order to maximise the profit of remanufactured computers, it is important to develop the method as to how to decide the EOL options of computer parts. To this end, this study deals with a decision-making problem to select the best EOL option policy of the computer parts for maximising the total profit of computer remanufacturing considering its incurred costs and demand of remanufactured computers during multiple production periods. In particular, to maximise the total profit, the conditional repair option is newly proposed. To resolve the problem, a genetic search algorithm and an ant colony search algorithm have been developed. Computational experiments have carried out to evaluate the algorithms and the proposed conditional repair option.     

An effective discrete harmony search algorithm for flexible job shop scheduling problem with fuzzy processing time

This study addresses flexible job shop scheduling problem (FJSP) with fuzzy processing time. The fuzzy or uncertainty of processing time is one of seven characteristics in remanufacturing. A discrete harmony search (DHS) algorithm is proposed for FJSP with fuzzy processing time. The objective is to minimise maximum fuzzy completion time. A simple and effective heuristic rule is proposed to initialise harmony population. Extensive computational experiments are carried out using five benchmark cases with eight instances from remanufacturing. The proposed heuristic rule is evaluated using five benchmark cases. The proposed DHS algorithm is compared to six metaheuristics. The results and comparisons show the effectiveness and efficiency of DHS for solving FJSP with fuzzy processing time.     

Scheduling of deadlock and failure-prone automated manufacturing systems via hybrid heuristic search

This work focuses on the scheduling problem of deadlock and failure-prone automated manufacturing systems, and presents a new scheduling method by combining a robust supervisory control policy and hybrid heuristic search. It aims to minimise makespan, i.e. the completion time of the last part. Based on the extended reach ability graph of the system, it establishes a new heuristic function and two dispatching rules to guide the search process for a schedule. By embedding a robust supervisory control policy into the search process, it develops a polynomial robust dynamic window search algorithm. Failure and repair events of unreliable resources may occur during the execution of a schedule obtained by the proposed algorithm and may make the schedule infeasible. To reduce the influence caused by them and ensure all parts to be finished, this work proposes two event-driven strategies. The first one suspends the execution of the parts requiring failed resources and those to be started until all failed resources are repaired and permits only those parts that have already been processed on working machines to be completed. The second one invokes the proposed algorithm to obtain a new schedule at the vertex generated after a resource failure or repair event and executes the new schedule. Both strategies are effective while the latter performs better at the expense of more computation.     

An artificial bee colony algorithm for the economic lot scheduling problem

In this study, we present an artificial bee colony (ABC) algorithm for the economic lot scheduling problem modelled through the extended basic period (EBP) approach. We allow both power-of-two (PoT) and non-power-of-two multipliers in the solution representation. We develop mutation strategies to generate neighbouring food sources for the ABC algorithm and these strategies are also used to develop two different variable neighbourhood search algorithms to further enhance the solution quality. Our algorithm maintains both feasible and infeasible solutions in the population through the use of some sophisticated constraint handling methods. Experimental results show that the proposed algorithm succeeds to find the all the best-known EBP solutions for the high utilisation 10-item benchmark problems and improves the best known solutions for two of the six low utilisation 10-item benchmark problems. In addition, we develop a new problem instance with 50 items and run it at different utilisation levels ranging from 50 to 99% to see the effectiveness of the proposed algorithm on large instances. We show that the proposed ABC algorithm with mixed solution representation outperforms the ABC that is restricted only to PoT multipliers at almost all utilisation levels of the large instance.     

A memetic algorithm for multi-objective flexible job-shop problem with worker flexibility

In existing scheduling models, the flexible job-shop scheduling problem mainly considers machine flexibility. However, human factor is also an important element existing in real production that is often neglected theoretically. In this paper, we originally probe into a multi-objective flexible job-shop scheduling problem with worker flexibility (MO-FJSPW). A non-linear integer programming model is presented for the problem. Correspondingly, a memetic algorithm (MA) is designed to solve the proposed MO-FJSPW whose objective is to minimise the maximum completion time, the maximum workload of machines and the total workload of all machines. A well-designed chromosome encoding/decoding method is proposed and the adaptive genetic operators are selected by experimental studies. An elimination process is executed to eliminate the repeated individuals in population. Moreover, a local search is incorporated into the non-dominated sorting genetic algorithm II. In experimental phase, the crossover operator and elimination operator in MA are examined firstly. Afterwards, some extensive comparisons are carried out between MA and some other multi-objective algorithms. The simulation results show that the MA performs better for the proposed MO-FJSPW than other algorithms.     

Dynamic disassembly planning for remanufacturing of multiple types of products

With the increased need for remanufacturing of end-of-life products, achieving economic efficiency in remanufacturing is urgently needed. The purpose of this study was to devise a cost-minimisation plan for disassembly and remanufacturing of end-of-life products returned by consumers. A returned end-of-life product is disassembled into remanufacturable parts, which are supposed to be used for new products after being remanufactured. Each end-of-life product is disassembled into parts at variable levels and through variable sequences as needed, taking into account not only disassembly but also manufacturing, remanufacturing, and holding inventory of remanufacturable parts. This study proposes a mixed integer linear programming (MILP) model for derivation of the optimal disassembly plan for each returned product, under deterministically known demand and return flows. For the purposes of an illustrative example, the proposed model was applied to the formulation of an optimal disassembly and remanufacturing plan of ‘fuser assembly’ of laser printers. The solution reveals that variable-level disassembly of products saves a significant remanufacturing cost compared with full disassembly.     

Heuristics for solving disassemble-to-order problems with stochastic yields

Within the realm of reverse logistics, remanufacturing has become renowned as a popular option in many reverse logistics settings. In remanufacturing, firms take back products at the end of their use, disassemble them to obtain components, and reassemble these components into a “good as new” remanufactured product. As a process, remanufacturing requires parts as an input, parts which are gained mostly from recovered products. As the quality of the returned products are not known in advance, likewise the amount of good quality parts recovered from the returned product is subject to uncertainty. In this paper, we develop two heuristics of different sophistication which take into consideration that the yields of disassembly are stochastic. The methodology is further illustrated with a numerical example, and performance of the heuristics is examined through a performance study. The performance study indicates excellent performance for the more sophisticated heuristic, but also reveals under which conditions the more simple heuristic can be recommended for application.     

A study of the optimal production strategy for hybrid production systems

Due to increased environmental awareness, the issue of recycling and disassembling damaged or malfunctioning products after consumption to obtain useable parts for remanufacturing has become essential. This study considers a hybrid production system with both external and internal reverse logistics in which the external recycled products are utilised for remanufacturing to satisfy demand first, and then the ordinary manufacturing process may supplement this if there is any shortage in production. In addition, the defective items produced internally by either the manufacturing or the remanufacturing process can also be repaired by a remediation process. The objective of this study is to determine the optimal strategy for the manufacturing, remanufacturing, disposal, and remediation rates. Three conditions are considered in which the production strategy varies with different yield rates and capacity limits. The impacts of related factors on the production strategy are investigated to probe the trade-offs between product consumption and environmental protection.     

Optimal acquisition policy in remanufacturing under general core quality distributions

The quality of acquirable used products (cores) is highly variable, which has made production planning and control of remanufacturing systems difficult. This paper studies an acquisition problem in presence of uncertain core quality. In order to derive optimal acquisition policy, the problem is formulated as a non-linear integer programming model in the framework of order statistics. The model is a strictly discrete convex problem with a unique global minimal solution. Then, a single bisection method is developed to obtain the optimal solution under a general continuous quality distribution. Moreover, the expressions of the optimal solution in some frequently used quality distributions are derived. Furthermore, the model is extended to the case of a general remanufacturing cost function, and corresponding results are presented. Finally, numerical experiments are conducted to test the effects of quality distribution, cost relationships of acquirable cores and remanufacturing cost function.     

基于改进遗传算法的分批调度研究

针对分批调度的批量划分和排序优化问题,提出两段染色体编码方式,分别描述工序信息和批量信息.提出舍弃比率概念来优化种群初始化过程.采用自适应交叉算子和变异算子,以双种群协同进化方式对遗传算法进行改进.以文献数据为例仿真测试了改进遗传算法的有效性,对于复杂的分批调度问题,改进遗传算法一般能够得到较为满意的解.成功应用分批调度改进遗传算法解决了某公司分批调度问题.     

An improved NSGA-II algorithm for multi-objective lot-streaming flow shop scheduling problem

Crossover and mutation operators in NSGA-II are random and aimless, and encounter difficulties in generating offspring with high quality. Aiming to overcoming these drawbacks, we proposed an improved NSGA-II algorithm (INSGA-II) and applied it to solve the lot-streaming flow shop scheduling problem with four criteria. We first presented four variants of NEH heuristic to generate the initial population, and then incorporated the estimation of distribution algorithm and a mutation operator based on insertion and swap into NSGA-II to replace traditional crossover and mutation operators. Last but not least, we performed a simple and efficient restarting strategy on the population when the diversity of the population is smaller than a given threshold. We conducted a serial of experiments, and the experimental results demonstrate that the proposed algorithm outperforms the comparative algorithms.