A model for the minimum cost configuration problem in flexible manufacturing systems

This paper presents a mathematical programming model to help select equipment for a flexible manufacturing system, i.e., the selection of the types and numbers of CNC machines, washing stations, load/unload stations, transportation vehicles, and pallets. The objective is to minimize equipment costs and work-in-process inventory cost, while fulfilling production requirements for an average period. Queueing aspects and part flow interactions are considered with the help of a Jacksonian-type closed queueing network model in order to evaluate the system's performance. Since the related decision problem of our model can be shown to be NP-complete, the proposed solution procedure is based on implicit enumeration. Four bounds are provided, two lower and two upper bounds. A tight lower bound is obtained by linearizing the model through the application of asymptotic bound analysis. Furthermore, asymptotic bound analysis allows the calculation of a lower bound for the number of pallets in the system. The first upper bound is given by the best feasible solution and the second is based on the anti-starshaped form of the throughput function.     

Performance management in flexible manufacturing systems

This article treats several performance management decision problems in flexible manufacturing systems (FMSs). This work differs from a number of other studies in that we allow the processing rates at the machines to be varied, and the system has to meet a given throughput goal per unit time. The managerial decision options modeled here include part routing and allocation of tasks to machines, work-in-progress (WIP) levels, capacity expansions, tool-type selection, the setting of throughput goals, and multiperiod production planning. We discuss and explain the insights and implications, partly nonintuitive, gained from our investigations. Finally, extensive numerical evaluations are included to illustrate the economic and performance impact of the various performance management alternatives. These results demonstrate that substantial economic benefits can be achieved by careful tuning of the FMS operational parameters.     

面向制造资源优化配置的制造过程协同管理研究

在数字化企业条件下，对基于制造资源优化配置的制造过程协同管理系统进行了深入的研究。论文首先提出了整个系统的组织形式，阐述了各子系统的功能结构，详细分析了各子系统间基于XML的制造数据集成方式，并建立了接口规范和基于XML WEB服务的集成模式。最后介绍了系统在企业中的应用情况。结果表明，整个系统可较好的实现面向订单的制造过程协同管理和社会制造资源的优化配置，已经达到了实用化程度，进而为企业提供了一套可重构的制造解决方案。     

Workload balance and part-transfer minimization in flexible manufacturing systems

Problems related to the flow management of a flexible manufacturing system (FMS) are here formulated in terms of combinatorial optimization. We consider a system consisting of several multitool automated machines, each one equipped with a possibly different tool set and linked to each other by a transportation system for part moving. The system operates with a given production mix.The focused flow-management problem is that of finding the part routings allowing for an optimal machine workload balancing. The problem is formulated in terms of a particular capacity assignment problem.With the proposed approach, a balanced solution can be achieved by routing parts on a limited number of different paths. Such a balancing routing can be found in polynomial time. We also give polynomial-time and-space algorithms for choosing, among all workload-balancing routings, the ones that minimize the global amount of part transfer among all machines.     

A line-balancing strategy for designing flexible assembly systems

We present a rough-cut analysis tool that quickly determines a few potential cost-effective designs at the initial design stage of flexible assembly systems (FASs) prior to a detailed analysis such as simulation. It uses quantitative methods for selecting and configuring the components of an FAS suitable for medium to high volumes of several similar products. The system is organized as a series of assembly stations linked with an automated material-handling system moving parts in a unidirectional flow. Each station consists of a single machine or of identical parallel machines. The methods exploit the ability of flexible hardware to switch almost instantaneously from product to product. Our approach is particularly suitable where the product mix is expected to be stable, since we combine the hardware-configuration phase with the task-allocation phase.For the required volume of products, we use integer programming to select the number of stations and the number of machines at each station and to allocate tasks to stations. We use queueing network analysis, which takes into account the mean and variance of processing times among different products to determine the necessary capacity of the material-handling system. We iterate between the two analyses to find the combined solution with the lowest costs. Work-in-process costs are also included in the analysis. Computational results are presented.     

A heuristic algorithm for the loading problem in flexible manufacturing systems

The paper considers the loading problem in flexible manufacturing systems (FMSs). This problem involves the assignment to the machine tools of all operations and associated cutting tools required for part types that have been selected to be produced simultaneously. The loading problem is first formulated as a linear mixed 0–1 program with the objective to minimize the greatest workload assigned to each machine. A heuristic procedure is presented in which an assignment of operations to machine tools is obtained by solving a parameterized generalized assignment problem with an objective function that approximates the use of tool slots required by the operations assigned to the machines. The algorithm is coded in FORTRAN and tested on an IBM-compatible personal computer. Computational results are presented for different test problems to demonstrate the efficiency and effectiveness of the suggested procedure.     

基于粗糙集理论的区域虚拟企业资源优化决策

通过分析区域虚拟企业结盟中制造任务导向和调度,建立了基于应用服务提供商资源优化配置的服务模型;构建了面向评价体系的制造资源模型,运用聚类分析和粗糙集理论,完成资源优化评价指标体系以及各属性权重因子决策的算法.最后,将算法应用于实践,验证了其有效性.     

Specification methods for material-handling control algorithms in flexible manufacturing systems

Good methods are needed to specify, test, and debug material-handling control logic. This article surveys a number of representative methods for defining and describing control algorithms for programmable material-handling equipment used in flexible manufacturing systems. The methods are evaluated with regard to their suitability for communication between people and as bases for interfaces to automatic program generators. It is concluded that no single method is entirely satisfactory. Three methods (position diagrams, function block diagrams, and operation networks) have potential to be combined into an effective hybrid approach that minimizes the need for the user to switch between various conceptual models.     

交互式CSP用于解决产品配置中交互问题的研究

传统CSP(Constraint Satisfaction Problem)难以用于描述和解决产品配置中的交互配置问题和使用户得到满意的配置结果。本文通过对传统CSP在交互配置中所存在缺陷的分析,定义了一类新的动态约束满足问题DCSP(Dynamic CSP),并以DCSP为基础提出了一种基于交互式约束满足问题ICSP(Interactive CSP)的交互配置方法的框架,解决了产品配置中的交互问题,使用户得到最优配置结果。最后进行了仿真验证。     

两阶齐套性约束的制造系统排队网建模与缓冲区优化

针对定制型装备制造企业,研究了具有研配工序的制造系统排队网建模和缓冲区容量配置优化问题.建立了两阶齐套性约束的有限缓冲区开排队网模型,基于3种不同假设模型:M/M/1/K、GI/M/1/K和GI/G/1/K,提出拓展的广义扩展法,处理双重同步约束和固定配对约束,以快速求解系统性能指标值.其次,通过算例实验与仿真结果进行对比,验证假设模型的有效性和求解方法的精确性,并分析缓冲区容量对系统性能的影响.最后,由于缓冲区容量配置优化问题是一个非线性整数规划问题,因此提出一种将拓展的广义扩展法嵌入Polyblock算法的优化方法,并通过案例结果验证了方法的有效性.     

A new branch and bound algorithm for loading problems in flexible manufacturing systems

Loading problems in flexible manufacturing systems involve assigning operations for selected part types and their associated tools to machines or machine groups. One of the objectives might be to maximize the expected production rate (throughput) of the system. Because of the difficulty in dealing with this objective directly, a commonly used surrogate objective is the closeness of the actual workload allocation to the continuous workload allocation that maximizes throughput. We test several measures of closeness and discuss correlations between these measures and throughput. Using the best measure, we show how to modify an existing branch and bound algorithm which was developed for the case of equal target workloads for all machine groups to accommodate unequal target workloads. We also develop a new branch and bound algorithm which can be used for both types of problems. The efficiency of the algorithm in finding optimal solutions is achieved through the application of better branching rules and improved dominance results. Computational results on randomly generated test problems indicate that the new algorithm performs well.     

柔性装配制造系统中生产优化的Petri网方法

本文在基本Ｐｅｔｒｉ网的基础上,给出了一种进行周期性生产的柔性装配制造系统的模型;同时,针对该系统,给出了一个求稳定需求下最佳生产指量的启发式调度方法。     

Heuristic solution approaches for combined-job sequencing and machine loading problem in flexible manufacturing systems

Job sequencing and machine loading are two vital and interrelated production planning problems in flexible manufacturing systems (FMSs). In this research, attempts have been made to address the combined job sequencing and machine loading problem using minimization of system unbalance and maximization of throughput as objective functions, while satisfying the constraints related to available machining time and tool slots. This research describes two heuristics to deal with the problems. Heuristic I uses predetermined fixed job sequencing rules as inputs for operation allocation decision on machines, whereas heuristic II uses genetic algorithm based approach for simultaneously addressing job sequences and operation machine allocation issues. Performance of these heuristics has been tested on problems representing three different FMS scenarios. Heuristic II (Genetic algorithm based) has been found more efficient and outperformed heuristic I in terms of solution quality.     

A dynamic heuristic-based algorithm to part input sequencing in flexible manufacturing systems for mass customization capability

In the increasingly competitive global markets, enterprises face challenges in responding to customer orders quickly, as well as producing customized products cost-effectively. This paper proposes a dynamic heuristic-based algorithm for the part input sequencing problem of flexible manufacturing systems (FMSs) in a mass customization (MC) environment. The FMS manufactures a variety of parts, and customer orders arrive dynamically with order size as small as one. Segmental set functions are established in the proposed algorithm to apply the strategy of dynamic workload balancing, and the shortest processing time (SPT) scheduling rule. Theoretical analysis is performed and the effectiveness of the algorithm in dynamic workload balancing under the complex and dynamic environment is proven. The application of the algorithm is illustrated by an example. The potential of its practical applications to the FMSs in make-to-order (MTO) supply chains is also discussed. Further research is provided.

相容决策支持问题法及其在变幅机构稳健优化中的应用

相容决策支持问题法是一种高效的多目标优化设计方法,与设计人员的工程经验紧密相联。将该方法引入到稳健优化设计中,建立了稳健优化设计的相容决策支持问题法模型,通过求解四连杆变幅机构的稳健优化问题,验证了该方法的有效性。     

Batch sizes and lead-time performance in flexible manufacturing systems

Production lead-time performance in flexible manufacturing systems is influenced by several factors which include: machine groupings, demand rates, machine processing rates, product batching, material handling system capacity, and so on. Hence, control of lead-time performance can be affected through the manipulation of one or more of these variables. In this article, we investigate the potential of batch sizing as a control variable for lead-time performance through the use of a queueing network model. We establish a functional relationship between the two variables, and incorporate the relationship in an optimization model to determine the optimal batch size(s) which minimizes the sum of annual work-in-process inventory and final inventory costs. The nonlinear batch sizing problem which results is solved by discrete optimization via marginal analysis. Results show that batch sizing can be a cheap and effective variable for controlling flexible manufacturing system throughput.     

The use of the Petri net reduction approach for an optimal deadlock prevention policy for flexible manufacturing systems

In a flexible manufacturing system (FMS) with multiple products, deadlocks can arise due to limited shared resources, such as machines, robots, buffers, fixtures etc. The development of efficient deadlock prevention policies, which can optimise the use of system resources, while preventing deadlocks from occurring, has long been an important issue to be addressed. In [1], an optimal deadlock prevention policy was proposed, based on the use of reachability graph (RG) analysis of the Petri net model (PNM) of a given FMS and the synthesis of a set of new net elements, namely places with initial marking and related arcs, to be added to the PNM, using the theory of regions. The policy proposed in [1] is optimal in the sense that it allows the maximal use of resources in the system according to the production requirements. For very big PNMs, the reachability graph of the PNMs becomes very large and the necessary computations to obtain an optimal deadlock prevention policy become more difficult. In this paper, we propose the use of the Petri net reduction approach to simplify very big PNMs so as to make necessary calculations easily in order to obtain an optimal deadlock prevention policy for FMSs. An example is provided for illustration.     

Bi-objective redundancy allocation problem for a system with mixed repairable and non-repairable components

Traditionally, in the redundancy allocation problem (RAP), two general classes of optimization problems are considered; reliability optimization and availability optimization. Contrary to reliability optimization, fewer researchers have studied availability optimization to find out the optimal combination of components type and redundancy levels for each subsystem in a system for maximizing (or minimizing) the objectives. In each problem it is assumed that either the entire components are repairable or they are non-repairable. However, in real world situations, systems usually consist of both repairable and non-repairable components. In this paper a new Mixed Integer Nonlinear Programming (MINLP) model is presented to analyze the availability optimization of a system with a given structure, using both repairable and non-repairable components, simultaneously. To find the solution of the introduced MINLP, an efficient Genetic Algorithm (GA) is also developed. Furthermore, to show the efficiency of the proposed GA, a numerical example is presented. Experimental results demonstrate that the proposed GA has a better performance compared to one of the most recommended algorithm in the literature.     

Optimisation of crew size and repair policy in flexible manufacturing systems

This paper presents a simulation-based scheduling algorithm for evaluating the performance of different repair policies and computating the optimum size of repair-crews in flexible manufacturing systems. The simulation experiments were conducted for a system with numbers of machines ranging from six to twelve, processing 15 different types of parts. The experiments were planned according to the rules of central composite rotatable experiment design, and the system performance was optimised on the basis of minimum unit production cost. It has been concluded that for the particular system configuration studied, a repair policy based on shortest repair time yields the best results. It has been shown further that the optimum size of repair crews is much more sensitive to labour costs than to other production-associated costs.     

Optimal strip sequencing strategies for flexible manufacturing operations in two and three dimensions

In this paper, optimal strip strategies are developed for a variety of two-dimensional and three-dimensional sequencing problems arising in flexible manufacturing. These strategies are appropriate for CNC drilling operations, NC punching operations, and circuit board population, for example. Seven different metrics are considered.