Dynamic Facility Layout for Cellular and Reconfigurable Manufacturing using Dynamic Programming and Multi-Objective Metaheuristics

The facility layout problem is one of the most classical yet influential problems in the planning of production systems. A well-designed layout minimizes the material handling costs (MHC), personnel flow distances, work in process, and improves the performance of these systems in terms of operating costs and time. Because of this importance, facility layout has a rich literature in industrial engineering and operations research. Facility layout problems (FLPs) are generally concerned with positioning a set of facilities to satisfy some criteria or objectives under certain constraints. Traditional FLPs try to put facilities with the high material flow as close as possible to minimize the MHC. In static facility layout problems (SFLP), the product demands and mixes are considered deterministic parameters with constant values. The material flow between facilities is fixed over the planning horizon. However, in today’s market, manufacturing systems are constantly facing changes in product demands and mixes. These changes make it necessary to change the layout from one period to the other to be adapted to the changes. Consequently, there is a need for dynamic approaches of FLP that aim to generate layouts with high adaptation concerning changes in product demand and mix. This thesis focuses on studying the layout problems, with an emphasis on the changing environment of manufacturing systems. Despite the fact that designing layouts within the dynamic environment context is more realistic, the SFLP is observed to have been remained worthy to be analyzed. Hence, a math-heuristic approach is developed to solve an SFLP. To this aim, first, the facilities are grouped into many possible vertical clusters, second, the best combination of the generated clusters to be in the final layout are selected by solving a linear programming model, and finally, the selected clusters are sequenced within the shop floor. Although the presented math-heuristic approach is effective in solving SFLP, applying approaches to cope with the changing manufacturing environment is required. One of the most well-known approaches to deal with the changing manufacturing environment is the dynamic facility layout problem (DFLP). DFLP suits reconfigurable manufacturing systems since their machinery and material handling devices are reconfigurable to encounter the new necessities for the variations of product mix and demand. In DFLP, the planning horizon is divided into some periods. The goal is to find a layout for each period to minimize the total MHC for all periods and the total rearrangement costs between the periods. Dynamic programming (DP) has been known as one of the effective methods to optimize DFLP. In the DP method, all the possible layouts for every single period are generated and given to DP as its state-space. However, by increasing the number of facilities, it is impossible to give all the possible layouts to DP and only a restricted number of layouts should be fed to DP. This leads to ignoring some layouts and losing the optimality; to deal with this difficulty, an improved DP approach is proposed. It uses a hybrid metaheuristic algorithm to select the initial layouts for DP that lead to the best solution of DP for DFLP. The proposed approach includes two phases. In the first phase, a large set of layouts are generated through a heuristic method. In the second phase, a genetic algorithm (GA) is applied to search for the best subset of layouts to be given to DP. DP, improved by starting with the most promising initial layouts, is applied to find the multi-period layout. Finally, a tabu search algorithm is utilized for further improvement of the solution obtained by improved DP. Computational experiments show that improved DP provides more efficient solutions than DP approaches in the literature. The improved DP can efficiently solve DFLP and find the best layout for each period considering both material handling and layout rearrangement costs. However, rearrangement costs may include some unpredictable costs concerning interruption in production or moving of facilities. Therefore, in some cases, managerial decisions tend to avoid any rearrangements. To this aim, a semi-robust approach is developed to optimize an FLP in a cellular manufacturing system (CMS). In this approach, the pick-up/drop-off (P/D) points of the cells are changed to adapt the layout with changes in product demand and mix. This approach suits more a cellular flexible manufacturing system or a conventional system. A multi-objective nonlinear mixed-integer programming model is proposed to simultaneously search for the optimum number of cells, optimum allocation of facilities to cells, optimum intra- and inter-cellular layout design, and the optimum locations of the P/D points of the cells in each period. A modified non-dominated sorting genetic algorithm (MNSGA-II) enhanced by an improved non-dominated sorting strategy and a modified dynamic crowding distance procedure is used to find Pareto-optimal solutions. The computational experiments are carried out to show the effectiveness of the proposed MNSGA-II against other popular metaheuristic algorithms

Overview of Multi-Objective Optimization Approaches in Construction Project Management

The difficulties that are met in construction projects include budget issues, contractual time constraints, complying with sustainability rating systems, meeting local building codes, and achieving the desired quality level, to name but a few. Construction researchers have proposed and construction practitioners have used optimization strategies to meet various objectives over the years. They started out by optimizing one objective at a time (e.g., minimizing construction cost) while disregarding others. Because the objectives of construction projects often conflict with each other, single-objective optimization does not offer practical solutions as optimizing one objective would often adversely affect the other objectives that are not being optimized. They then experimented with multi-objective optimization. The many multi-objective optimization approaches that they used have their own advantages and drawbacks when used in some scenarios with different sets of objectives. In this chapter, a review is presented of 16 multi-objective optimization approaches used in 55 research studies performed in the construction industry and that were published in the period 2012–2016. The discussion highlights the strengths and weaknesses of these approaches when used in different scenarios

Develop an autonomous product-based reconfigurable manufacturing system

With the ever-emerging market including mass customization and product variety, reconfigurable manufacturing systems (RMS) have been presented as the solution. A manufacturing system that combines the benefits of the two classic manufacturing systems to increase responsiveness and reduce production time and costs. To cope with the lack of physical systems, an RMS system have been built at UiT Narvik. Today, both reconfiguration and deciding layout must be executed manually by a human. A task that is both incredibly time consuming and far from optimal. A method of automating the layout generation and thus the manufacturing system is presented in this thesis. To the author’s knowledge such experiment has not been performed previously. Layouts is generated with a NSGA-II algorithm in Python by minimizing objectives from a developed mathematical model. The results have been tested with a MiR-100 mobile robot placing five modules in two different layouts. The results have been compared with a digital visualization for validation. In addition to the visualization, videos of the physical system's automated layout generation are presented. The results concludes that the method both generates feasible layouts as well as enhancing the automation of the system

Multi-level evolutionary algorithms resource allocation utilizing model-based systems engineering

This research presents an innovative approach to solve the resource allocation problems using Multi-level Evolutionary Algorithms. Evolutionary Algorithms are used to solve resource allocation problems in different domains and their results are then incorporated into a higher level system solution using another Evolutionary Algorithm to solve base camp planning problems currently faced by the U.S. Department of Defense. Two models are introduced to solve two domain specific models: a logistics model and a power model. The logistic model evaluates routes for logistics vehicles on a daily basis with a goal of reducing fuel usage by delivery trucks. The evaluation includes distance traveled and other constraints such as available resource levels and priority of refilling. The Power model incorporates an open source electrical distribution simulator to evaluate the placement of structures and generators on a map to reduce fuel usage. These models are used as the fitness function for two separate Evolutionary Algorithms to find solutions that reduce fuel consumption within the individual domains. A multi-level Evolutionary Algorithm is then presented, where the two Evolutionary Algorithms share information with a higher level Evolutionary Algorithm that combines the results to account for problem complexity from the interfacing of these systems. The results of using these methods on 5 different base camp sizes show that the techniques provide a considerable reduction of fuel consumption. While the Evolutionary Algorithms show significant improvement over the current methods, the multi-level Evolutionary Algorithm shows better performance than using individual Evolutionary Algorithms, with the results showing a 19.25 % decrease in fuel consumption using the multi-level Evolutionary Algorithm --Abstract, page iii

Optimization of Airfield Parking and Fuel Asset Dispersal to Maximize Survivability and Mission Capability Level

While the US focus for the majority of the past two decades has been on combatting insurgency and promoting stability in Southwest Asia, strategic focus is beginning to shift toward concerns of conflict with a near-peer state. Such conflict brings with it the risk of ballistic missile attack on air bases. With 26 conflicts worldwide in the past 100 years including attacks on air bases, new doctrine and modeling capacity are needed to enable the Department of Defense to continue use of vulnerable bases during conflict involving ballistic missiles. Several models have been developed to date for Air Force strategic planning use, but these models have limited use on a tactical level or for civil engineer use. This thesis presents the development of a novel model capable of identifying base layout characteristics for aprons and fuel depots to maximize dispersal and minimize impact on sortie generation times during normal operations. This model is implemented using multi-objective genetic algorithms to identify solutions that provide optimal tradeoffs between competing objectives and is assessed using an application example. These capabilities are expected to assist military engineers in the layout of parking plans and fuel depots that ensure maximum resilience while providing minimal impact to the user while enabling continued sortie generation in a contested region

Innovative Applications of Genetic Algorithms to Problems in Accelerator Physics

The genetic algorithm (GA) is a powerful technique that implements the principles nature uses in biological evolution to optimize a multidimensional nonlinear problem. The GA works especially well for problems with a large number of local extrema, where traditional methods (such as conjugate gradient, steepest descent, and others) fail or, at best, underperform. The field of accelerator physics, among others, abounds with problems which lend themselves to optimization via GAs. In this paper, we report on the successful application of GAs in several problems related to the existing Continuous Electron Beam Accelerator Facility nuclear physics machine, the proposed Medium-energy Electron-Ion Collider at Jefferson Lab, and a radio frequency gun-based injector. These encouraging results are a step forward in optimizing accelerator design and provide an impetus for application of GAs to other problems in the field. To that end, we discuss the details of the GAs used, include a newly devised enhancement which leads to improved convergence to the optimum, and make recommendations for future GA developments and accelerator applications

Improving Design Optimization and Optimization-based Design Knowledge Discovery

The use of design optimization in the early stages of architectural design process has attracted a high volume of research in recent years. However, traditional design optimization requires a significant amount of computing time, especially when there are multiple design objectives to achieve. What’s more, there is a lack of studies in the current research on automatic generation of architectural design knowledge from optimization results. This paper presents computational methods for creating and improving a closed loop of design optimization and knowledge discovery in architecture. It first introduces a design knowledge-assisted optimization improvement method with the techniques - offline simulation and Divide & Conquer (D&C) - to reduce the computing time and improve the efficiency of the design optimization process utilizing architectural domain knowledge. It then describes a new design knowledge discovery system where design knowledge can be discovered from optimization through an automatic data mining approach. The discovered knowledge has the potential to further help improve the efficiency of the optimization method, thus forming a closed loop of improving optimization and knowledge discovery. The validations of both methods are presented in the context of a case study with parametric form-finding for a nursing unit design with two design objectives: minimizing the nurses’ travel distance and maximizing daylighting performance in patient rooms