Facility layout planning. An extended literature review

[EN] Facility layout planning (FLP) involves a set of design problems related to the arrangement of the elements that shape industrial production systems in a physical space. The fact that they are considered one of the most important design decisions as part of business operation strategies, and their proven repercussion on production systems' operation costs, efficiency and productivity, mean that this theme has been widely addressed in science. In this context, the present article offers a scientific literature review about FLP from the operations management perspective. The 232 reviewed articles were classified as a large taxonomy based on type of problem, approach and planning stage and characteristics of production facilities by configuring the material handling system and methods to generate and assess layout alternatives. We stress that the generation of layout alternatives was done mainly using mathematical optimisation models, specifically discrete quadratic programming models for similar sized departments, or continuous linear and non-linear mixed integer programming models for different sized departments. Other approaches followed to generate layout alternatives were expert's knowledge and specialised software packages. Generally speaking, the most frequent solution algorithms were metaheuristics.The research leading to these results received funding from the European Union H2020 Program under grant agreement No 958205 `Industrial Data Services for Quality Control in Smart Manufacturing (i4Q)'and from the Spanish Ministry of Science, Innovation and Universities under grant agreement RTI2018-101344-B-I00 `Optimisation of zerodefectsproduction technologies enabling supply chains 4.0 (CADS4.0)'Pérez-Gosende, P.; Mula, J.; Díaz-Madroñero Boluda, FM. (2021). Facility layout planning. An extended literature review. International Journal of Production Research. 59(12):3777-3816. https://doi.org/10.1080/00207543.2021.189717637773816591

Simulation in Automated Guided Vehicle System Design

The intense global competition that manufacturing companies face today results in an increase of product variety and shorter product life cycles. One response to this threat is agile manufacturing concepts. This requires materials handling systems that are agile and capable of reconfiguration. As competition in the world marketplace becomes increasingly customer-driven, manufacturing environments must be highly reconfigurable and responsive to accommodate product and process changes, with rigid, static automation systems giving way to more flexible types. Automated Guided Vehicle Systems (AGVS) have such capabilities and AGV functionality has been developed to improve flexibility and diminish the traditional disadvantages of AGV-systems. The AGV-system design is however a multi-faceted problem with a large number of design factors of which many are correlating and interdependent. Available methods and techniques exhibit problems in supporting the whole design process. A research review of the work reported on AGVS development in combination with simulation revealed that of 39 papers only four were industrially related. Most work was on the conceptual design phase, but little has been reported on the detailed simulation of AGVS. Semi-autonomous vehicles (SA V) are an innovative concept to overcome the problems of inflexible -systems and to improve materials handling functionality. The SA V concept introduces a higher degree of autonomy in industrial AGV -systems with the man-in-the-Ioop. The introduction of autonomy in industrial applications is approached by explicitly controlling the level of autonomy at different occasions. The SA V s are easy to program and easily reconfigurable regarding navigation systems and material handling equipment. Novel approaches to materials handling like the SA V -concept place new requirements on the AGVS development and the use of simulation as a part of the process. Traditional AGV -system simulation approaches do not fully meet these requirements and the improved functionality of AGVs is not used to its full power. There is a considerflble potential in shortening the AGV -system design-cycle, and thus the manufacturing system design-cycle, and still achieve more accurate solutions well suited for MRS tasks. Recent developments in simulation tools for manufacturing have improved production engineering development and the tools are being adopted more widely in industry. For the development of AGV -systems this has not fully been exploited. Previous research has focused on the conceptual part of the design process and many simulation approaches to AGV -system design lack in validity. In this thesis a methodology is proposed for the structured development of AGV -systems using simulation. Elements of this methodology address the development of novel functionality. The objective of the first research case of this research study was to identify factors for industrial AGV -system simulation. The second research case focuses on simulation in the design of Semi-autonomous vehicles, and the third case evaluates a simulation based design framework. This research study has advanced development by offering a framework for developing testing and evaluating AGV -systems, based on concurrent development using a virtual environment. The ability to exploit unique or novel features of AGVs based on a virtual environment improves the potential of AGV-systems considerably.University of Skovde. European Commission for funding the INCO/COPERNICUS Projec

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

Optimisation de laboratoires médicaux

This thesis focuses on the optimization of clinical laboratory design and operating decisions. A clinicallaboratory is an organization gathering human and machinery resources to analyze blood samples. Inthis thesis, a decision support tool including mathematical models, a heuristic algorithm and acustomized simulation model is developed to aid decision makers for the main strategic, tactical andoperational problems in clinical laboratory design and operations management. This decision supporttool follows a top-down stepwise framework starting from strategic problems and ending withoperational ones, including a recursive loop for modification and improvement. In this thesis, machineselection and facility layout are studied as the main strategic problems, analyzer configuration problemas the tactical problem, and assignment, aliquoting, and scheduling as the principal operationalproblems. In order to deal with machine selection problem for clinical laboratory, a mathematical modelis proposed which aids to select the most appropriate machines to equip the system. To tackle physicalarrangement of instruments within the laboratory area, a heuristic approach is developed. The proposedheuristic comprises the key constraints of laboratory layout design. To address the analyzerconfiguration problem which mainly deals with the assignment of chemical materials to the analyzersin clinical laboratory, a bi-objective mathematical model is developed. In addition, to determine anefficient assignment of sample tubes to the analyzers, a mathematical model with three objectives isproposed. A customized, flexible, and fine-grained simulation model is developed in FlexSim to studythe clinical laboratory designed through the outputs of developed mathematical models and layoutalgorithm. Simulation model plays a key role in the proposed framework as it is used for many purposes.The simulation model helps the designer to construct and analyze a complete clinical laboratory takinginto account all major features of the system. This simulation attribute provides the ability to scrutinizethe system behaviour and to find out whether the designed system is efficient. System performanceanalysis through simulation and resulting key performance indicators give helpful feedbacks for systemimprovement. Furthermore, simulation model can be fruitful to decide on scheduling, aliquoting andstaffing problems through the evaluation of various scenarios proposed by decision maker for each ofthese problems. To verify the validity of the proposed framework, data extracted from a real case isused. The output results seal on the applicability and the efficiency of the proposed framework as wellas competency of proposed techniques to deal with each optimization problem. To the best of ourknowledge, this thesis is one of the leading studies on the optimization of clinical laboratories.Cette thèse porte sur l'optimisation de la conception et des décisions opérationnelles des laboratoires d'analyses médicales. Dans cette thèse, un outil d'aide à la décision comprenant des modèles mathématiques, un algorithme heuristique et un modèle de simulation personnalisé est développé pour aider les décideurs à résoudre les principaux problèmes stratégiques, tactiques et opérationnels en conception et gestion des opérations des laboratoires d'analyses médicales. Dans cette thèse, la sélection des machines et la disposition des instruments sont étudiées en tant que principaux problèmes stratégiques, le problème de configuration des analyseurs en tant que problème tactique et l’affectation, l’aliquotage et l'ordonnancement en tant que principaux problèmes opérationnels. Un modèle de simulation personnalisé et flexible est développé dans FlexSim pour étudier le laboratoire d'analyse médicale conçu à l'aide des résultats de modèles mathématiques et d'un algorithme de layout développés. Le modèle de simulation aide le concepteur à construire et à analyser un laboratoire complet en tenant compte de toutes les principales caractéristiques du système. Cet attribut de simulation permet d'analyser le comportement du système et de déterminer si le système conçu est efficace. Pour vérifier la validité du cadre proposé, les données extraites d’un cas réel sont utilisées. Les résultats de sortie scellent l'applicabilité et l'efficacité du cadre proposé ainsi que la compétence des techniques proposées pour traiter chaque problème d'optimisation. À notre connaissance, cette thèse est l’une des principales études sur l’optimisation des laboratoires d'analyses médicales

A Combined Fuzzy Goal Programming and Big-Bang Big-Crunch Algorithm for Workforce Optimisation with Facility Layout Consideration

Small scale enterprises constitute an important subset of manufacturing economy and the contribution of facility redesign in bridging the performance gaps in small-scale enterprises is necessary for enterprise growth and stability. In this paper, a bi-objective programming-based facility layout design problem is formulated. We minimise workforce costs and maximise efficiency improvement in a layout. We utilised fuzzy goal programming and big-bang big-crunch algorithm in generating a Pareto solution. The model was tested using a small-scale sachet water production enterprise data. Increase in finished goods area was 66.55% while reduction in total annual distance travelled in the facility was 48.22% when the proposed layout was compared with existing one. Reduction in annual cost of labour was 16.2%. The possibility of using work-centres with high number of interrelationship was confirmed using quality function deployment and Hurwicz criterion. The optimal workforce size was found to be 14 workers against the existing workforce strength of 18 workers. The study provides a framework upon which small-scale sachet water production factories can be designed for optimum performance

Algorithms and Methods for Designing and Scheduling Smart Manufacturing Systems

This book, as a Special Issue, is a collection of some of the latest advancements in designing and scheduling smart manufacturing systems. The smart manufacturing concept is undoubtedly considered a paradigm shift in manufacturing technology. This conception is part of the Industry 4.0 strategy, or equivalent national policies, and brings new challenges and opportunities for the companies that are facing tough global competition. Industry 4.0 should not only be perceived as one of many possible strategies for manufacturing companies, but also as an important practice within organizations. The main focus of Industry 4.0 implementation is to combine production, information technology, and the internet. The presented Special Issue consists of ten research papers presenting the latest works in the field. The papers include various topics, which can be divided into three categories—(i) designing and scheduling manufacturing systems (seven articles), (ii) machining process optimization (two articles), (iii) digital insurance platforms (one article). Most of the mentioned research problems are solved in these articles by using genetic algorithms, the harmony search algorithm, the hybrid bat algorithm, the combined whale optimization algorithm, and other optimization and decision-making methods. The above-mentioned groups of articles are briefly described in this order in this book

Development of transportation and supply chain problems with the combination of agent-based simulation and network optimization

Demand drives a different range of supply chain and logistics location decisions, and agent-based modeling (ABM) introduces innovative solutions to address supply chain and logistics problems. This dissertation focuses on an agent-based and network optimization approach to resolve those problems and features three research projects that cover prevalent supply chain management and logistics problems. The first case study evaluates demographic densities in Norway, Finland, and Sweden, and covers how distribution center (DC) locations can be established using a minimizing trip distance approach. Furthermore, traveling time maps are developed for each scenario. In addition, the Nordic area consisting of those three countries is analyzed and five DC location optimization results are presented. The second case study introduces transportation cost modelling in the process of collecting tree logs from several districts and transporting them to the nearest collection point. This research project presents agent-based modelling (ABM) that incorporates comprehensively the key elements of the pick-up and delivery supply chain model and designs the components as autonomous agents communicating with each other. The modelling merges various components such as GIS routing, potential facility locations, random tree log pickup locations, fleet sizing, trip distance, and truck and train transportation. The entire pick-up and delivery operation are modeled by ABM and modeling outcomes are provided by time series charts such as the number of trucks in use, facilities inventory and travel distance. In addition, various scenarios of simulation based on potential facility locations and truck numbers are evaluated and the optimal facility location and fleet size are identified. In the third case study, an agent-based modeling strategy is used to address the problem of vehicle scheduling and fleet optimization. The solution method is employed to data from a real-world organization, and a set of key performance indicators are created to assess the resolution's effectiveness. The ABM method, contrary to other modeling approaches, is a fully customized method that can incorporate extensively various processes and elements. ABM applying the autonomous agent concept can integrate various components that exist in the complex supply chain and create a similar system to assess the supply chain efficiency.Tuotteiden kysyntä ohjaa erilaisia toimitusketju- ja logistiikkasijaintipäätöksiä, ja agenttipohjainen mallinnusmenetelmä (ABM) tuo innovatiivisia ratkaisuja toimitusketjun ja logistiikan ongelmien ratkaisemiseen. Tämä väitöskirja keskittyy agenttipohjaiseen mallinnusmenetelmään ja verkon optimointiin tällaisten ongelmien ratkaisemiseksi, ja sisältää kolme tapaustutkimusta, jotka voidaan luokitella kuuluvan yleisiin toimitusketjun hallinta- ja logistiikkaongelmiin. Ensimmäinen tapaustutkimus esittelee kuinka käyttämällä väestötiheyksiä Norjassa, Suomessa ja Ruotsissa voidaan määrittää strategioita jakelukeskusten (DC) sijaintiin käyttämällä matkan etäisyyden minimoimista. Kullekin skenaariolle kehitetään matka-aikakartat. Lisäksi analysoidaan näistä kolmesta maasta koostuvaa pohjoismaista aluetta ja esitetään viisi mahdollista sijaintia optimointituloksena. Toinen tapaustutkimus esittelee kuljetuskustannusmallintamisen prosessissa, jossa puutavaraa kerätään useilta alueilta ja kuljetetaan lähimpään keräyspisteeseen. Tämä tutkimusprojekti esittelee agenttipohjaista mallinnusta (ABM), joka yhdistää kattavasti noudon ja toimituksen toimitusketjumallin keskeiset elementit ja suunnittelee komponentit keskenään kommunikoiviksi autonomisiksi agenteiksi. Mallinnuksessa yhdistetään erilaisia komponentteja, kuten GIS-reititys, mahdolliset tilojen sijainnit, satunnaiset puunhakupaikat, kaluston mitoitus, matkan pituus sekä monimuotokuljetukset. ABM:n avulla mallinnetaan noutojen ja toimituksien koko ketju ja tuloksena saadaan aikasarjoja kuvaamaan käytössä olevat kuorma-autot, sekä varastomäärät ja ajetut matkat. Lisäksi arvioidaan erilaisia simuloinnin skenaarioita mahdollisten laitosten sijainnista ja kuorma-autojen lukumäärästä sekä tunnistetaan optimaalinen toimipisteen sijainti ja tarvittava autojen määrä. Kolmannessa tapaustutkimuksessa agenttipohjaista mallinnusstrategiaa käytetään ratkaisemaan ajoneuvojen aikataulujen ja kaluston optimoinnin ongelma. Ratkaisumenetelmää käytetään dataan, joka on peräisin todellisesta organisaatiosta, ja ratkaisun tehokkuuden arvioimiseksi luodaan lukuisia keskeisiä suorituskykyindikaattoreita. ABM-menetelmä, toisin kuin monet muut mallintamismenetelmät, on täysin räätälöitävissä oleva menetelmä, joka voi sisältää laajasti erilaisia prosesseja ja elementtejä. Autonomisia agentteja soveltava ABM voi integroida erilaisia komponentteja, jotka ovat olemassa monimutkaisessa toimitusketjussa ja luoda vastaavan järjestelmän toimitusketjun tehokkuuden arvioimiseksi yksityiskohtaisesti.fi=vertaisarvioitu|en=peerReviewed

Technology and Management Applied in Construction Engineering Projects

This book focuses on fundamental and applied research on construction project management. It presents research papers and practice-oriented papers. The execution of construction projects is specific and particularly difficult because each implementation is a unique, complex, and dynamic process that consists of several or more subprocesses that are related to each other, in which various aspects of the investment process participate. Therefore, there is still a vital need to study, research, and conclude the engineering technology and management applied in construction projects. This book present unanimous research approach is a result of many years of studies, conducted by 35 well experienced authors. The common subject of research concerns the development of methods and tools for modeling multi-criteria processes in construction engineering

An evaluation methodology for the level of service at the airport landside system

A methodology is proposed for evaluating the level of service within an airport landside system from the passenger's point of view using linguistic service criteria. The new concept of level of service for a transport system, particularly within the airports indicates that there must be strong stimulation in order to proceed with the current stereotyped service standards which are being criticised due to their being based on, either physical capacity/volume or temporal/spatial standards that directly incorporates the perception of passengers, the dominant users. Most service evaluation methodologies have been concentrated on the factors of the time spent and the space provided. These quantitative factors are reasonably simple to measure but represent a narrow approach. Qualitative service level attributes are definitely important factors when evaluating the level of service from a user's point of view. This study has adopted three main evaluation factors: temporal or spatial factors as quantitative measurements and comfort factors and reasonable service factors as qualitative measurements. The service level evaluation involves the passenger's subjective judgement as a perception for service provision. To evaluate the level of service in the airport landside system from the user's perception, this research proposes to apply a multi-decision model using fuzzy set theory, in particular fuzzy approximate reasoning. Fuzzy set theory provides a strict mathematical framework for vague conceptual phenomena and a modelling language for real situations. The multi-decision model was applied to a case study at Kimpo International Airport in Seoul, Korea. Results are presented in terms of passenger satisfaction and dissatisfaction with a variety of different values