Solving Weighted Number of Operation Plus Processing Time Due-Date Assignment, Weighted Scheduling and Process Planning Integration Problem Using Genetic and Simulated Annealing Search Methods

Traditionally, the three important manufacturing functions, which are process planning, scheduling and due-date assignment, are performed separately and sequentially. For couple of decades, hundreds of studies are done on integrated process planning and scheduling problems and numerous researches are performed on scheduling with due date assignment problem, but unfortunately the integration of these three important functions are not adequately addressed. Here, the integration of these three important functions is studied by using genetic, random-genetic hybrid, simulated annealing, random-simulated annealing hybrid and random search techniques. As well, the importance of the integration of these three functions and the power of meta-heuristics and of hybrid heuristics are studied

Improving just-in-time delivery performance of IoT-enabled flexible manufacturing systems with AGV based material transportation

Autonomous guided vehicles (AGVs) are driverless material handling systems used for transportation of pallets and line side supply of materials to provide flexibility and agility in shop-floor logistics. Scheduling of shop-floor logistics in such systems is a challenging task due to their complex nature associated with the multiple part types and alternate material transfer routings. This paper presents a decision support system capable of supporting shop-floor decision-making activities during the event of manufacturing disruptions by automatically adjusting both AGV and machine schedules in Flexible Manufacturing Systems (FMSs). The proposed system uses discrete event simulation (DES) models enhanced by the Internet-of-Things (IoT) enabled digital integration and employs a nonlinear mixed integer programming Genetic Algorithm (GA) to find near-optimal production schedules prioritising the just-in-time (JIT) material delivery performance and energy efficiency of the material transportation. The performance of the proposed system is tested on the Integrated Manufacturing and Logistics (IML) demonstrator at WMG, University of Warwick. The results showed that the developed system can find the near-optimal solutions for production schedules subjected to production anomalies in a negligible time, thereby supporting shop-floor decision-making activities effectively and rapidly

Improving just-in-time delivery performance of IoT-enabled flexible manufacturing systems with AGV based material transportation

© 2020 by the authors. Licensee MDPI, Basel, Switzerland. Autonomous guided vehicles (AGVs) are driverless material handling systems used for transportation of pallets and line side supply of materials to provide flexibility and agility in shop-floor logistics. Scheduling of shop-floor logistics in such systems is a challenging task due to their complex nature associated with the multiple part types and alternate material transfer routings. This paper presents a decision support system capable of supporting shop-floor decision-making activities during the event of manufacturing disruptions by automatically adjusting both AGV and machine schedules in Flexible Manufacturing Systems (FMSs). The proposed system uses discrete event simulation (DES) models enhanced by the Internet-of-Things (IoT) enabled digital integration and employs a nonlinear mixed integer programming Genetic Algorithm (GA) to find near-optimal production schedules prioritising the just-in-time (JIT) material delivery performance and energy efficiency of the material transportation. The performance of the proposed system is tested on the Integrated Manufacturing and Logistics (IML) demonstrator at WMG, University of Warwick. The results showed that the developed system can find the near-optimal solutions for production schedules subjected to production anomalies in a negligible time, thereby supporting shop-floor decision-making activities effectively and rapidly

A dispatching-fuzzy ahp-topsis model for scheduling flexible job-shop systems in industry 4.0 context

Scheduling flexible job-shop systems (FJSS) has become a major challenge for different smart factories due to the high complexity involved in NP-hard problems and the constant need to satisfy customers in real time. A key aspect to be addressed in this particular aim is the adoption of a multi-criteria approach incorporating the current dynamics of smart FJSS. Thus, this paper proposes an integrated and enhanced method of a dispatching algorithm based on fuzzy AHP (FAHP) and TOPSIS. Initially, the two first steps of the dispatching algorithm (identification of eligible operations and machine selection) were implemented. The FAHP and TOPSIS methods were then integrated to underpin the multi-criteria operation selection process. In particular, FAHP was used to calculate the criteria weights under uncertainty, and TOPSIS was later applied to rank the eligible operations. As the fourth step of dispatching the algorithm, the operation with the highest priority was scheduled together with its initial and final time. A case study from the smart apparel industry was employed to validate the effectiveness of the proposed approach. The results evidenced that our approach outperformed the current company’s scheduling method by a median lateness of 3.86 days while prioritizing high-throughput products for earlier delivery. View Full-Tex

Bi-objective supply chain problem using MOPSO and NSGA-II

The increase competition and decline economy has increased the relevant importance of having reliable supply chain. The primary objective of many supply chain problems is to reduce the cost of services and, at the same time, to increase the quality of services. In this paper, we present a multi-level supply chain network by considering multi products, single resource and deterministic cost and demand. The proposed model of this paper is formulated as a mixed integer programming and we present two metaheuristics namely MOPSO and NSGA-II to solve the resulted problems. The performance of the proposed models of this paper has been examined using some randomly generated numbers and the results are discussed. The preliminary results indicate that while MOPSO is able to generate more Pareto solutions in relatively less amount of time, NSGA-II is capable of providing better quality results

Use of bio-inspired techniques to solve complex engineering problems: industrial automation case study

Nowadays local markets have disappeared and the world lives in a global economy. Due to this reality, every company virtually competes with all others companies in the world. In addition to this, markets constantly search products with higher quality at lower costs, with high customization. Also, products tend to have a shorter period of life, making the demanding more intense. With this scenario, companies, to remain competitive, must constantly adapt themselves to the market changes, i.e., companies must exhibit a great degree of self-organization and self-adaptation. Biology with the millions of years of evolution may offer inspiration to develop new algorithms, methods and techniques to solve real complex problems. As an example, the behaviour of ants and bees, have inspired researchers in the pursuit of solutions to solve complex and evolvable engineering problems. This dissertation has the goal of explore the world of bio-inspired engineering. This is done by studying some of the bio-inspired solutions and searching for bio-inspired solutions to solve the daily problems. A more deep focus will be made to the engineering problems and particularly to the manufacturing domain. Multi-agent systems is a concept aligned with the bio-inspired principles offering a new approach to develop solutions that exhibit robustness, flexibility, responsiveness and re-configurability. In such distributed bio-inspired systems, the behaviour of each entity follows simple few rules, but the overall emergent behaviour is very complex to understand and to demonstrate. Therefore, the design and simulation of distributed agent-based solutions, and particularly those exhibiting self-organizing, are usually a hard task. Agent Based Modelling (ABM) tools simplifies this task by providing an environment for programming, modelling and simulating agent-based solutions, aiming to test and compare alternative model configurations. A deeply analysis of the existing ABM tools was also performed aiming to select the platform to be used in this work. Aiming to demonstrate the benefits of bio-inspired techniques for the industrial automation domain, a production system was used as case study for the development of a self-organizing agent-based system developed using the NetLogo tool. Hoje em dia os mercados locais desapareceram e o mundo vive numa economia global. Devido a esta realidade, cada companhia compete, virtualmente, com todas as outras companhias do mundo. A acrescentar a isto, os mercados estão constantemente à procura de produtos com maior qualidade a preços mais baixos e com um grande nível de customização Também, os produtos tendem a ter um tempo curto de vida, fazendo com que a procura seja mais intensa. Com este cenário, as companhias, para permanecer competitivas, têm que se adaptar constantemente de acordo com as mudanças de mercado, i.e., as companhias têm que exibir um alto grau de auto-organização e auto-adaptação. A biologia com os milhões de anos de evolução, pode oferecer inspiração para desenvolver novos algoritmos, métodos e técnicas para resolver problemas complexos reais. Como por exemplo, o comportamento das formigas e das abelhas inspiraram investigadores na descoberta de soluções para resolver problemas complexos e evolutivos de engenharia. Esta dissertação tem como objectivo explorar o mundo da engenharia bio-inspirada. Isto é feito através do estudo de algumas das soluções bio-inspiradas existentes e da procura de soluções bio-inspiradas para resolver os problemas do dia-a-dia. Uma atenção especial vai ser dada aos problemas de engenharia e particularmente aos problemas do domínio da manufactura. Os sistemas multi-agentes são um conceito que estão em linha com os princípios bio-inspirados oferecendo uma abordagem nova para desenvolver soluções que exibam robustez, flexibilidade, rapidez de resposta e reconfiguração. Nestes sistemas distribuídos bio-inspirados, o comportamento de cada entidade segue um pequeno conjunto de regras simples, mas o comportamento emergente global é muito complexo de perceber e de demonstrar. Por isso, o desenho e simulação de soluções distribuídas de agentes, e particularmente aqueles que exibem auto-organização, são normalmente uma tarefa árdua. As ferramentas de Modelação Baseada de Agentes (MBA) simplificam esta tarefa providenciando um ambiente para programar, modelar e simular, com o objectivo de testar e comparar diferentes configurações do modelo. Uma análise mais aprofundada das ferramentas MBA foi também efectuada tendo como objectivo seleccionar a plataforma a usar neste trabalho

Proposition d’une architecture holonique auto-organisée et évolutive pour le pilotage des systèmes de production

The manufacturing world is being deeply challenged with a set of ever demanding constraints where from one side, the costumers are requiring products to be more customizable, with higher quality at lower prices, and on other side, companies have to deal on a daily basis with internal disturbances that range from machine breakdown to worker absence and from demand fluctuation to frequent production changes. This dissertation proposes a manufacturing control architecture, following the holonic principles developed in the ADAptive holonic COntrol aRchitecture (ADACOR) and extending it taking inspiration in evolutionary theories and making use of self- organization mechanisms. The use of evolutionary theories enrich the proposed control architecture by allowing evolution in two distinct ways, responding accordingly to the type and degree of the disturbance that appears. The first component, named behavioural self- organization, allows each system’s entity to dynamically adapt its internal behaviour, addressing small disturbances. The second component, named structural self-organization, addresses bigger disturbances by allowing the system entities to re-arrange their rela- tionships, and consequently changing the system in a structural manner. The proposed self-organized holonic manufacturing control architecture was validated at a AIP-PRIMECA flexible manufacturing cell. The achieved experimental results have also shown an improvement of the key performance indicators over the hierarchical and heterarchical control architecture.Le monde des entreprises est profondément soumis à un ensemble de contraintes toujours plus exigeantes provenant d’une part des clients, exigeant des produits plus personnalisables, de qualité supérieure et à faible coût, et d’autre part des aléas internes auxentreprises, comprenant les pannes machines, les défaillances humaines, la fluctuation de la demande, les fréquentes variations de production. Cette thèse propose une architecture de contrôle de systèmes de production, basée sur les principes holoniques développées dans l’architecture ADACOR (ADAptive holonic COntrol aRchitecture), et l’étendant en s’inspirant des théories de l’évolution et en utilisant des mécanismes d’auto-organisation. L’utilisation des théories de l’évolution enrichit l’architecture de contrôle en permettant l’évolution de deux manières distinctes, en réponse au type et au degré de la perturbation apparue. Le premier mode d’adaptation, appelé auto-organisation comportementale, permet à chaque entité qui compose le système d’adapter dynamiquement leur comportement interne, gérant de cette façon de petites perturbations. Le second mode, nommé auto-organisation structurelle, traite de plus grandes perturbations, en permettant aux entités du système de ré-organiser leurs relations, et par conséquent modifier structurellement le système. L’architecture holonique auto-organisée de contrôle de systèmes de production proposée dans cette thèse a été validée sur une cellule de production flexible AIP-PRIMECA. Les résultats ont montré une amélioration des indicateurs clés de performance par rapport aux architectures de contrôle hiérarchiques et hétérarchiques

An efficient particle swarm optimizer with application to Man-Day project scheduling problems

The multimode resource-constrained project scheduling problem (MRCPSP) has been confirmed to be an NP-hard problem. Particle swarm optimization (PSO) has been efficiently applied to the search for near optimal solutions to various NP-hard problems. MRCPSP involves solving two subproblems: mode assignment and activity priority determination. Hence, two PSOs are applied to each subproblem. A constriction PSO is proposed for the activity priority determination while a discrete PSO is employed for mode assignment. A least total resource usage (LTRU) heuristic and minimum slack (MSLK) heuristic ensure better initial solutions. To ensure a diverse initial collection of solutions and thereby enhancing the PSO efficiency, a best heuristic rate (HR) is suggested. Moreover, a new communication topology with random links is also introduced to prevent slow and premature convergence. To verify the performance of the approach, the MRCPSP benchmarks in PSPLIB were evaluated and the results compared to other state-of-the-art algorithms. The results demonstrate that the proposed algorithm outperforms other algorithms for the MRCPSP problems. Finally, a real-world man-day project scheduling problem (MDPSP)—a MRCPSP problem—was evaluated and the results demonstrate that MDPSP can be solved successfull

The optimisation and integration of AGVs with the manufacturing process

In recent years, the manufacturing environment, driven by the growth of advanced technologies and the increasing demand for customised products, has becomes increasingly competitive. In this context, manufacturing systems are now required to be more automated, flexible and reconfigurable. Thus, Autonomous Guided Vehicle (AGV), as a key enabler of dynamic shop floor logistics, are being increasingly widely deployed into the manufacturing sector for the lineside materials supplying, work-in-progress transportation, and finished products collection. A large number of companies and institutions are researching on different AGV systems to integrate AGVs-based shop floor logistics with manufacturing equipment and processes. However, these AGV systems are typically equipped with various communication protocols and utilise ad-hoc communication methods. They lack a generic framework to integrate the AGV systems into the manufacturing systems with minimal engineering effort and system reconfiguration. Current scheduling optimisation methods for multiple AGVs in shop floor logistics now support effective task allocation, shortest route planning, and conflict-free supervision, allocating the delivery tasks based on the location and availability of AGVs. However, these current methods do not give enough consideration to real-time operational information during the manufacturing process and have difficulties in analysing the real-time delivery requests from manufacturing work stations. This not only reduces the efficiency and flexibility of the shop floor logistics, ii but also significantly impacts on the overall performance of manufacturing processes. This thesis presents a generic integration approach, called Smart AGV Management System (SAMS), to support the integration of AGVs with manufacturing processes. The proposed framework enables enhanced interoperability between AGVs-based shop floor logistics and the manufacturing process through a generic data-sharing platform. Moreover, a Digital Twin (DT)-based optimisation method is developed in SAMS that can simulate and analyse the real-time manufacturing process to schedule AGVs for optimising multiple objectives, including the utilisation of work stations, delivery Justin- time (JIT) performance, charging of AGVs and overall energy consumption. This approach is experimentally deployed and evaluated from various perspectives to identify its integration and optimisation capabilities during the reconfiguration and operational phases. The results show that the proposed integration framework can enable a more effective integration with manufacturing process compared to traditional integration methods. In addition, the results demonstrate that the proposed optimisation method can schedule and reschedule AGV-based shop floor logistics when facing a range of system disruptions