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

Cell formation problem - A Lagrangean relaxation to mathematical programming approach and a linear performance measure

Two topics in the part-machine cell formation problem are discussed: In the first part, a Lagrangean relaxation in a mathematical programming model is proposed to simultaneously set machines into groups and parts into families in a cellular manufacturing system. The objective of this model is to find the optimal number of cells while minimizing inter-cellular part moves and increasing utilization of machines within the cells. The method uses a 0-1 integer programming model. The Lagrangean relaxation relaxes the model through an iterative search. In the second part, we introduce a new performance measure and compare it to some known performance measures. The new measure preserved some important features of previous performance measures and overcomes a number of drawbacks. Both the measure and the model are applied to benchmark problems as well as randomly generated problems. The new measure and model are comparable to the existing models and measures

Meta-raps: Parameter Setting And New Applications

Recently meta-heuristics have become a popular solution methodology, in terms of both research and application, for solving combinatorial optimization problems. Meta-heuristic methods guide simple heuristics or priority rules designed to solve a particular problem. Meta-heuristics enhance these simple heuristics by using a higher level strategy. The advantage of using meta-heuristics over conventional optimization methods is meta-heuristics are able to find good (near optimal) solutions within a reasonable computation time. Investigating this line of research is justified because in most practical cases with medium to large scale problems, the use of meta-heuristics is necessary to be able to find a solution in a reasonable time. The specific meta-heuristic studied in this research is, Meta-RaPS; Meta-heuristic for Randomized Priority Search which is developed by DePuy and Whitehouse in 2001. Meta-RaPS is a generic, high level strategy used to modify greedy algorithms based on the insertion of a random element (Moraga, 2002). To date, Meta-RaPS had been applied to different types of combinatorial optimization problems and achieved comparable solution performance to other meta-heuristic techniques. The specific problem studied in this dissertation is parameter setting of Meta-RaPS. The topic of parameter setting for meta-heuristics has not been extensively studied in the literature. Although the parameter setting method devised in this dissertation is used primarily on Meta-RaPS, it is applicable to any meta-heuristic\u27s parameter setting problem. This dissertation not only enhances the power of Meta-RaPS by parameter tuning but also it introduces a robust parameter selection technique with wide-spread utility for many meta-heuristics. Because the distribution of solution values generated by meta-heuristics for combinatorial optimization problems is not normal, the current parameter setting techniques which employ a parametric approach based on the assumption of normality may not be appropriate. The proposed method is Non-parametric Based Genetic Algorithms. Based on statistical tests, the Non-parametric Based Genetic Algorithms (NPGA) is able to enhance the solution quality of Meta-RaPS more than any other parameter setting procedures benchmarked in this research. NPGA sets the best parameter settings, of all the methods studied, for 38 of the 41 Early/Tardy Single Machine Scheduling with Common Due Date and Sequence-Dependent Setup Time (ETP) problems and 50 of the 54 0-1 Multidimensional Knapsack Problems (0-1 MKP). In addition to the parameter setting procedure discussed, this dissertation provides two Meta-RaPS combinatorial optimization problem applications, the 0-1 MKP, and the ETP. For the ETP problem, the Meta-RaPS application in this dissertation currently gives the best meta-heuristic solution performance so far in the literature for common ETP test sets. For the large ETP test set, Meta-RaPS provided better solution performance than Simulated Annealing (SA) for 55 of the 60 problems. For the small test set, in all four different small problem sets, the Meta-RaPS solution performance outperformed exiting algorithms in terms of average percent deviation from the optimal solution value. For the 0-1 MKP, the present Meta-RaPS application performs better than the earlier Meta-RaPS applications by other researchers on this problem. The Meta-RaPS 0-1 MKP application presented here has better solution quality than the existing Meta-RaPS application (Moraga, 2005) found in the literature. Meta-RaPS gives 0.75% average percent deviation, from the best known solutions, for the 270 0-1 MKP test problems

Micro/Nano Manufacturing

Micro manufacturing involves dealing with the fabrication of structures in the size range of 0.1 to 1000 µm. The scope of nano manufacturing extends the size range of manufactured features to even smaller length scales—below 100 nm. A strict borderline between micro and nano manufacturing can hardly be drawn, such that both domains are treated as complementary and mutually beneficial within a closely interconnected scientific community. Both micro and nano manufacturing can be considered as important enablers for high-end products. This Special Issue of Applied Sciences is dedicated to recent advances in research and development within the field of micro and nano manufacturing. The included papers report recent findings and advances in manufacturing technologies for producing products with micro and nano scale features and structures as well as applications underpinned by the advances in these technologies

A meta-heuristic algorithm to solve quadratic assignment formulations of cell formation problems without presetting number of cells

The purpose of cellular manufacturing (CM) is to find part-families and machine cells which form self-sufficient units of production with a certain amount of autonomy that result in easier control (Kusiak, 1987, 1990). One of the most important steps in CM is to optimally identify cells from a given part-machine incidence matrix. Several formulations of various complexities are proposed in the literature to deal with this problem. One of the mostly known formulations for CM is the quadratic assignment formulation (Kusiak and Chow, 1988). The problem with the quadratic assignment based formulation is the difficulty of its solution due to its combinatorial nature. The formulation is also known as NP-hard (Kusiak and Chow, 1988). In this paper a novel simulated annealing based meta-heuristic algorithm is developed to solve quadratic assignment formulations of the manufacturing cell formation problems. In the paper a novel solution representation scheme is developed. Using the proposed solution representation scheme, feasible neighborhoods can be generated easily. Moreover, the proposed algorithm has the ability to self determine the optimal number of cell during the search process. A test problem is solved to present working of the proposed algorithm

Proceedings of the Seventh Congress of the European Society for Research in Mathematics Education

International audienceThis volume contains the Proceedings of the Seventh Congress of the European Society for Research in Mathematics Education (ERME), which took place 9-13 February 2011, at Rzeszñw in Poland

Annals of Scientific Society for Assembly, Handling and Industrial Robotics 2021

This Open Access proceedings presents a good overview of the current research landscape of assembly, handling and industrial robotics. The objective of MHI Colloquium is the successful networking at both academic and management level. Thereby, the colloquium focuses an academic exchange at a high level in order to distribute the obtained research results, to determine synergy effects and trends, to connect the actors in person and in conclusion, to strengthen the research field as well as the MHI community. In addition, there is the possibility to become acquatined with the organizing institute. Primary audience is formed by members of the scientific society for assembly, handling and industrial robotics (WGMHI)

Annals of Scientific Society for Assembly, Handling and Industrial Robotics 2021

This Open Access proceedings presents a good overview of the current research landscape of assembly, handling and industrial robotics. The objective of MHI Colloquium is the successful networking at both academic and management level. Thereby, the colloquium focuses an academic exchange at a high level in order to distribute the obtained research results, to determine synergy effects and trends, to connect the actors in person and in conclusion, to strengthen the research field as well as the MHI community. In addition, there is the possibility to become acquatined with the organizing institute. Primary audience is formed by members of the scientific society for assembly, handling and industrial robotics (WGMHI)