Best matching processes in distributed systems

The growing complexity and dynamic behavior of modern manufacturing and service industries along with competitive and globalized markets have gradually transformed traditional centralized systems into distributed networks of e- (electronic) Systems. Emerging examples include e-Factories, virtual enterprises, smart farms, automated warehouses, and intelligent transportation systems. These (and similar) distributed systems, regardless of context and application, have a property in common: They all involve certain types of interactions (collaborative, competitive, or both) among their distributed individuals—from clusters of passive sensors and machines to complex networks of computers, intelligent robots, humans, and enterprises. Having this common property, such systems may encounter common challenges in terms of suboptimal interactions and thus poor performance, caused by potential mismatch between individuals. For example, mismatched subassembly parts, vehicles—routes, suppliers—retailers, employees—departments, and products—automated guided vehicles—storage locations may lead to low-quality products, congested roads, unstable supply networks, conflicts, and low service level, respectively. This research refers to this problem as best matching, and investigates it as a major design principle of CCT, the Collaborative Control Theory. The original contribution of this research is to elaborate on the fundamentals of best matching in distributed and collaborative systems, by providing general frameworks for (1) Systematic analysis, inclusive taxonomy, analogical and structural comparison between different matching processes; (2) Specification and formulation of problems, and development of algorithms and protocols for best matching; (3) Validation of the models, algorithms, and protocols through extensive numerical experiments and case studies. The first goal is addressed by investigating matching problems in distributed production, manufacturing, supply, and service systems based on a recently developed reference model, the PRISM Taxonomy of Best Matching. Following the second goal, the identified problems are then formulated as mixed-integer programs. Due to the computational complexity of matching problems, various optimization algorithms are developed for solving different problem instances, including modified genetic algorithms, tabu search, and neighbourhood search heuristics. The dynamic and collaborative/competitive behaviors of matching processes in distributed settings are also formulated and examined through various collaboration, best matching, and task administration protocols. In line with the third goal, four case studies are conducted on various manufacturing, supply, and service systems to highlight the impact of best matching on their operational performance, including service level, utilization, stability, and cost-effectiveness, and validate the computational merits of the developed solution methodologies

Dynamic small-series fashion order allocation and supplier selection: a ga-topsis-based model

The fashion industry is currently confronted with significant economic and environmental challenges, necessitating the exploration of novel business models. Among the promising approaches is small series production on demand, though this poses considerable complexities in the highly competitive sector. Traditional supplier selection and production planning processes, known for their lengthy and intricate nature, must be replaced with more dynamic and effective decision-making procedures. To tackle this problem, GA-TOPSIS hybrid model is proposed as the methodology. The model integrates Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) evaluation into the fitness function of Genetic Algorithm (GA) to comprehensively consider both qualitative and quantitative criteria for supplier selection. Simultaneously, GA efficiently optimizes the order sequence for production planning. The model's efficacy is demonstrated through implementation on real orders, showcasing its ability to handle diverse evaluation criteria and support supplier selection in different scenarios. Moreover, the proposed model is employed to compute the Pareto front, which provides optimal sets of solutions for the given objective criteria. This allows for an effective demand-driven strategy, particularly relevant for fashion retailers to select supplier and order planning optimization decisions in dynamic and multi-criteria context. Overall, GA-TOPSIS hybrid model offers an innovative and efficient decision support system for fashion retailers to adapt to changing demands and achieve effective supplier selection and production planning optimization. The model's incorporation of both qualitative and quantitative criteria in a dynamic environment contributes to its originality and potential for addressing the complexities of the fashion industry's supply chain challenge

Concurrent Design of Assembly Plans and Supply Chains: Models, Algorithms, and Strategies.

Assembly planning and supply chain designs are two inter-dependent activities in product development. The traditional sequential approach of designing the supply chain after completing assembly planning results in long lead time for product realization and sub-optimal product cost. The weakness of the sequential method is exacerbated nowadays as product proliferation brings more challenges to assembly system design and supply chain management. Making concurrent decisions on assembly plans and supply chain configurations is a desirable strategy. However, due to the complexity of both assembly representations and supply chain modeling, there have been limited systematic models, optimization algorithms, or deep understanding of the interaction between assembly-plan and supply-chain designs. This dissertation first analyzes and compares existing assembly representation methods. Hyper AND/OR Graph (HAG) is then developed to incorporate both assembly planning and supply chain configuration information by adding one additional layer representing supplier information on top of a typical assembly AND/OR graph. Based on HAG, a DP based algorithm with a polynomial complexity for typical assembly products is developed to generate the assembly plans and supplier assignment at the optimal cost. For the problem with a lead time constraint, a revised DP algorithm with a pseudo-polynomial complexity is also presented. Under the scenario of product family designs, an investigation is carried out on the optimal strategies to design assembly supply chains when commonality is limited between products in the family. The impact of product variety on safety inventory is derived and then evaluated with a performance measure. Strategies of prioritized differentiation and branch balancing are suggested for optimal process sequencing and assembly decomposition. The outcome of this research are threefold: (1) it establishes a foundation for the research on integrated designs of assembly plans and supply chains as well as other concurrent design problems; (2) it offers a tool for integrated assembly plan and supply chain designs using which manufacturers can shorten the product development time, lower the product cost, and increase the responsiveness to fluctuations in supply chains; and (3) it provides a measure of the impact of product variety on inventory and insightful strategies to manage complicated assembly supply chains.PhDMechanical EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttp://deepblue.lib.umich.edu/bitstream/2027.42/133210/1/hekuang_1.pd

Robust dynamic schedule coordination control in the supply chain

International audienceCoordination plays crucial role in supply chain management. In this paper, we extend the existing body of literature on supply chain coordination by representing a robust schedule coordination approach. A hybrid discrete/continuous flow shop supply chain with job shop processes at each supplier stage is studied. For this purpose, the developed scheduling model comprises operations control (for customer order fulfillment dynamics), channel control (production machine and transportation dynamics), resource control (material supply dynamics), and flow control (processing and shipment dynamics) with multiple objectives. Based on the scheduling model, we introduce a robust analysis of schedule coordination in the presence of disruptions in capacities and supply. The application of attainable sets opens a possibility to analyse schedule coordination dynamics under disruptions. The results provide insights of how to integrate the coordination issues into schedule robustness analysis. We exemplify the developed approach for the case of two-stage supply chain coordination, and derive managerial insights for both considered scheduling problem and application of dynamic control methods to supply chain coordination in general

AI and OR in management of operations: history and trends

The last decade has seen a considerable growth in the use of Artificial Intelligence (AI) for operations management with the aim of finding solutions to problems that are increasing in complexity and scale. This paper begins by setting the context for the survey through a historical perspective of OR and AI. An extensive survey of applications of AI techniques for operations management, covering a total of over 1200 papers published from 1995 to 2004 is then presented. The survey utilizes Elsevier's ScienceDirect database as a source. Hence, the survey may not cover all the relevant journals but includes a sufficiently wide range of publications to make it representative of the research in the field. The papers are categorized into four areas of operations management: (a) design, (b) scheduling, (c) process planning and control and (d) quality, maintenance and fault diagnosis. Each of the four areas is categorized in terms of the AI techniques used: genetic algorithms, case-based reasoning, knowledge-based systems, fuzzy logic and hybrid techniques. The trends over the last decade are identified, discussed with respect to expected trends and directions for future work suggested

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

Modeling and Solution Methodologies for Mixed-Model Sequencing in Automobile Industry

The global competitive environment leads companies to consider how to produce high-quality products at a lower cost. Mixed-model assembly lines are often designed such that average station work satisfies the time allocated to each station, but some models with work-intensive options require more than the allocated time. Sequencing varying models in a mixed-model assembly line, mixed-model sequencing (MMS), is a short-term decision problem that has the objective of preventing line stoppage resulting from a station work overload. Accordingly, a good allocation of models is necessary to avoid work overload. The car sequencing problem (CSP) is a specific version of the MMS that minimizes work overload by controlling the sequence of models. In order to do that, CSP restricts the number of work-intensive options by applying capacity rules. Consequently, the objective is to find the sequence with the minimum number of capacity rule violations. In this dissertation, we provide exact and heuristic solution approaches to solve different variants of MMS and CSP. First, we provide five improved lower bounds for benchmark CSP instances by solving problems optimally with a subset of options. We present four local search metaheuristics adapting efficient transformation operators to solve CSP. The computational experiments show that the Adaptive Local Search provides a significant advantage by not requiring tuning on the operator weights due to its adaptive control mechanism. Additionally, we propose a two-stage stochastic program for the mixed-model sequencing (MMS) problem with stochastic product failures, and provide improvements to the second-stage problem. To tackle the exponential number of scenarios, we employ the sample average approximation approach and two solution methodologies. On one hand, we develop an L-shaped decomposition-based algorithm, where the computational experiments show its superiority over solving the deterministic equivalent formulation with an off-the-shelf solver. We also provide a tabu search algorithm in addition to a greedy heuristic to tackle case study instances inspired by our car manufacturer partner. Numerical experiments show that the proposed solution methodologies generate high-quality solutions by utilizing a sample of scenarios. Particularly, a robust sequence that is generated by considering car failures can decrease the expected work overload by more than 20\% for both small- and large-sized instances. To the best of our knowledge, this is the first study that considers stochastic failures of products in MMS. Moreover, we propose a two-stage stochastic program and formulation improvements for a mixed-model sequencing problem with stochastic product failures and integrated reinsertion process. We present a bi-objective evolutionary optimization algorithm, a two-stage bi-objective local search algorithm, and a hybrid local search integrated evolutionary optimization algorithm to tackle the proposed problem. Numerical experiments over a case study show that while the hybrid algorithm provides a better exploration of the Pareto front representation and more reliable solutions in terms of waiting time of failed vehicles, the local search algorithm provides more reliable solutions in terms of work overload objective. Finally, dynamic reinsertion simulations are executed over industry-inspired instances to assess the quality of the solutions. The results show that integrating the reinsertion process in addition to considering vehicle failures can keep reducing the work overload by around 20\% while significantly decreasing the waiting time of the failed vehicles

Mixed-model Sequencing with Reinsertion of Failed Vehicles: A Case Study for Automobile Industry

In the automotive industry, some vehicles, failed vehicles, cannot be produced according to the planned schedule due to some reasons such as material shortage, paint failure, etc. These vehicles are pulled out of the sequence, potentially resulting in an increased work overload. On the other hand, the reinsertion of failed vehicles is executed dynamically as suitable positions occur. In case such positions do not occur enough, either the vehicles waiting for reinsertion accumulate or reinsertions are made to worse positions by sacrificing production efficiency. This study proposes a bi-objective two-stage stochastic program and formulation improvements for a mixed-model sequencing problem with stochastic product failures and integrated reinsertion process. Moreover, an evolutionary optimization algorithm, a two-stage local search algorithm, and a hybrid approach are developed. Numerical experiments over a case study show that while the hybrid algorithm better explores the Pareto front representation, the local search algorithm provides more reliable solutions regarding work overload objective. Finally, the results of the dynamic reinsertion simulations show that we can decrease the work overload by ~20\% while significantly decreasing the waiting time of the failed vehicles by considering vehicle failures and integrating the reinsertion process into the mixed-model sequencing problem.Comment: 26 pages, 6 figures, 5 table

Assignment of Customer-Specific Orders to Plants with Mixed-Model Assembly Lines in Global Production Networks

Build-to-order series production is gaining increasing importance as markets demand customer-specific product variants. Orders have to be assigned to plants and periods in global production networks and then to lines and cycles. Consequently, respective workloads as well as supplied materials have to be balanced due to limitations in resource capacities. As first step planning defines the solution space for second step planning, this paper introduces a mathematical model for order assignments to plants and periods anticipating assignments to lines and cycles. Given that orders are not fully specified for first step planning, the approach includes provisions for dealing with uncertainty