Integrating Multiobjective Optimization With The Six Sigma Methodology For Online Process Control

Over the past two decades, the Define-Measure-Analyze-Improve-Control (DMAIC) framework of the Six Sigma methodology and a host of statistical tools have been brought to bear on process improvement efforts in today’s businesses. However, a major challenge of implementing the Six Sigma methodology is maintaining the process improvements and providing real-time performance feedback and control after solutions are implemented, especially in the presence of multiple process performance objectives. The consideration of a multiplicity of objectives in business and process improvement is commonplace and, quite frankly, necessary. However, balancing the collection of objectives is challenging as the objectives are inextricably linked, and, oftentimes, in conflict. Previous studies have reported varied success in enhancing the Six Sigma methodology by integrating optimization methods in order to reduce variability. These studies focus these enhancements primarily within the Improve phase of the Six Sigma methodology, optimizing a single objective. The current research and practice of using the Six Sigma methodology and optimization methods do little to address the real-time feedback and control for online process control in the case of multiple objectives. This research proposes an innovative integrated Six Sigma multiobjective optimization (SSMO) approach for online process control. It integrates the Six Sigma DMAIC framework with a nature-inspired optimization procedure that iteratively perturbs a set of decision variables providing feedback to the online process, eventually converging to a set of tradeoff process configurations that improves and maintains process stability. For proof of concept, the approach is applied to a general business process model – a well-known inventory management model – that is formally defined and specifies various process costs as objective functions. The proposed iv SSMO approach and the business process model are programmed and incorporated into a software platform. Computational experiments are performed using both three sigma (3σ)-based and six sigma (6σ)-based process control, and the results reveal that the proposed SSMO approach performs far better than the traditional approaches in improving the stability of the process. This research investigation shows that the benefits of enhancing the Six Sigma method for multiobjective optimization and for online process control are immense

A review of design optimization methods for electrical machines

© 2017 by the authors. Licensee MDPI, Basel, Switzerland. Electrical machines are the hearts of many appliances, industrial equipment and systems. In the context of global sustainability, they must fulfill various requirements, not only physically and technologically but also environmentally. Therefore, their design optimization process becomes more and more complex as more engineering disciplines/domains and constraints are involved, such as electromagnetics, structural mechanics and heat transfer. This paper aims to present a review of the design optimization methods for electrical machines, including design analysis methods and models, optimization models, algorithms and methods/strategies. Several efficient optimization methods/strategies are highlighted with comments, including surrogate-model based and multi-level optimization methods. In addition, two promising and challenging topics in both academic and industrial communities are discussed, and two novel optimization methods are introduced for advanced design optimization of electrical machines. First, a system-level design optimization method is introduced for the development of advanced electric drive systems. Second, a robust design optimization method based on the design for six-sigma technique is introduced for high-quality manufacturing of electrical machines in production. Meanwhile, a proposal is presented for the development of a robust design optimization service based on industrial big data and cloud computing services. Finally, five future directions are proposed, including smart design optimization method for future intelligent design and production of electrical machines

Probability and variance-based stochastic design optimization of a radial compressor concerning fluid-structure interaction

Since the engineering of turbo machines began the improvement of specific physical behaviour, especially the efficiency, has been one of the key issues. However, improvement of the efficiency of a turbo engine, is hard to archive using a conventional deterministic optimization, since the geometry is not perfect and many other parameters vary in the real approach. In contrast, stochastic design optimization is a methodology that enables the solving of optimization problems which model the effects of uncertainty in manufacturing, design configuration and environment, in which robustness and reliability are explicit optimization goals. Therein, a coupling of stochastic and optimization problems implies high computational efforts, whereby the calculation of the stochastic constraints represents the main effort. In view of this fact, an industrially relevant algorithm should satisfy the conditions of precision, robustness and efficiency. In this paper an efficient approach is presented to assist reducing the number of design evaluations necessary, in particular the number of nonlinear fluid-structure interaction analyses. In combination with a robust estimation of the safety level within the iteration and a final precise reliability analysis, the method presented is particularly suitable for solving reliability-based structural design optimization problems with ever-changing failure probabilities of the nominal designs. The applicability for real case applications is demonstrated through the example of a radial compressor, with a very high degree of complexity and a large number of design parameters and random variables

Geometrically-constrained, parasitic-aware synthesis of analog ICs

In order to speed up the design process of analog ICs, iterations between different design stages should be avoided as much as possible. More specifically, spins between electrical and physical synthesis should be reduced for this is a very time-consuming task: if circuit performance including layout-induced degradations proves unacceptable, a re-design cycle must be entered, and electrical, physical, or both synthesis processes, would have to be repeated. It is also worth noting that if geometric optimization (e.g., area minimization) is undertaken after electrical synthesis, it may add up as another source of unexpected degradation of the circuit performance due to the impact of the geometric variables (e.g., transistor folds) on the device and the routing parasitic values. This awkward scenario is caused by the complete separation of said electrical and physical synthesis, a design practice commonly followed so far. Parasitic-aware synthesis, consisting in including parasitic estimates to the circuit netlist directly during electrical synthesis, has been proposed as solution. While most of the reported contributions either tackle parasitic-aware synthesis without paying special attention to geometric optimization or approach both issues only partially, this paper addresses the problem in a unified way. In what has been called layout-aware electrical synthesis, a simulation-based optimization algorithm explores the design space with geometric variables constrained to meet certain user-defined goals, which provides reliable estimates of layout-induced parasitics at each iteration, and, thereby, accurate evaluation of the circuit ultimate performance. This technique, demonstrated here through several design examples, requires knowing layout details beforehand; to facilitate this, procedural layout generation is used as physical synthesis approach due to its rapidness and ability to capture analog layout know-how.Ministerio de Educación y Ciencia TEC2004-0175

Redesigning the Barranquilla's public emergency care network to improve the patient waiting time

Tesis por compendio[ES] La oportunidad en la atención es uno de los críticos de mayor relevancia en la satisfacción de los pacientes que acuden a los servicios de Urgencias. Por tal motivo, las instituciones prestadoras de servicio y las organizaciones gubernamentales deben propender conjuntamente por una atención cada vez más oportuna a costos operacionales razonables. En el caso de la Red Pública en Servicios de Urgencias de Barrannquilla, compuesta por 8 puntos de atención y 2 hospitales, la tendencia marca un continuo crecimiento de la oportunidad en la atención con una tasa de 3,08 minutos/semestre y una probabilidad del 93,13% de atender a los pacientes después de una espera mayor a 30 minutos. Lo anterior se constituye en un síntoma inequívoco de la incapacidad de la Red para satisfacer los estándares de oportunidad establecidos por el Ministerio de Salud, hecho que podría desencadenar el desarrollo de sintomatologías de mayor complejidad, el incremento de la probabilidad de mortalidad, el requerimiento de servicios clínicos más complejos (hospitalización y cuidados intensivos) y el aumento de los costos asociados al servicio. En consecuencia, la presente tesis doctoral presenta el rediseño de la Red Pública en Servicios de Urgencias anteriormente mencionada a fin de otorgar a la población diana un servicio eficiente y altamente oportuno donde tanto las instituciones prestadoras del servicio como los organismos gubernamentales converjan efectivamente. Para ello, fue necesaria la ejecución de 4 grandes fases a través de las cuales se consolidó una propuesta orientada al desarrollo efectivo y sostenible de las operaciones de la Red. Primero, se caracterizó la Red Pública de Servicios de Urgencias en Salud considerando su comportamiento actual en términos de demanda y oportunidad de la atención. Luego, a través de una revisión sistemática de la literatura, se identificaron los enfoques metodológicos que se han implementado para la mejora de la oportunidad y otros indicadores de rendimiento asociados al servicio de Urgencias. Posteriormente, se diseñó una metodología para la creación de redes de Urgencias eficientes y sostenibles la cual luego se validó en la Red Pública sudamericana a fin de disminuir la oportunidad de atención promedio en Urgencias y garantizar la distribución equitativa de los beneficios financieros derivados de la colaboración. Finalmente, se construyó un modelo multicriterio que permitió evaluar el rendimiento de los departamentos de Urgencia e impulsó la creación de estrategias de mejora focalizadas en incrementar su respuesta ante la demanda cambiante, los críticos de satisfacción y las condiciones de operación estipuladas en la ley. Los resultados de esta aplicación evidenciaron que los pacientes que acceden a la Red tienden a esperar en promedio 201,6 min con desviación de estándar de 81,6 min antes de ser atendidos por urgencia. Por otro lado, de acuerdo con la revisión de literatura, la combinación de técnicas de investigación de operaciones, ingeniería de la calidad y analítica de datos es ampliamente recomendada para abordar este problema. En ese sentido, una metodología basada en modelos colaterales de pago, simulación de procesos y lean seis sigma fue propuesta y validada generando un rediseño de Red cuya oportunidad de atención promedio podría disminuir entre 6,71 min y 9,08 min con beneficios financieros promedio de US$29,980/nodo. En último lugar, un modelo compuesto por 8 criterios y 35 sub-criterios fue diseñado para evaluar el rendimiento general de los departamentos de Urgencias. Los resultados del modelo evidenciaron el rol crítico de la infraestructura (Peso global = 21,5i garantir la distribució equitativa dels beneficis financers derivats de la col´laboració. Finalment, es va construir un model multicriteri que va permetre avaluar el rendiment dels departaments d'Urgència i va impulsar la creació d'estratègies de millora focalitzades en incrementar la seva resposta davant la demanda canviant, els crítics de satisfacció i les condicions d'operació estipulades en la llei. Els resultats d'aquesta aplicació van evidenciar que els pacients que accedeixen a la Xarxa tendeixen a esperar de mitjana 201,6 min amb desviació d'estàndard de 81,6 min abans de ser atesos per urgència. D'altra banda, d'acord amb la revisió de literatura, la combinació de tècniques d'investigació d'operacions, enginyeria de la qualitat i analítica de dades és àmpliament recomanada per abordar aquest problema. En aquest sentit, una metodologia basada en models col´laterals de pagament, simulació de processos i llegeixin 6 sigma va ser proposada i validada generant un redisseny de Xarxa la oportunitat d'atenció mitjana podria disminuir entre 6,71 min i 9,08 min amb beneficis financers mitjana d'US$ 29,980 / node. En darrer lloc, un model compost per 8 criteris i 35 sub-criteris va ser dissenyat per avaluar el rendiment general dels departaments d'Urgències. Els resultats de el model evidenciar el paper crític de la infraestructura (Pes global = 21,5%) en el rendiment dels departaments d'Urgència i la naturalesa interactiva de la Seguretat de l'Pacient (C + R = 12,771).[EN] Waiting time is one of the most critical measures in the satisfaction of patients admitted within emergency departments. Therefore, hospitals and governmental organizations should jointly aim to provide timely attention at reasonable costs. In the case of Barranquilla's Pubic Emergency Service Network, composed by 8 Points of care (POCs) and 2 hospitals, the trend evidences a continuous growing of the waiting time with a rate of 3,08 min/semester and a 93,13% likelihood of serving patients after waiting for more than 30 minutes. This is an unmistakable symptom of the network inability for satisfying the standards established by the Ministry of Health, which may trigger the development of more complex symptoms, increase in the death rate, requirement for more complex clinical services (hospitalization and intensive care unit) and increased service costs. This doctoral dissertation then illustrates the redesign of the aforementioned Public Emergency Service Network aiming at providing the target population with an efficient and highly timely service where both hospitals and governmental institutions effectively converge. It was then necessary to implement a 4-phase methodology consolidating a proposal oriented to the effective and sustainable development of network operations. First, the Public Emergency Service Network was characterized considering its current behavior in terms of demand and waiting time. A systematic literature review was then undertaken for identifying the methodological approaches that have been implementing for improving the waiting time and other performance indicators associated with the emergency care service. Following this, a methodology for the creation of efficient and sustainable emergency care networks was designed and later validated in the Southamerican Public network for lessening the average waiting time and ensuring the equitable distribution of profits derived from the collaboration. Ultimately, a multicriteria decision-making model was created for assessing the performance of the emergency departments and propelling the design of improvement strategies focused on bettering the response against the changing demand conditions, critical to satisfaction and operational conditions. The results evidenced that the patients accessing to the network tend to wait 201,6 min on average with a standard deviation of 81,6 min before being served by the emergency care unit. On the other hand, based on the reported literature, it is highly suggested to combine Operations Research (OR) methods, quality-based techniques, and data-driven approaches for addressing this problem. In this sense, a methodology based on collateral payment models, Discrete-event simulation, and Lean Six Sigma was proposed and validated resulting in a redesigned network whose average waiting time may diminish between 6,71 min and 9,08 min with an average profit US$29,980/node. Lately, a model comprising of 8 criteria and 35 sub-criteria was designed for evaluating the overall performance of emergency departments. The model outcomes revealed the critical role of Infrastructure (Global weight = 21,5%) in ED performance and the interactive nature of Patient Safety (C + R = 12,771).Ortíz Barrios, MÁ. (2020). Redesigning the Barranquilla's public emergency care network to improve the patient waiting time [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/156215TESISCompendi

Numerical product design: Springback prediction, compensation and optimization

Numerical simulations are being deployed widely for product design. However, the accuracy of the numerical tools is not yet always sufficiently accurate and reliable. This article focuses on the current state and recent developments in different stages of product design: springback prediction, springback compensation and optimization by finite element (FE) analysis. To improve the springback prediction by FE analysis, guidelines regarding the mesh discretization are provided and a new through-thickness integration scheme for shell elements is launched. In the next stage of virtual product design the product is compensated for springback. Currently, deformations due to springback are manually compensated in the industry. Here, a procedure to automatically compensate the tool geometry, including the CAD description, is presented and it is successfully applied to an industrial automotive part. The last stage in virtual product design comprises optimization. This article presents an optimization scheme which is capable of designing optimal and robust metal forming processes efficiently

Why simheuristics? : Benefits, limitations, and best practices when combining metaheuristics with simulation

Many decision-making processes in our society involve NP-hard optimization problems. The largescale, dynamism, and uncertainty of these problems constrain the potential use of stand-alone optimization methods. The same applies for isolated simulation models, which do not have the potential to find optimal solutions in a combinatorial environment. This paper discusses the utilization of modelling and solving approaches based on the integration of simulation with metaheuristics. These 'simheuristic' algorithms, which constitute a natural extension of both metaheuristics and simulation techniques, should be used as a 'first-resort' method when addressing large-scale and NP-hard optimization problems under uncertainty -which is a frequent case in real-life applications. We outline the benefits and limitations of simheuristic algorithms, provide numerical experiments that validate our arguments, review some recent publications, and outline the best practices to consider during their design and implementation stages

Methodological approaches to support process improvement in emergency departments: a systematic review

The most commonly used techniques for addressing each Emergency Department (ED) problem (overcrowding, prolonged waiting time, extended length of stay, excessive patient flow time, and high left-without-being-seen (LWBS) rates) were specified to provide healthcare managers and researchers with a useful framework for effectively solving these operational deficiencies. Finally, we identified the existing research tendencies and highlighted opportunities for future work. We implemented the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) methodology to undertake a review including scholarly articles published between April 1993 and October 2019. The selected papers were categorized considering the leading ED problems and publication year. Two hundred and three (203) papers distributed in 120 journals were found to meet the inclusion criteria. Furthermore, computer simulation and lean manufacturing were concluded to be the most prominent approaches for addressing the leading operational problems in EDs. In future interventions, ED administrators and researchers are widely advised to combine Operations Research (OR) methods, quality-based techniques, and data-driven approaches for upgrading the performance of EDs. On a different tack, more interventions are required for tackling overcrowding and high left-without-being-seen rate

Design for Producibility in Fabricated Aerospace Components - A framework for predicting and controlling geometrical variation and weld quality defects during multidisciplinary design

In the aerospace industry, weight reduction has been one of the key factors in making aircraft more fuel efficient in order to satisfy environmental demands and increase competitiveness. One strategy adopted by aircraft component suppliers to reduce weight has been fabrication, in which small cast or forged parts are welded together into a final shape. Fabrication increases design freedom due to the possibility of configuring several materials and geometries, which broadens out the design space and allows multioptimization in product weight, performance quality and cost. However, with fabrication, the number of assembly steps and the complexity of the manufacturing process have increased. The use of welding has brought to the forefront important producibility problems related to geometrical variation and weld quality.The goal of this research is to analyze the current situation in industry and academia and propose methods and tools within Engineering Design and Quality Engineering to solve producibility problems involving welded high performance integrated components. The research group “Geometry Assurance and Robust Design” at Chalmers University of Technology, in which this thesis has been produced, has the objective to simulate and foresee geometrical quality problems during the early phases of the product realization process to allow the development of robust concepts and the optimization of tolerances, thus solving producibility problems. Virtual manufacturing is a key within the multidisciplinary design process of aerospace components, in which automated processes analyze broad sets of design variants to trade-off requirements among various disciplines. However, as studied in this thesis, existing methods and tools to analyze producibility do not cover all aspects that define the quality of welded structures. Furthermore, to this day, not all phenomena related to welding can be virtually modelled. Understanding causes and effects still relies on expert judgements and physical experimentation to a great deal. However, when it comes to assessing the capability of many geometrical variants, such an effort might be costly. This deficiency indicates the need for virtual assessment methods and systematic experimentation to analyze the producibility of the design variants and produce process capability data that can be reused in future projects.To fulfill that need, this thesis provides support to designers in assessing producibility by virtually and rapidly predicting the welding quality of a large number of product design variants during the multidisciplinary design space process of fabricated aerospace components.The first step has been to map the fabrication process during which producibility problems might potentially occur. The producibility conceptual model has been proposed to represent the fabrication process in order to understand how variation is originated and propagated. With this representation at hand, a number of methods have been developed and employed to provide support to: 1) Identify and 2) Measure what affects producibility; 3) Analyze the effect of the interaction between factors that affect producibility and 4)Predict producibility. These activities and methods constitute the core of the proposed Design for Producibility framework. This framework combines specialized information about welding problems (know-hows), and inspection, testing and simulation data to systematically predict and evaluate the welding producibility of a set of product design variants. Through this thesis, producibility evaluations are no longer limited to a single geometry and the study of the process parameter window. Instead, a set of geometrical variants within the design space can be analyzed. The results can be used to perform optimization and evaluate trade-offs among different disciplines during design space exploration and analysis, thus supporting the multidisciplinary design process of fabricated (welded) aerospace components