Scheduling of non-repetitive lean manufacturing systems under uncertainty using intelligent agent simulation

World-class manufacturing paradigms emerge from specific types of manufacturing systems with which they remain associated until they are obsolete. Since its introduction the lean paradigm is almost exclusively implemented in repetitive manufacturing systems employing flow-shop layout configurations. Due to its inherent complexity and combinatorial nature, scheduling is one application domain whereby the implementation of manufacturing philosophies and best practices is particularly challenging. The study of the limited reported attempts to extend leanness into the scheduling of non-repetitive manufacturing systems with functional shop-floor configurations confirms that these works have adopted a similar approach which aims to transform the system mainly through reconfiguration in order to increase the degree of manufacturing repetitiveness and thus facilitate the adoption of leanness. This research proposes the use of leading edge intelligent agent simulation to extend the lean principles and techniques to the scheduling of non-repetitive production environments with functional layouts and no prior reconfiguration of any form. The simulated system is a dynamic job-shop with stochastic order arrivals and processing times operating under a variety of dispatching rules. The modelled job-shop is subject to uncertainty expressed in the form of high priority orders unexpectedly arriving at the system, order cancellations and machine breakdowns. The effect of the various forms of the stochastic disruptions considered in this study on system performance prior and post the introduction of leanness is analysed in terms of a number of time, due date and work-in-progress related performance metrics

A new adaptive neural network and heuristics hybrid approach for job-shop scheduling

Copyright @ 2001 Elsevier Science LtdA new adaptive neural network and heuristics hybrid approach for job-shop scheduling is presented. The neural network has the property of adapting its connection weights and biases of neural units while solving the feasible solution. Two heuristics are presented, which can be combined with the neural network. One heuristic is used to accelerate the solving process of the neural network and guarantee its convergence, the other heuristic is used to obtain non-delay schedules from the feasible solutions gained by the neural network. Computer simulations have shown that the proposed hybrid approach is of high speed and efficiency. The strategy for solving practical job-shop scheduling problems is provided.This work is supported by the National Nature Science Foundation (No. 69684005) and National High -Tech Program of P. R. China (No. 863-511-9609-003)

Theory of constraints (TOC) production and manufacturing performance

This paper is based on an empirical study of the relationship between Theory of Constraints (TOC) production and operational performance in manufacturing plants. The study uses a survey questionnaire to collect data from a sample of 61 European firms which have implemented the TOC approach. Analysis of variance (ANOVA) technique and regression models have been employed to test the research hypotheses. The results detect many differences and similarities in adoption of TOC practices across the countries and suggest that manufacturing managers should consider adopting some TOC practices instead of others. In particular the Drum-buffer-rope methodology, the development of a Master Production Schedule based on constraints and the use of Non-constraint resources with excess capacity are among the most important practices to enhance competitive performance of manufacturing plants

Global supply chains of high value low volume products

Imperial Users onl

Supply chain management: An opportunity for metaheuristics

In today’s highly competitive and global marketplace the pressure on organizations to find new ways to create and deliver value to customers grows ever stronger. In the last two decades, logistics and supply chain has moved to the center stage. There has been a growing recognition that it is through an effective management of the logistics function and the supply chain that the goal of cost reduction and service enhancement can be achieved. The key to success in Supply Chain Management (SCM) require heavy emphasis on integration of activities, cooperation, coordination and information sharing throughout the entire supply chain, from suppliers to customers. To be able to respond to the challenge of integration there is the need of sophisticated decision support systems based on powerful mathematical models and solution techniques, together with the advances in information and communication technologies. The industry and the academia have become increasingly interested in SCM to be able to respond to the problems and issues posed by the changes in the logistics and supply chain. We present a brief discussion on the important issues in SCM. We then argue that metaheuristics can play an important role in solving complex supply chain related problems derived by the importance of designing and managing the entire supply chain as a single entity. We will focus specially on the Iterated Local Search, Tabu Search and Scatter Search as the ones, but not limited to, with great potential to be used on solving the SCM related problems. We will present briefly some successful applications.Supply chain management, metaheuristics, iterated local search, tabu search and scatter search

Application of lean scheduling and production control in non-repetitive manufacturing systems using intelligent agent decision support

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Lean Manufacturing (LM) is widely accepted as a world-class manufacturing paradigm, its currency and superiority are manifested in numerous recent success stories. Most lean tools including Just-in-Time (JIT) were designed for repetitive serial production systems. This resulted in a substantial stream of research which dismissed a priori the suitability of LM for non-repetitive non-serial job-shops. The extension of LM into non-repetitive production systems is opposed on the basis of the sheer complexity of applying JIT pull production control in non-repetitive systems fabricating a high variety of products. However, the application of LM in job-shops is not unexplored. Studies proposing the extension of leanness into non-repetitive production systems have promoted the modification of pull control mechanisms or reconfiguration of job-shops into cellular manufacturing systems. This thesis sought to address the shortcomings of the aforementioned approaches. The contribution of this thesis to knowledge in the field of production and operations management is threefold: Firstly, a Multi-Agent System (MAS) is designed to directly apply pull production control to a good approximation of a real-life job-shop. The scale and complexity of the developed MAS prove that the application of pull production control in non-repetitive manufacturing systems is challenging, perplex and laborious. Secondly, the thesis examines three pull production control mechanisms namely, Kanban, Base Stock and Constant Work-in-Process (CONWIP) which it enhances so as to prevent system deadlocks, an issue largely unaddressed in the relevant literature. Having successfully tested the transferability of pull production control to non-repetitive manufacturing, the third contribution of this thesis is that it uses experimental and empirical data to examine the impact of pull production control on job-shop performance. The thesis identifies issues resulting from the application of pull control in job-shops which have implications for industry practice and concludes by outlining further research that can be undertaken in this direction

Manufacturing Lead Time Estimation with the Combination of Simulation and Statistical Learning Methods

In the paper, a novel method is introduced for selecting tuning parameters improving accuracy and robustness for multi-model based prediction of manufacturing lead times. Prediction is made by setting up models using statistical learning methods (multivariate regression); trained, validated and tested on log data gathered by manufacturing execution systems (MES). Relevant features, i.e., the predictors most contributing to the response, are selected from a wider range of system parameters. The proposed method is tested on data provided by a discrete event simulation model (as a part of a simulation-based prediction framework) of a small-sized flow-shop system. Accordingly, log data are generated by simulation experiments, substituting the function of a MES system, while considering several different system settings (e.g., job arrival rate, test rejection rate). By inserting the prediction models into a simulation-based decision support system, prospective simulations anticipating near-future deviations and/or disturbances, could be supported. Consequently, simulation could be applied for reactive, disturbance-handling purposes, and, moreover, for training the prediction models. (C) 2015 The Authors. Published by Elsevier B.V

A review and classification of computer-based manufacturing scheduling tools

Computer-based manufacturing scheduling tools can play a key role in the management of industrial operations, as obtaining economic and reliable schedules is at the core of excellence in customer service and of efficiency in manufacturing companies. As a consequence, this topic has been receiving an increasing interest in the last decades, resulting in a number of case studies and descriptions of implementation of these tools. However, to the best of our knowledge, there is no review of these cases in order to classify existing references and to identify relevant issues still not properly addressed. Therefore, in this paper we carry out a systematic review of case studies of manufacturing scheduling tools. In order to provide a coherent taxonomy for the analysis of these tools, we develop a classification based on the functionalities of the manufacturing scheduling tools. Using this framework, existing contributions are classified and discussed, and a number of conclusions and open issues are identified. We hope that our work can establish a coherent picture of the topic so it serves as a starting point for future research

Exact and suboptimal reactive strategies for resource-constrained project scheduling with uncertain resource availabilities.

In order to cope with the uncertainty inherent in practical project management, proactive and/or reactive strategies can be used. Proactive strategies try to anticipate future disruptions by incorporating slack time or excess resource availability into the schedule, whereas reactive strategies react after a disruption happened and try to revert to a feasible schedule. Traditionally, reactive approaches have focused on obtaining a good schedule with respect to the original objective function or a schedule that deviates as little as possible from the baseline schedule. In this paper, we present various approaches, exact as well as heuristic, for optimizing the latter objective and thus encouraging schedule stability. Furthermore, in contrast to traditional rescheduling algorithms, we present a new heuristic that also takes future uncertainty into account when repairing the schedule. We consider a variant of the resource- constrained project scheduling problem in which the uncertainty is modeled by means of unexpected resource breakdowns. The results of an extensive computational experiment are given to compare the performance of the proposed strategies.Schedule stability; Stability; Algorithms; Heuristic; Uncertainty; Project scheduling; Scheduling; Performance; Strategy; Order; Project management; Management; Time;

QoS-aware predictive workflow scheduling

This research places the basis of QoS-aware predictive workflow scheduling. This research novel contributions will open up prospects for future research in handling complex big workflow applications with high uncertainty and dynamism. The results from the proposed workflow scheduling algorithm shows significant improvement in terms of the performance and reliability of the workflow applications