Design and Management of Manufacturing Systems

Although the design and management of manufacturing systems have been explored in the literature for many years now, they still remain topical problems in the current scientific research. The changing market trends, globalization, the constant pressure to reduce production costs, and technical and technological progress make it necessary to search for new manufacturing methods and ways of organizing them, and to modify manufacturing system design paradigms. This book presents current research in different areas connected with the design and management of manufacturing systems and covers such subject areas as: methods supporting the design of manufacturing systems, methods of improving maintenance processes in companies, the design and improvement of manufacturing processes, the control of production processes in modern manufacturing systems production methods and techniques used in modern manufacturing systems and environmental aspects of production and their impact on the design and management of manufacturing systems. The wide range of research findings reported in this book confirms that the design of manufacturing systems is a complex problem and that the achievement of goals set for modern manufacturing systems requires interdisciplinary knowledge and the simultaneous design of the product, process and system, as well as the knowledge of modern manufacturing and organizational methods and techniques

Stochastic Optimization and Applications with Endogenous Uncertainties Via Discrete Choice Models

Stochastic optimization is an optimization method that solves stochastic problems for minimizing or maximizing an objective function when there is randomness in the optimization process. In this dissertation, various stochastic optimization problems from the areas of Manufacturing, Health care, and Information Cascade are investigated in networks systems. These stochastic optimization problems aim to make plan for using existing resources to improve production efficiency, customer satisfaction, and information influence within limitation. Since the strategies are made for future planning, there are environmental uncertainties in the network systems. Sometimes, the environment may be changed due to the action of the decision maker. To handle this decision-dependent situation, the discrete choice model is applied to estimate the dynamic environment in the stochastic programming model. In the manufacturing project, production planning of lot allocation is performed to maximize the expected output within a limited time horizon. In the health care project, physician is allocated to different local clinics to maximize the patient utilization. In the information cascade project, seed selection of the source user helps the information holder to diffuse the message to target users using the independent cascade model to reach influence maximization. The computation complexities of the three projects mentioned above grow exponentially by the network size. To solve the stochastic optimization problems of large-scale networks within a reasonable time, several problem-specific algorithms are designed for each project. In the manufacturing project, the sampling average approximation method is applied to reduce the scenario size. In the health care project, both the guided local search with gradient ascent and large neighborhood search with Tabu search are developed to approach the optimal solution. In the information cascade project, the myopic policy is used to separate stochastic programming by discrete time, and the Markov decision process is implemented in policy evaluation and updating

A review of data mining applications in semiconductor manufacturing

The authors acknowledge Fundacao para a Ciencia e a Tecnologia (FCT-MCTES) for its financial support via the project UIDB/00667/2020 (UNIDEMI).For decades, industrial companies have been collecting and storing high amounts of data with the aim of better controlling and managing their processes. However, this vast amount of information and hidden knowledge implicit in all of this data could be utilized more efficiently. With the help of data mining techniques unknown relationships can be systematically discovered. The production of semiconductors is a highly complex process, which entails several subprocesses that employ a diverse array of equipment. The size of the semiconductors signifies a high number of units can be produced, which require huge amounts of data in order to be able to control and improve the semiconductor manufacturing process. Therefore, in this paper a structured review is made through a sample of 137 papers of the published articles in the scientific community regarding data mining applications in semiconductor manufacturing. A detailed bibliometric analysis is also made. All data mining applications are classified in function of the application area. The results are then analyzed and conclusions are drawn.publishersversionpublishe

Intelligent shop scheduling for semiconductor manufacturing

Semiconductor market sales have expanded massively to more than 200 billion dollars annually accompanied by increased pressure on the manufacturers to provide higher quality products at lower cost to remain competitive. Scheduling of semiconductor manufacturing is one of the keys to increasing productivity, however the complexity of manufacturing high capacity semiconductor devices and the cost considerations mean that it is impossible to experiment within the facility. There is an immense need for effective decision support models, characterizing and analyzing the manufacturing process, allowing the effect of changes in the production environment to be predicted in order to increase utilization and enhance system performance. Although many simulation models have been developed within semiconductor manufacturing very little research on the simulation of the photolithography process has been reported even though semiconductor manufacturers have recognized that the scheduling of photolithography is one of the most important and challenging tasks due to complex nature of the process. Traditional scheduling techniques and existing approaches show some benefits for solving small and medium sized, straightforward scheduling problems. However, they have had limited success in solving complex scheduling problems with stochastic elements in an economic timeframe. This thesis presents a new methodology combining advanced solution approaches such as simulation, artificial intelligence, system modeling and Taguchi methods, to schedule a photolithography toolset. A new structured approach was developed to effectively support building the simulation models. A single tool and complete toolset model were developed using this approach and shown to have less than 4% deviation from actual production values. The use of an intelligent scheduling agent for the toolset model shows an average of 15% improvement in simulated throughput time and is currently in use for scheduling the photolithography toolset in a manufacturing plant

Online Simulation in Semiconductor Manufacturing

In semiconductor manufacturing discrete event simulation systems are quite established to support multiple planning decisions. During the recent years, the productivity is increasing by using simulation methods. The motivation for this thesis is to use online simulation not only for planning decisions, but also for a wide range of operational decisions. Therefore an integrated online simulation system for short term forecasting has been developed. The production environment is a mature high mix logic wafer fab. It has been selected because of its vast potential for performance improvement. In this thesis several aspects of online simulation will be addressed: The first aspect is the implementation of an online simulation system in semiconductor manufacturing. The general problem is to achieve a high speed, a high level of detail, and a high forecast accuracy. To resolve these problems, an online simulation system has been created. The simulation model has a high level of detail. It is created automatically from underling fab data. To create such a simulation model from fab data, additional problems related to the underlying data arise. The major parts are the data access, the data integration, and the data quality. These problems have been solved by using an integrated data model with several data extraction, data transformation, and data cleaning steps. The second aspect is related to the accuracy of online simulation. The overall problem is to increase the forecast horizon, increase the level of detail of the forecast and reduce the forecast error. To provide useful forecast results, the simulation model contains a high level of modeling details and a proper initialization. The influences on the forecast quality will be analyzed. The results show that the simulation forecast accuracy achieves good quality to predict future fab performance. The last aspect is to find ways to use simulation forecast results to improve the fab performance. Numerous applications have been identified. For each application a description is available. It contains the requirements of such a forecast, the decision variables, and background information. An application example shows, where a performance problem exists and how online simulation is able to resolve it. To further enhance the real time capability of online simulation, a major part is to investigate new ways to connect the simulation model with the wafer fab. For fab driven simulation, the simulation model and the real wafer fab run concurrently. The wafer fab provides several events to update the simulation during runtime. So the model is always synchronized with the real fab. It becomes possible to start a simulation run in real time. There is no further delay for data extraction, data transformation and model creation. A prototype for a single work center has been implemented to show the feasibility

A hyper-heuristic based ensemble genetic programming approach for stochastic resource constrained project scheduling problem

In project scheduling studies, to the best of our knowledge, the hyper-heuristic collaborative scheduling is first-time applied to project scheduling with random activity durations. A hyper-heuristic based ensemble genetic programming (HH-EGP) method is proposed for solving stochastic resource constrained project scheduling problem (SRCPSP) by evolving an ensemble of priority rules (PRs). The proposed approach features with (1) integrating the critical path method into the resource-based policy class to generate schedules; (2) improving the existing single hyper-heuristic project scheduling research to construct a suitable solution space for solving SRCPSP; and (3) bettering genetic evolution of each subpopulation from a decision ensemble with three different local searches in corporation with discriminant mutation and discriminant population renewal. In addition, a sequence voting mechanism is designed to deal with collaborative decision-making in the scheduling process for SRCPSP. The benchmark PSPLIB is performed to verify the advantage of the HH-EGP over heuristics, meta-heuristics and the single hyper-heuristic approaches