Scheduling of automated guided vehicles in a FMS Environment using particle swarm optimization

Efficiency in management of the material handling system plays an important role in planning and operation of a flexible manufacturing system. Many researchers have addressed material handling and vehicle scheduling as two different problems. The following work focuses on cheduling of both machines and automated guided vehicles (AGVs) in a flexible manufacturing system (FMS). We have made an attempt to consider the scheduling of machines and vehicles in an integrated manner. Particle swarm optimization (PSO) is one of the efficient algorithms that aims to converge and give optimal solution in shorter time. Therefore we have considered PSO for such scheduling

Optimization of Simultaneous Scheduling for Machines and Automated Guided Vehicles Using Fuzzy Genetic Algorithm

Flexible manufacturing system (FMS) has been introduced by the researchers as an integrated manufacturing environment. Automated guided vehicles (AGVs) introduced as the main tool of material handling systems in FMS. While the scheduling of AGVs and machines are highly related; simultaneous scheduling of machines and AGVs has been proposed in the literature. Genetic algorithm (GA) proposed as a robust tool for optimization of scheduling problems. Setting the proper crossover and mutation rates are of vital importance for the performance of the GA. Fuzzy logic controllers (FLCs) have been used in the literature to control key parameters of the GA which is addressed as fuzzy GA (FGA). A new application of FGA method in simultaneous scheduling of AGVs and machines is presented. The general GA is modified for the aforementioned application; more over an FLC is developed to control mutation and crossover rates of the GA. The objective of proposed FGA method is to minimize the makespan, production completion time of all jobs that they are produced simultaneously. An optimal sequence of operations is obtained by GA. There is a heuristic algorithm to assign the AGVs to the operations. As the main findings, the performance of GA in simultaneous scheduling of AGVs and machines is enhanced by using proposed method, furthermore a new mutation operator has been proposed. Several experiments have been done to the proposed test cases. The results showed that tournament selection scheme may outperform roulette wheel in this problem. Various combinations of population size and number of generations are compared to each other in terms of their objective function. In large scale problems FGA method may outperforms GA method, while in small and medium problems they have the same performance. The fluctuation of obtained makespan in FGA method is less than GA method which means that it is more probable to find a better solution by FGA rather than GA

A Hybrid Differential Evolution Approach for Simultaneous SchedulingProblems in a Flexible Manufacturing Environment

Scheduling of machines and transportation devices like Automated Guided Vehicles (AGVs) in a Flexible Manufacturing System(FMS) is a typical N-P hard problem. Even though several algorithms were employed to solve this combinatorial optimization problem, most of the work concentrated on solving the problems of machines and material handling independently. In this paper the authors have attempted to schedule both the machines and AGVs simultaneously, with makespan minimization as objective, for which Differential Evolution (DE) is applied. Operations based coding is employed to represent the solution vector, which is further modified to suit the DE application. The authors have proposed two new strategies of DE in this paper which better suits the problem. We have developed a separate heuristic for assigning the vehicles and this is integrated with the traditional DE approach. The hybridized approach is tested on a number of benchmark problems whose results outperformed those available in the literature

Evolutionary approaches for scheduling a flexible manufacturing system with automated guided vehicles and robots

This paper addresses the scheduling of machines, an Automated Guided Vehicle (AGV) and two robots in a Flexible Manufacturing System (FMS) formed in three loop layouts, with objectives to minimize the makespan, mean flow time and mean tardiness. The scheduling optimization is carried out using Sheep Flock Heredity Algorithm (SFHA) and Artificial Immune System (AIS) algorithm. AGV is used for carrying jobs between the Load/Unload station and the machines. The robots are used for loading and unloading the jobs in the machines, and also used for transferring jobs between the machines. The algorithms are applied for test problems taken from the literature and the results obtained using the two algorithms are compared. The results indicate that SFHA performs better than AIS for this problem

Improving just-in-time delivery performance of IoT-enabled flexible manufacturing systems with AGV based material transportation

Autonomous guided vehicles (AGVs) are driverless material handling systems used for transportation of pallets and line side supply of materials to provide flexibility and agility in shop-floor logistics. Scheduling of shop-floor logistics in such systems is a challenging task due to their complex nature associated with the multiple part types and alternate material transfer routings. This paper presents a decision support system capable of supporting shop-floor decision-making activities during the event of manufacturing disruptions by automatically adjusting both AGV and machine schedules in Flexible Manufacturing Systems (FMSs). The proposed system uses discrete event simulation (DES) models enhanced by the Internet-of-Things (IoT) enabled digital integration and employs a nonlinear mixed integer programming Genetic Algorithm (GA) to find near-optimal production schedules prioritising the just-in-time (JIT) material delivery performance and energy efficiency of the material transportation. The performance of the proposed system is tested on the Integrated Manufacturing and Logistics (IML) demonstrator at WMG, University of Warwick. The results showed that the developed system can find the near-optimal solutions for production schedules subjected to production anomalies in a negligible time, thereby supporting shop-floor decision-making activities effectively and rapidly

Improving just-in-time delivery performance of IoT-enabled flexible manufacturing systems with AGV based material transportation

© 2020 by the authors. Licensee MDPI, Basel, Switzerland. Autonomous guided vehicles (AGVs) are driverless material handling systems used for transportation of pallets and line side supply of materials to provide flexibility and agility in shop-floor logistics. Scheduling of shop-floor logistics in such systems is a challenging task due to their complex nature associated with the multiple part types and alternate material transfer routings. This paper presents a decision support system capable of supporting shop-floor decision-making activities during the event of manufacturing disruptions by automatically adjusting both AGV and machine schedules in Flexible Manufacturing Systems (FMSs). The proposed system uses discrete event simulation (DES) models enhanced by the Internet-of-Things (IoT) enabled digital integration and employs a nonlinear mixed integer programming Genetic Algorithm (GA) to find near-optimal production schedules prioritising the just-in-time (JIT) material delivery performance and energy efficiency of the material transportation. The performance of the proposed system is tested on the Integrated Manufacturing and Logistics (IML) demonstrator at WMG, University of Warwick. The results showed that the developed system can find the near-optimal solutions for production schedules subjected to production anomalies in a negligible time, thereby supporting shop-floor decision-making activities effectively and rapidly

An Integrated Approach for the Analysis of Manufacturing System States

With advancement in the manufacturing technology and rise in the purchasing ability, demand for newer products is increasing continuously. This is forcing manufacturing companies to persistently look for new techniques to improve the productivity of a manufacturing system and ensure optimum utilization of all the elements of a manufacturing system, including facility layout. Traditional research had viewed facility layout, material handling and productivity improvement as separate activities.  Researchers depending on their area of specialization focused on either the production aspects of a company, the material handling aspects or facility layout. However, to ensure productivity, this study proposes a new theory to analyze the current state of the system with an integrated approach of production system and material handling system. In this study, the current state of the system is classified into three different states and a methodology is proposed to identify the current state of the system. This new theory can be used by manufacturers to identify appropriate strategies for improving productivity.  The identification of the state of the system is necessary for effective improvement of the system

Intelligent Simulation Modeling of a Flexible Manufacturing System with Automated Guided Vehicles

Although simulation is a very flexible and cost effective problem solving technique, it has been traditionally limited to building models which are merely descriptive of the system under study. Relatively new approaches combine improvement heuristics and artificial intelligence with simulation to provide prescriptive power in simulation modeling. This study demonstrates the synergy obtained by bringing together the "learning automata theory" and simulation analysis. Intelligent objects are embedded in the simulation model of a Flexible Manufacturing System (FMS), in which Automated Guided Vehicles (AGVs) serve as the material handling system between four unique workcenters. The objective of the study is to find satisfactory AGV routing patterns along available paths to minimize the mean time spent by different kinds of parts in the system. System parameters such as different part routing and processing time requirements, arrivals distribution, number of palettes, available paths between workcenters, number and speed of AGVs can be defined by the user. The network of learning automata acts as the decision maker driving the simulation, and the FMS model acts as the training environment for the automata network; providing realistic, yet cost-effective and risk-free feedback. Object oriented design and implementation of the simulation model with a process oriented world view, graphical animation and visually interactive simulation (using GUI objects such as windows, menus, dialog boxes; mouse sensitive dynamic automaton trace charts and dynamic graphical statistical monitoring) are other issues dealt with in the study

A hybrid CFGTSA based approach for scheduling problem: a case study of an automobile industry

In the global competitive world swift, reliable and cost effective production subject to uncertain situations, through an appropriate management of the available resources, has turned out to be the necessity for surviving in the market. This inspired the development of the more efficient and robust methods to counteract the existing complexities prevailing in the market. The present paper proposes a hybrid CFGTSA algorithm inheriting the salient features of GA, TS, SA, and chaotic theory to solve the complex scheduling problems commonly faced by most of the manufacturing industries. The proposed CFGTSA algorithm has been tested on a scheduling problem of an automobile industry, and its efficacy has been shown by comparing the results with GA, SA, TS, GTS, and hybrid TSA algorithms