Dynamic scheduling in a multi-product manufacturing system

To remain competitive in global marketplace, manufacturing companies need to improve their operational practices. One of the methods to increase competitiveness in manufacturing is by implementing proper scheduling system. This is important to enable job orders to be completed on time, minimize waiting time and maximize utilization of equipment and machineries. The dynamics of real manufacturing system are very complex in nature. Schedules developed based on deterministic algorithms are unable to effectively deal with uncertainties in demand and capacity. Significant differences can be found between planned schedules and actual schedule implementation. This study attempted to develop a scheduling system that is able to react quickly and reliably for accommodating changes in product demand and manufacturing capacity. A case study, 6 by 6 job shop scheduling problem was adapted with uncertainty elements added to the data sets. A simulation model was designed and implemented using ARENA simulation package to generate various job shop scheduling scenarios. Their performances were evaluated using scheduling rules, namely, first-in-first-out (FIFO), earliest due date (EDD), and shortest processing time (SPT). An artificial neural network (ANN) model was developed and trained using various scheduling scenarios generated by ARENA simulation. The experimental results suggest that the ANN scheduling model can provided moderately reliable prediction results for limited scenarios when predicting the number completed jobs, maximum flowtime, average machine utilization, and average length of queue. This study has provided better understanding on the effects of changes in demand and capacity on the job shop schedules. Areas for further study includes: (i) Fine tune the proposed ANN scheduling model (ii) Consider more variety of job shop environment (iii) Incorporate an expert system for interpretation of results. The theoretical framework proposed in this study can be used as a basis for further investigation

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

Active learning of soft rules for system modelling

Using rule learning algorithms to model systems has gained considerable interest in the past. The underlying idea of active learning is to learning algorithm influence the selection of training examples. The presented method estimates the utility of new experiments based on the knowledge represented by the existing rulebase. An extended rule format allows to deal with uncertainty. Experiments with different artificial system functions show that the presented method improves the model quality respectively decreases the number of experiments needed to reach a specific level of performance

Dynamic adjustment of dispatching rule parameters in flow shops with sequence dependent setup times

Decentralized scheduling with dispatching rules is applied in many fields of production and logistics, especially in highly complex manufacturing systems. Since dispatching rules are restricted to their local information horizon, there is no rule that outperforms other rules across various objectives, scenarios and system conditions. In this paper, we present an approach to dynamically adjust the parameters of a dispatching rule depending on the current system conditions. The influence of different parameter settings of the chosen rule on system performance is estimated by a machine learning method, whose learning data is generated by preliminary simulation runs. Using a dynamic flow shop scenario with sequence dependent setup times, we demonstrate that our approach is capable of significantly reducing the mean tardiness of jobs

Learning-based scheduling of flexible manufacturing systems using ensemble methods

Dispatching rules are commonly applied to schedule jobs in Flexible Manufacturing Systems (FMSs). However, the suitability of these rules relies heavily on the state of the system; hence, there is no single rule that always outperforms the others. In this scenario, machine learning techniques, such as support vector machines (SVMs), inductive learning-based decision trees (DTs), backpropagation neural networks (BPNs), and case based-reasoning (CBR), offer a powerful approach for dynamic scheduling, as they help managers identify the most appropriate rule in each moment. Nonetheless, different machine learning algorithms may provide different recommendations. In this research, we take the analysis one step further by employing ensemble methods, which are designed to select the most reliable recommendations over time. Specifically, we compare the behaviour of the bagging, boosting, and stacking methods. Building on the aforementioned machine learning algorithms, our results reveal that ensemble methods enhance the dynamic performance of the FMS. Through a simulation study, we show that this new approach results in an improvement of key performance metrics (namely, mean tardiness and mean flow time) over existing dispatching rules and the individual use of each machine learning algorithm

A hierarchical Mamdani-type fuzzy modelling approach with new training data selection and multi-objective optimisation mechanisms: A special application for the prediction of mechanical properties of alloy steels

In this paper, a systematic data-driven fuzzy modelling methodology is proposed, which allows to construct Mamdani fuzzy models considering both accuracy (precision) and transparency (interpretability) of fuzzy systems. The new methodology employs a fast hierarchical clustering algorithm to generate an initial fuzzy model efficiently; a training data selection mechanism is developed to identify appropriate and efficient data as learning samples; a high-performance Particle Swarm Optimisation (PSO) based multi-objective optimisation mechanism is developed to further improve the fuzzy model in terms of both the structure and the parameters; and a new tolerance analysis method is proposed to derive the confidence bands relating to the final elicited models. This proposed modelling approach is evaluated using two benchmark problems and is shown to outperform other modelling approaches. Furthermore, the proposed approach is successfully applied to complex high-dimensional modelling problems for manufacturing of alloy steels, using ‘real’ industrial data. These problems concern the prediction of the mechanical properties of alloy steels by correlating them with the heat treatment process conditions as well as the weight percentages of the chemical compositions

An improved approach for automatic process plan generation of complex borings

The authors are grateful for funding provided to this project by the French Ministry of Industry, Dassault Aviation, Dassault Systemes, and F. Vernadat for his review and recommendations.The research concerns automated generation of process plans using knowledge formalization and capitalization. Tools allowing designers to deal with issues and specifications of the machining domain are taken into account. The main objective of the current work is to prevent designers from designing solutions that would be expensive and difficult to machine. Among all available solutions to achieve this goal, two are distinguished: the generative approach and the analogy approach. The generative approach is more adapted to generate the machining plans of parts composed of numerous boring operations in interaction. However, generative systems have two major problems: proposed solutions are often too numerous and are only geometrically but not technologically relevant. In order to overcome these drawbacks, two new concepts of feature and three control algorithms are developed. The paper presents the two new features: the Machining Enabled Geometrical Feature (MEGF) and the Machinable Features (MbF). This development is the result of the separation of the geometrical and the technological data contained in one machining feature. The second objective of the paper is to improve the current Process Ascending Generation (PAG) system with control algorithms in order to limit the combinatorial explosion and disable the generation of unusable or not machinable solutions