Simulation of production scheduling in manufacturing systems

Research into production scheduling environments has been primarily concerned with developing local priority rules for selecting jobs from a queue to be processed on a set of individual machines. Most of the research deals with the scheduling problems in terms of the evaluation of priority rules with respect to given criteria. These criteria have a direct effect on the production cost, such as mean make-span, flow-time, job lateness, m-process inventory and machine idle time. The project under study consists of the following two phases. The first is to deal with the development of computer models for the flow-shop problem, which obtain the optimum make-span and near-optimum solutions for the well-used criteria in the production scheduling priority rules. The second is to develop experimental analysis using a simulation technique, for the two main manufacturing systems, 1. Job-shop 2. Flexible Manufacturing System The two manufacturing types were investigated under the following conditions i. Dynamic problem conditions ii. Different operation time distributions iii. Different shop loads iv. Seven replications per experiment with different streams of random number v. The approximately steady state point for each replication was obtained. In the FMS, the material handling system used was the automated guided Vehicles (AGVs), buffer station and load/ unload area were also used. The aim of these analyses is to deal with the effectiveness of the priority rules on the selected criteria performance. The SIMAN software simulation was used for these studies

Serial production line performance under random variation:Dealing with the ‘Law of Variability’

Many Queueing Theory and Production Management studies have investigated specific effects of variability on the performance of serial lines since variability has a significant impact on performance. To date, there has been no single summary source of the most relevant research results concerned with variability, particularly as they relate to the need to better understand the ‘Law of Variability’. This paper fills this gap and provides readers the foundational knowledge needed to develop intuition and insights on the complexities of stochastic simple serial lines, and serves as a guide to better understand and manage the effects of variability and design factors related to improving serial production line performance, i.e. throughput, inter-departure time and flow time, under random variation

Multi-objective Operating Room Planning and Scheduling

abstract: Surgery is one of the most important functions in a hospital with respect to operational cost, patient flow, and resource utilization. Planning and scheduling the Operating Room (OR) is important for hospitals to improve efficiency and achieve high quality of service. At the same time, it is a complex task due to the conflicting objectives and the uncertain nature of surgeries. In this dissertation, three different methodologies are developed to address OR planning and scheduling problem. First, a simulation-based framework is constructed to analyze the factors that affect the utilization of a catheterization lab and provide decision support for improving the efficiency of operations in a hospital with different priorities of patients. Both operational costs and patient satisfaction metrics are considered. Detailed parametric analysis is performed to provide generic recommendations. Overall it is found the 75th percentile of process duration is always on the efficient frontier and is a good compromise of both objectives. Next, the general OR planning and scheduling problem is formulated with a mixed integer program. The objectives include reducing staff overtime, OR idle time and patient waiting time, as well as satisfying surgeon preferences and regulating patient flow from OR to the Post Anesthesia Care Unit (PACU). Exact solutions are obtained using real data. Heuristics and a random keys genetic algorithm (RKGA) are used in the scheduling phase and compared with the optimal solutions. Interacting effects between planning and scheduling are also investigated. Lastly, a multi-objective simulation optimization approach is developed, which relaxes the deterministic assumption in the second study by integrating an optimization module of a RKGA implementation of the Non-dominated Sorting Genetic Algorithm II (NSGA-II) to search for Pareto optimal solutions, and a simulation module to evaluate the performance of a given schedule. It is experimentally shown to be an effective technique for finding Pareto optimal solutions.Dissertation/ThesisPh.D. Industrial Engineering 201

A STUDY OF QUEUING THEORY IN LOW TO HIGH REWORK ENVIRONMENTS WITH PROCESS AVAILABILITY

In manufacturing systems subject to machine and operator resource constraints the effects of rework can be profound. High levels of rework burden the resources unnecessarily and as the utilization of these resources increases the expected queuing time of work in process increases exponentially. Queuing models can help managers to understand and control the effects of rework, but often this tool is overlooked in part because of concerns over accuracy in complex environments and/or the need for limiting assumptions. One aim of this work is to increase understanding of system variables on the accuracy of simple queuing models. A queuing model is proposed that combines G/G/1 modeling techniques for rework with effective processing time techniques for machine availability and the accuracy of this model is tested under varying levels of rework, external arrival variability, and machine availability. Results show that the model performs best under exponential arrival patterns and can perform well even under high rework conditions. Generalizations are made with regards to the use of this tool for allocation of jobs to specific workers and/or machines based on known rework rates with the ultimate aim of queue time minimization

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

Buffer allocation strategies in shop floor using simulation

Buffer allocation is considered to be an important strategy in real life production system because 75% of working capital is tied up in-process inventory in any industry. Therefore an optimum buffer allocation strategy may help in better inventory management of the industry. Consideration of buffer strategy and work distribution play vital role in design of flow lines. However analysis of flow lines using queuing theory become intractable when number of machines increases. Simulation models were made with discrete event simulation being adopted to gain better insight into the problem. To this end, a flow line model has been developed using EXTEND- v.4 to conduct experiments to meet the objective of designing flow lines for buffer allocation and work allocation. The effect of varying number of inter-stage buffers, varying time of each machine, using different process input to study the corresponding outcome is to be experimented ahead. On the basis of analysis of all three models we came to know about some basic patterns like 1) Maximum queue length increase with buffer capacity. 2) Average queue length increases with buffer capacity. 3) Average wait increases with buffer capacity. 4) Throughput increases with buffer capacity. 5) Machine utilization increases with buffer capacity to some extend 6) Maximum wait increases with buffer capacity. Now coming to the most important part of the project that is analysis of practical model from toy car industry. This industry has a small floor space between the assembling line which can accommodate a maximum of ten buffers. So they wanted us to analyze their flow process and tell them what would be the best strategy for smooth flow of assembling process. Then we made the simulation model of there process and analyzed for three most important inter-stage buffers. By increasing the middle buffer than side buffer gave higher output than by increasing the side buffers. This trend was prominent, but only upto the strategy 4-6-4 then the increase in throughput was very marginal and will not be economical considering increase in required floor area, reprocessing investment( in some cases due to long wait). On the basis of all this study we concluded and suggested them that 4 – 6 – 4 buffer allocation strategies will be the best one for their toy car assembling process

Autonomous Finite Capacity Scheduling using Biological Control Principles

The vast majority of the research efforts in finite capacity scheduling over the past several years has focused on the generation of precise and almost exact measures for the working schedule presupposing complete information and a deterministic environment. During execution, however, production may be the subject of considerable variability, which may lead to frequent schedule interruptions. Production scheduling mechanisms are developed based on centralised control architecture in which all of the knowledge base and databases are modelled at the same location. This control architecture has difficulty in handling complex manufacturing systems that require knowledge and data at different locations. Adopting biological control principles refers to the process where a schedule is developed prior to the start of the processing after considering all the parameters involved at a resource involved and updated accordingly as the process executes. This research reviews the best practices in gene transcription and translation control methods and adopts these principles in the development of an autonomous finite capacity scheduling control logic aimed at reducing excessive use of manual input in planning tasks. With autonomous decision-making functionality, finite capacity scheduling will as much as practicably possible be able to respond autonomously to schedule disruptions by deployment of proactive scheduling procedures that may be used to revise or re-optimize the schedule when unexpected events occur. The novelty of this work is the ability of production resources to autonomously take decisions and the same way decisions are taken by autonomous entities in the process of gene transcription and translation. The idea has been implemented by the integration of simulation and modelling techniques with Taguchi analysis to investigate the contributions of finite capacity scheduling factors, and determination of the ‘what if’ scenarios encountered due to the existence of variability in production processes. The control logic adopts the induction rules as used in gene expression control mechanisms, studied in biological systems. Scheduling factors are identified to that effect and are investigated to find their effects on selected performance measurements for each resource in used. How they are used to deal with variability in the process is one major objective for this research as it is because of the variability that autonomous decision making becomes of interest. Although different scheduling techniques have been applied and are successful in production planning and control, the results obtained from the inclusion of the autonomous finite capacity scheduling control logic has proved that significant improvement can still be achieved