Comparative simulation study of production scheduling in the hybrid and the parallel flow

Scheduling is one of the most important decisions in production control. An approach is proposed for supporting users to solve scheduling problems, by choosing the combination of physical manufacturing system configuration and the material handling system settings. The approach considers two alternative manufacturing scheduling configurations in a two stage product oriented manufacturing system, exploring the hybrid flow shop (HFS) and the parallel flow shop (PFS) environments. For illustrating the application of the proposed approach an industrial case from the automotive components industry is studied. The main aim of this research to compare results of study of production scheduling in the hybrid and the parallel flow, taking into account the makespan minimization criterion. Thus the HFS and the PFS performance is compared and analyzed, mainly in terms of the makespan, as the transportation times vary. The study shows that the performance HFS is clearly better when the work stations' processing times are unbalanced, either in nature or as a consequence of the addition of transport times just to one of the work station processing time but loses advantage, becoming worse than the performance of the PFS configuration when the work stations' processing times are balanced, either in nature or as a consequence of the addition of transport times added on the work stations' processing times. This means that physical layout configurations along with the way transport time are including the work stations' processing times should be carefully taken into consideration due to its influence on the performance reached by both HFS and PFS configurations.This work was supported by National Funds through FCT "Fundacao para a Ciencia e a Tecnologia" under the program: PEst2015-2020, ref. UID/CEC/00319/2013.info:eu-repo/semantics/publishedVersio

New efficient constructive heuristics for the hybrid flowshop to minimise makespan: A computational evaluation of heuristics

This paper addresses the hybrid flow shop scheduling problem to minimise makespan, a well-known scheduling problem for which many constructive heuristics have been proposed in the literature. Nevertheless, the state of the art is not clear due to partial or non homogeneous comparisons. In this paper, we review these heuristics and perform a comprehensive computational evaluation to determine which are the most efficient ones. A total of 20 heuristics are implemented and compared in this study. In addition, we propose four new heuristics for the problem. Firstly, two memory-based constructive heuristics are proposed, where a sequence is constructed by inserting jobs one by one in a partial sequence. The most promising insertions tested are kept in a list. However, in contrast to the Tabu search, these insertions are repeated in future iterations instead of forbidding them. Secondly, we propose two constructive heuristics based on Johnson’s algorithm for the permutation flowshop scheduling problem. The computational results carried out on an extensive testbed show that the new proposals outperform the existing heuristics.Ministerio de Ciencia e Innovación DPI2016-80750-

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

Flexible flow shop scheduling with stochastic processing times: A decomposition-based approach

Flexible flow shop scheduling problems are NP-hard and tend to become more complex when stochastic uncertainties are taken into consideration. Although some methods have been developed to address such problems, they remain inherently difficult to solve by any single approach. This paper presents a novel decomposition-based approach (DBA), which combines both the shortest processing time (SPT) and the genetic algorithm (GA), to minimizing the makespan of a flexible flow shop (FFS) with stochastic processing times. In the proposed DBA, a neighbouring K-means clustering algorithm is developed to firstly group the machines of an FFS into an appropriate number of machine clusters, based on their stochastic nature. Two optimal back propagation networks (BPN), corresponding to the scenarios of simultaneous and non-simultaneous job arrivals, are then selectively adopted to assign either SPT or GA to each machine cluster for sub-schedule generation. Finally, an overall schedule is generated by integrating the sub-schedules of machine clusters. Computation results show that the DBA outperforms SPT and GA alone for FFS scheduling with stochastic processing times. © 2012 Elsevier Ltd. All rights reserved.postprin

A survey of simulation techniques in commerce and defence

Despite the developments in Modelling and Simulation (M&S) tools and techniques over the past years, there has been a gap in the M&S research and practice in healthcare on developing a toolkit to assist the modellers and simulation practitioners with selecting an appropriate set of techniques. This study is a preliminary step towards this goal. This paper presents some results from a systematic literature survey on applications of M&S in the commerce and defence domains that could inspire some improvements in the healthcare. Interim results show that in the commercial sector Discrete-Event Simulation (DES) has been the most widely used technique with System Dynamics (SD) in second place. However in the defence sector, SD has gained relatively more attention. SD has been found quite useful for qualitative and soft factors analysis. From both the surveys it becomes clear that there is a growing trend towards using hybrid M&S approaches

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

Scheduling research in multiple resource constrained job shops: a review and critique

Over the past several years, a number of survey, classification, and review articles have focused on scheduling research in machine [only] constrained job shops. Barring the work of Treleven (1989), there is no reported research that presents a detailed review of the issues related to scheduling and sequencing in job shops with multiple resource constraints. In his article, Treleven reviewed the research in job shops constrained by machines and labour. Job shops are not only constrained by machines and labour, but by auxiliary resources (in the form of tooling. etc.) as well. This paper extends the work of Treleven by reviewing the literature on scheduling in job shops constrained by more than one resource and comparing the scheduling research in auxiliary resource-constrained job shops with that of labour-constrained job shops. In addition, this article raises some issues for future scheduling research in multiple resource-constrained job shops