A genetic algorithm approach to designing and modelling of a multi-functional fractal manufacturing layout

A dynamic and optimal shop floor design, modelling and implementation is key to achieving successful Fractal Manufacturing System (FrMS). To build adaptive and fault-tolerant fractal layout, attention is paid to issues of shop floor planning, function layout, determination of capacity level, cell composition planning and flow distances of products. A full fledged FrMS. layout is multi-functional and is capable of producing a variety of products with minimal reconfiguration. This paper is part and a progression of an on-going project whereby Genetic Algorithm (GA) is adopted to design and model a flexible and multi-functional FrMS floor layout. GA is used in the project for modeling and simulation. The design implementation is done using MATLAB. The result is a fault tolerant configuration that self-regulates and adapts to unpredictable changes in the manufacturing environment arising from lead time reduction pressure, inventories, product customization and other challenges of a dynamic and volatile operational environment

Flexible Robot Configuration Cell In Manufacturing Industry

Manufacturing configuration work is a very tedious process that relies on the way a system is determined and the experience of the person involved. This work is also based on the requirements set by the user. In this research work, the development of flexible approach for configuring robot work cell in manufacturing industry is presented. An articulated robot with six (6) degree of freedom (DOF) is taken as reference to represent the configuration layout because it is one of the most widely used robot in industries. The purpose of this research is to develop a new flexible approach for easy configuring robot work cell with minimal configuration time, less human or expert involvement and at little or no further investment. The different emerging strategies which focus on the configuration work has been highlighted and reviewed. In this work, a variant-shaped configuration concept with its mathematical equation for both workspace area, Aw and the manufacturing throughput time, MTT of each configuration layout have been developed. Later, a configuration framework with a set of rule selection has been created for further development of a graphical user interface (GUI) of flexible configuration model (FlexCoM). The developed FlexCoM would be used in determining the ideal robot work cell while satisfying the user requirements. Matlab and CATIA V5 software where it involves the CATIA VBA and macro tools were used in this research work. The developed FlexCoM has been tested and evaluated by three (3) different industries where the outcome of this research showed that the developed FlexCoM could assist design engineers in minimizing the configuration time, optimizing the human and expert involvement as well as capitalizing the available resource for investment while conducting robot work cell configuration work in the future. This research hopes that the industry will benefit from the outcome by having the ability to optimize the configuration system and to minimize the risk of investment

Modeling a complex production line using virtual cells

This chapter presents modeling and simulation of a complex multistage multiproduct production line with four closed loop networks configuration, which also act as a virtual cell. This allows for a greater understanding of the functions within the production line through the simplification of the production flow with the addition of buffers between the cells. Virtual cells are crucial in this instance due to the dynamic configuration, which could help production system designers in optimizing the complex configuration of production

A review of design methodologies for manufacturing systems

This paper presents a review of design methodologies for manufacturing systems, with focus on Product Oriented Manufacturing Systems (POMS). POMS organization is discussed and compared against function oriented manufacturing. The methodologies for manufacturing systems design are described and grouped in three classes: generic, specific and product oriented focused. Several methodologies in the first class are referred. They tend to be suitable for whatever kind of product that is necessary to develop or design, including manufacturing systems. Usually, they arrive to a general, conceptual first approximation manufacturing system solution, which need refinement. Manufacturing systems specific methodologies are more objective being able to offer a clearer picture of the manufacturing system ultimate solution. A number of them are reviewed. The product focused class of the manufacturing systems design methodologies is divided in two groups: methodologies for designing new manufacturing systems, referred as construction methodologies, and methodologies for reengineering or reconfiguring existing ones. A few methodologies are referred and a methodology referred as the GCD methodology is explained in more detail due to its particular focus on POMS design. Through it a better understanding is given of the POMS design needs. The GCD methodology is also put in perspective in relation to other reviewed methodologies

Design of Introspective Circuits for Analysis of Cell-Level Dis-orientation in Self-Assembled Cellular Systems

This paper discusses a novel approach to managing complexity in a large self-assembled system, by utilizing the self-assembling components themselves to address the complexity. A particular challenge is discussed – namely the question of how to deal with elements that are assembled in different orientations from each other – and a solution based on the idea ofintrospective circuitry is described. A methodology for using a set of cells to determine a nearby cell’s orientation is given, leading to a slow (O(n)) means of orienting a 2D region of cells. A modified algorithm is then describe to allow parallel analysis of/adaption to dis-oriented cells, thus allowing re-orientation of an entire 2D region of cells with better-than-linear time performance (O(sqrt(n))). The significance of this work is discussed not only in terms of managing arrays of dis-oriented cells but also more importantly as an example of the usefulness of local, distributed self-configuration to create and use introspective circuitry

Application of Artificial Intelligence (AI) methods for designing and analysis of Reconfigurable Cellular Manufacturing System (RCMS)

This work focuses on the design and control of a novel hybrId manufacturing system: Reconfigurable Cellular Manufacturing System (RCMS) by using Artificial Intelligence (AI) approach. It is hybrid as it combines the advantages of Cellular Manufacturing System (CMS) and Reconfigurable Manufacturing System (RMS). In addition to inheriting desirable properties from CMS and RMS, RCMS provides additional benefits including flexibility and the ability to respond to changing products, product mix and market conditions during its useful life, avoiding premature obsolescence of the manufacturing system. The emphasis of this research is the formation of Reconfigurable Manufacturing Cell (RMC) which is the dynamic and logical clustering of some manufacturing resources, driven by specific customer orders, aiming at optimally fulfilling customers' orders along with other RMCs in the RCMS

Distributed design of product oriented manufacturing systems

Manufacturing leanness and agility are requirements of today’s manufacturing systems. Leanness call for a best fit of the manufacturing systems to products, therefore requiring product oriented manufacturing systems (POMS). Manufacturing agility can be achieved through easy systems reconfiguration to fit changing manufacturing requirements, which may mean dynamically configuring POMS. For this a suitable design system is required. Due to complexity of this design, and to the need for using suitable design methods, which may not be available locally, distributed sources of design services can be used. This paper presents and describes a prototype of a Distributed Design system for POMS based on a POMS design methodology and distributed suppliers of design services

Development of An Automated Configuration System for Robot Work Cell

Configuration robot work cell has received considerable attention in the last few years due to it is very knowledge-intensive, intricate, and time-consuming process. This paper elaborated the development process of the automated configuration system (ACS) for (re-)configuring robot work cell while satisfying certain requirements of users in an innovative way. The primary purpose of this work was to provide a fast configuration system with less cost and human involvement at little or no further investment. The ACS was constructed based on the variant-shaped configuration concept with its mathematical model. A configuration and programming structure with a graphical user interface (GUI) were the outcomes of this work that were capable of determining the optimal robot work cell according to the user requirements e.g. the number of a robot, Nr and the types of configuration. This work utilized both macro and Visual Basic (VB) editor in CATIA 3D CAD software for creating a completed user interface. The current outcomes of this work will provide a basis for future investigation in determining the optimal layout of robot work cell that is dependable on other requirements