Analusis and Modeling of Flexible Manufacturing System

Analysis and modeling of flexible manufacturing system (FMS) consists of scheduling of the system and optimization of FMS objectives. Flexible manufacturing system (FMS) scheduling problems become extremely complex when it comes to accommodate frequent variations in the part designs of incoming jobs. This research focuses on scheduling of variety of incoming jobs into the system efficiently and maximizing system utilization and throughput of system where machines are equipped with different tools and tool magazines but multiple machines can be assigned to single operation. Jobs have been scheduled according to shortest processing time (SPT) rule. Shortest processing time (SPT) scheduling rule is simple, fast, and generally a superior rule in terms of minimizing completion time through the system, minimizing the average number of jobs in the system, usually lower in-process inventories (less shop congestion) and downstream idle time (higher resource utilization). Simulation is better than experiment with the real world system because the system as yet does not exist and experimentation with the system is expensive, too time consuming, too dangerous. In this research, Taguchi philosophy and genetic algorithm have been used for optimization. Genetic algorithm (GA) approach is one of the most efficient algorithms that aim at converging and giving optimal solution in a shorter time. Therefore, in this work, a suitable fitness function is designed to generate optimum values of factors affecting FMS objectives (maximization of system utilization and maximization of throughput of system by Genetic Algorithm (GA) approach

Evaluation of different dispatching rules in computer integrated manufacturing using design of experiment techniques

This research is based on the study of process planning and scheduling in job shop flexible manufacturing systems. This project need to evaluate planning algorithms, determine appropriate algorithms and suggest better algorithm as a tool to optimize the process planning. Extensive computational experiments are carried out to verify the efficiency of our algorithm using OpenCIM software. By using the OpenCIM simulation software, the evalution of planning algorithms were carried out base on different scheduling algorithms such as First In First Out (FIFO), Shortest Processing Time (SPT), and Maximum Priority. The target of this study is to evaluate the performance of selected dispatching rules for different operation on the existing Computer Integrated Manufacturing (CIM) facility using a simulation model against different performance measures and to compare the results with the literature. Three factors with three levels of severity along with 3 different scheduling dispatching rules, a 3 x 3 x 3 = 27 full factorial Design of Experiment (DOE) set-up were used to evaluated the performance of the system under study. Analysis of variance (AVONA) was used to identify the interactions between factors. Three performance measures, Total Run Time, Maximum Queue Length and Machine Efficiency were used in the experiments. The system performance depended on Machine Efficiency when the number of released parts is maximum and the number of priority is minimum. Furthermore, considering the maximum queue length, the system performs much better when the selected dispatching rule is either MAX PRIORITY or SPT with number of priority is one and number of part release is eight. The system’s total run time performs markedly better when the number of released parts is set at eight or higher. It was concluded that the overall best simple dispatching rules among all other simple rules in order of their performance are Shortest Processing Time (SPT), Maximum Priority, First In First Out (FIFO)

Simulation and optimization techniques applied in semiconductor assembly and test operations

The importance of back-end operations in semiconductor manufacturing has been growing steadily in the face of higher customer expectations and stronger competition in the industry. In order to achieve low cycle times, high throughput, and high utilization while improving due-date performance, more effective tools are needed to support machine setup and lot dispatching decisions. In previous work, the problem of maximizing the weighted throughput of lots undergoing assembly and test (AT), while ensuring that critical lots are given priority, was investigated and a greedy randomized adaptive search procedure (GRASP) developed to find solutions. Optimization techniques have long been used for scheduling manufacturing operations on a daily basis. Solutions provide a prescription for machine setups and job processing over a finite the planning horizon. In contrast, simulation provides more detail but in a normative sense. It tells you how the system will evolve in real time for a given demand, a given set of resources and rules for using them. A simulation model can also accommodate changeovers, initial setups and multi-pass requirements easily. The first part of the research is to show how the results of an optimization model can be integrated with the decisions made within a simulation model. The problem addressed is defined in terms of four hierarchical objectives: minimize the weighted sum of key device shortages, maximize weighted throughput, minimize the number of machines used, and minimize makespan for a given set of lots in queue, and a set of resources that includes machines and tooling. The facility can be viewed as a reentrant flow shop. The basic simulation was written in AutoSched AP (ASAP) and then enhanced with the help of customization features available in the software. Several new dispatch rules were developed. Rule_First_setup is able to initialize the simulation with the setups obtained with the GRASP. Rule_All_setups enables a machine to select the setup provided by the optimization solution whenever a decision is about to be made on which setup to choose subsequent to the initial setup. Rule_Hotlot was also proposed to prioritize the processing of the hot lots that contain key devices. The objective of the second part of the research is to design and implement heuristics within the simulation model to schedule back-end operations in a semiconductor AT facility. Rule_Setupnum lets the machines determine which key device to process according to a machine setup frequency table constructed from the GRASP solution. GRASP_asap embeds a more robust selection features of GRASP in the ASAP model through customization. This allows ASAP to explore a larger portion of the feasible region at each decision point by randomizing machine setups using adaptive probability distributions that are a function of solution quality. Rule_Greedy, which is a simplification of GRASP_asap, always picks the setup for a particular machine that gives the greatest marginal improvement in the objective function among all candidates. The purpose of the third part of the research is to statistically validate the relative effectiveness of our top six dispatch rules by comparing their performance on 30 real and randomly generated data sets. Using both GRASP and our ASAP discrete event simulation model, we have (1) identified the general order of dispatch rule performance, (2) investigated the impact of having setups installed on machines at time zero on rule performance, (3) determined the conditions under which restricting the maximum number of changeover affects the rule performance, and (4) studied the factors that might simultaneously affect rule performance with the help of a common random numbers experimental design. In the analysis, the first two objectives, weighted key device shortages and weighted throughput, are used to measure outcomes.Operations Research and Industrial Engineerin

A Review Of Design And Control Of Automated Guided Vehicle Systems

This paper presents a review on design and control of automated guided vehicle systems. We address most key related issues including guide-path design, estimating the number of vehicles, vehicle scheduling, idle-vehicle positioning, battery management, vehicle routing, and conflict resolution. We discuss and classify important models and results from key publications in literature on automated guided vehicle systems, including often-neglected areas, such as idle-vehicle positioning and battery management. In addition, we propose a decision framework for design and implementation of automated guided vehicle systems, and suggest some fruitful research directions

Optimizing emergency preparedness and resource utilization in mass-casualty incidents

This paper presents a response model for the aftermath of a Mass-Casualty Incident (MCI) that can be used to provide operational guidance for regional emergency planning as well as to evaluate strategic preparedness plans. A mixed integer programming (MIP) formulation is proposed for the combined ambulance dispatching, patient-to-hospital assignment, and treatment ordering problem. T he goal is to allocate effectively the limited resources during the response so as to improve patient outcomes, while the objectives are to minimize the overall response time and the total flow time required to treat all patients, in a hierarchical fashion. The model is solved via exact and MIP-based heuristic solution methods. The applicability of the model and the performance of the new methods are challenged on realistic MCI scenarios. We consider the hypothetical case of a terror attack at the New York Stock Exchange in Lower Manhattan with up to 150 trauma patients. We quantify the impact of capacity-based bottlenecks for both ambulances and available hospital beds. We also explore the trade-off between accessing remote hospitals for demand smoothing versus reduced ambulance transportation times

Bottleneck Management through Strategic Sequencing in Smart Manufacturing Systems

Nowadays, industries put a significant emphasis on finding the optimum order for carrying out jobs in sequence. This is a crucial element in determining net productivity. Depending on the demand criterion, all production systems, including flexible manufacturing systems, follow a predefined sequence of job-based machine operations. The complexity of the problem increases with increasing machines and jobs to sequence, demanding the use of an appropriate sequencing technique. The major contribution of this work is to modify an existing algorithm with a very unusual machine setup and find the optimal sequence which will really minimize the makespan. This custom machine setup completes all tasks by maintaining precedence and satisfying all other constraints. This thesis concentrates on identifying the most effective technique of sequencing which will be validated in a lab environment and a simulated environment. It illustrates some of the key methods of addressing a circular non permutation flow shop sequencing problem with some additional constraints. Additionally, comparisons among the various heuristics algorithms are presented based on different sequencing criteria. The optimum sequence is provided as an input to a real-life machine set up and a simulated environment for selecting the best performing algorithm which is the basic goal of this research. To achieve this goal, at first, a code using python programming language was generated to find an optimum sequence. By analyzing the results, the makespan is increasing with the number of jobs but additional pallet constraint shows, adding more pallets will help to reduce makespan for both flow shops and job shops. Though the sequence obtained from both algorithms is different, for flow shops the makespan remains same for both cases but in the job shop scenario Nawaz, Enscore and Ham (NEH) algorithms always perform better than Campbell Dudek Smith (CDS) algorithms. For job shops with different combinations the makespan decreases mostly for maximum percentage of easy category jobs combined with equal percentage of medium and complex category jobs

Dynamic Resource Scheduling in Mobile Edge Cloud with Cloud Radio Access Network

Nowadays, by integrating the cloud radio access network (C-RAN) with the mobile edge cloud computing (MEC) technology, mobile service provider (MSP) can efficiently handle the increasing mobile traffic and enhance the capabilities of mobile devices. But the power consumption has become skyrocketing for MSP and it gravely affects the profit of MSP. Previous work often studied the power consumption in C-RAN and MEC separately while less work had considered the integration of C-RAN with MEC. In this paper, we present an unifying framework for the power-performance tradeoff of MSP by jointly scheduling network resources in C-RAN and computation resources in MEC to maximize the profit of MSP. To achieve this objective, we formulate the resource scheduling issue as a stochastic problem and design a new optimization framework by using an extended Lyapunov technique. Specially, because the standard Lyapunov technique critically assumes that job requests have fixed lengths and can be finished within each decision making interval, it is not suitable for the dynamic situation where the mobile job requests have variable lengths. To solve this problem, we extend the standard Lyapunov technique and design the VariedLen algorithm to make online decisions in consecutive time for job requests with variable lengths. Our proposed algorithm can reach time average profit that is close to the optimum with a diminishing gap (1/V) for the MSP while still maintaining strong system stability and low congestion. With extensive simulations based on a real world trace, we demonstrate the efficacy and optimality of our proposed algorithm

Towards Optimality in Parallel Scheduling

To keep pace with Moore's law, chip designers have focused on increasing the number of cores per chip rather than single core performance. In turn, modern jobs are often designed to run on any number of cores. However, to effectively leverage these multi-core chips, one must address the question of how many cores to assign to each job. Given that jobs receive sublinear speedups from additional cores, there is an obvious tradeoff: allocating more cores to an individual job reduces the job's runtime, but in turn decreases the efficiency of the overall system. We ask how the system should schedule jobs across cores so as to minimize the mean response time over a stream of incoming jobs. To answer this question, we develop an analytical model of jobs running on a multi-core machine. We prove that EQUI, a policy which continuously divides cores evenly across jobs, is optimal when all jobs follow a single speedup curve and have exponentially distributed sizes. EQUI requires jobs to change their level of parallelization while they run. Since this is not possible for all workloads, we consider a class of "fixed-width" policies, which choose a single level of parallelization, k, to use for all jobs. We prove that, surprisingly, it is possible to achieve EQUI's performance without requiring jobs to change their levels of parallelization by using the optimal fixed level of parallelization, k*. We also show how to analytically derive the optimal k* as a function of the system load, the speedup curve, and the job size distribution. In the case where jobs may follow different speedup curves, finding a good scheduling policy is even more challenging. We find that policies like EQUI which performed well in the case of a single speedup function now perform poorly. We propose a very simple policy, GREEDY*, which performs near-optimally when compared to the numerically-derived optimal policy