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

Design and Control of Warehouse Order Picking: a literature review

Order picking has long been identified as the most labour-intensive and costly activity for almost every warehouse; the cost of order picking is estimated to be as much as 55% of the total warehouse operating expense. Any underperformance in order picking can lead to unsatisfactory service and high operational cost for its warehouse, and consequently for the whole supply chain. In order to operate efficiently, the orderpicking process needs to be robustly designed and optimally controlled. This paper gives a literature overview on typical decision problems in design and control of manual order-picking processes. We focus on optimal (internal) layout design, storage assignment methods, routing methods, order batching and zoning. The research in this area has grown rapidly recently. Still, combinations of the above areas have hardly been explored. Order-picking system developments in practice lead to promising new research directions.Order picking;Logistics;Warehouse Management

Application of Multi-Objective Optimization Based on Genetic Algorithm for Sustainable Strategic Supplier Selection under Fuzzy Environment

Purpose: The incorporation of environmental objective into the conventional supplier selection practices is crucial for corporations seeking to promote green supply chain management (GSCM). Challenges and risks associated with green supplier selection have been broadly recognized by procurement and supplier management professionals. This paper aims to solve a Tetra “S” (SSSS) problem based on a fuzzy multi-objective optimization with genetic algorithm in a holistic supply chain environment. In this empirical study, a mathematical model with fuzzy coefficients is considered for sustainable strategic supplier selection (SSSS) problem and a corresponding model is developed to tackle this problem. Design/methodology/approach: Sustainable strategic supplier selection (SSSS) decisions are typically multi-objectives in nature and it is an important part of green production and supply chain management for many firms. The proposed uncertain model is transferred into deterministic model by applying the expected value measure (EVM) and genetic algorithm with weighted sum approach for solving the multi-objective problem. This research focus on a multiobjective optimization model for minimizing lean cost, maximizing sustainable service and greener product quality level. Finally, a mathematical case of textile sector is presented to exemplify the effectiveness of the proposed model with a sensitivity analysis. Findings: This study makes a certain contribution by introducing the Tetra ‘S’ concept in both the theoretical and practical research related to multi-objective optimization as well as in the study of sustainable strategic supplier selection (SSSS) under uncertain environment. Our results suggest that decision makers tend to select strategic supplier first then enhance the sustainability. Research limitations/implications: Although the fuzzy expected value model (EVM) with fuzzy coefficients constructed in present research should be helpful for solving real world problems. A detailed comparative analysis by using other algorithms is necessary for solving similar problems of agriculture, pharmaceutical, chemicals and services sectors in future. Practical implications: It can help the decision makers for ordering to different supplier for managing supply chain performance in efficient and effective manner. From the procurement and engineering perspectives, minimizing cost, sustaining the quality level and meeting production time line is the main consideration for selecting the supplier. Empirically, this can facilitate engineers to reduce production costs and at the same time improve the product quality. Originality/value: In this paper, we developed a novel multi-objective programming model based on genetic algorithm to select sustainable strategic supplier (SSSS) under fuzzy environment. The algorithm was tested and applied to solve a real case of textile sector in Pakistan. The experimental results and comparative sensitivity analysis illustrate the effectiveness of our proposed model.Peer Reviewe

Meta-heuristic based Construction Supply Chain Modelling and Optimization

Driven by the severe competition within the construction industry, the necessity of improving and optimizing the performance of construction supply chain has been aroused. This thesis proposes three problems with regard to the construction supply chain optimization from three perspectives, namely, deterministic single objective optimization, stochastic optimization and multi-objective optimization respectively. Mathematical models for each problem are constructed accordingly and meta-heuristic algorithms are developed and applied for resolving these three problems

Global supply chains of high value low volume products

Imperial Users onl

Stochastic-optimization of equipment productivity in multi-seam formations

Short and long range planning and execution for multi-seam coal formations (MSFs) are challenging with complex extraction mechanisms. Stripping equipment selection and scheduling are functions of the physical dynamics of the mine and the operational mechanisms of its components, thus its productivity is dependent on these parameters. Previous research studies did not incorporate quantitative relationships between equipment productivities and extraction dynamics in MSFs. The intrinsic variability of excavation and spoiling dynamics must also form part of existing models. This research formulates quantitative relationships of equipment productivities using Branch-and-Bound algorithms and Lagrange Parameterization approaches. The stochastic processes are resolved via Monte Carlo/Latin Hypercube simulation techniques within @RISK framework. The model was presented with a bituminous coal mining case in the Appalachian field. The simulated results showed a 3.51% improvement in mining cost and 0.19% increment in net present value. A 76.95yd³ drop in productivity per unit change in cycle time was recorded for sub-optimal equipment schedules. The geologic variability and equipment operational parameters restricted any possible change in the cost function. A 50.3% chance of the mining cost increasing above its current value was driven by the volume of material re-handled with 0.52 regression coefficient. The study advances the optimization process in mine planning and scheduling algorithms, to efficiently capture future uncertainties surrounding multivariate random functions. The main novelty includes the application of stochastic-optimization procedures to improve equipment productivity in MSFs --Abstract, page iii

Dynamic Facility Layout for Cellular and Reconfigurable Manufacturing using Dynamic Programming and Multi-Objective Metaheuristics

The facility layout problem is one of the most classical yet influential problems in the planning of production systems. A well-designed layout minimizes the material handling costs (MHC), personnel flow distances, work in process, and improves the performance of these systems in terms of operating costs and time. Because of this importance, facility layout has a rich literature in industrial engineering and operations research. Facility layout problems (FLPs) are generally concerned with positioning a set of facilities to satisfy some criteria or objectives under certain constraints. Traditional FLPs try to put facilities with the high material flow as close as possible to minimize the MHC. In static facility layout problems (SFLP), the product demands and mixes are considered deterministic parameters with constant values. The material flow between facilities is fixed over the planning horizon. However, in today’s market, manufacturing systems are constantly facing changes in product demands and mixes. These changes make it necessary to change the layout from one period to the other to be adapted to the changes. Consequently, there is a need for dynamic approaches of FLP that aim to generate layouts with high adaptation concerning changes in product demand and mix. This thesis focuses on studying the layout problems, with an emphasis on the changing environment of manufacturing systems. Despite the fact that designing layouts within the dynamic environment context is more realistic, the SFLP is observed to have been remained worthy to be analyzed. Hence, a math-heuristic approach is developed to solve an SFLP. To this aim, first, the facilities are grouped into many possible vertical clusters, second, the best combination of the generated clusters to be in the final layout are selected by solving a linear programming model, and finally, the selected clusters are sequenced within the shop floor. Although the presented math-heuristic approach is effective in solving SFLP, applying approaches to cope with the changing manufacturing environment is required. One of the most well-known approaches to deal with the changing manufacturing environment is the dynamic facility layout problem (DFLP). DFLP suits reconfigurable manufacturing systems since their machinery and material handling devices are reconfigurable to encounter the new necessities for the variations of product mix and demand. In DFLP, the planning horizon is divided into some periods. The goal is to find a layout for each period to minimize the total MHC for all periods and the total rearrangement costs between the periods. Dynamic programming (DP) has been known as one of the effective methods to optimize DFLP. In the DP method, all the possible layouts for every single period are generated and given to DP as its state-space. However, by increasing the number of facilities, it is impossible to give all the possible layouts to DP and only a restricted number of layouts should be fed to DP. This leads to ignoring some layouts and losing the optimality; to deal with this difficulty, an improved DP approach is proposed. It uses a hybrid metaheuristic algorithm to select the initial layouts for DP that lead to the best solution of DP for DFLP. The proposed approach includes two phases. In the first phase, a large set of layouts are generated through a heuristic method. In the second phase, a genetic algorithm (GA) is applied to search for the best subset of layouts to be given to DP. DP, improved by starting with the most promising initial layouts, is applied to find the multi-period layout. Finally, a tabu search algorithm is utilized for further improvement of the solution obtained by improved DP. Computational experiments show that improved DP provides more efficient solutions than DP approaches in the literature. The improved DP can efficiently solve DFLP and find the best layout for each period considering both material handling and layout rearrangement costs. However, rearrangement costs may include some unpredictable costs concerning interruption in production or moving of facilities. Therefore, in some cases, managerial decisions tend to avoid any rearrangements. To this aim, a semi-robust approach is developed to optimize an FLP in a cellular manufacturing system (CMS). In this approach, the pick-up/drop-off (P/D) points of the cells are changed to adapt the layout with changes in product demand and mix. This approach suits more a cellular flexible manufacturing system or a conventional system. A multi-objective nonlinear mixed-integer programming model is proposed to simultaneously search for the optimum number of cells, optimum allocation of facilities to cells, optimum intra- and inter-cellular layout design, and the optimum locations of the P/D points of the cells in each period. A modified non-dominated sorting genetic algorithm (MNSGA-II) enhanced by an improved non-dominated sorting strategy and a modified dynamic crowding distance procedure is used to find Pareto-optimal solutions. The computational experiments are carried out to show the effectiveness of the proposed MNSGA-II against other popular metaheuristic algorithms

Intelligent design of manufacturing systems.

The design of a manufacturing system is normally performed in two distinct stages, i.e. steady state design and dynamic state design. Within each system design stage a variety of decisions need to be made of which essential ones are the determination of the product range to be manufactured, the layout of equipment on the shopfloor, allocation of work tasks to workstations, planning of aggregate capacity requirements and determining the lot sizes to be processed. This research work has examined the individual problem areas listed above in order to identify the efficiency of current solution techniques and to determine the problems experienced with their use. It has been identified that for each design problem. although there are an assortment of solution techniques available, the majority of these techniques are unable to generate optimal or near optimal solutions to problems of a practical size. In addition, a variety of limitations have been identified that restrict the use of existing techniques. For example, existing methods are limited with respect to the external conditions over which they are applicable and/or cannot enable qualitative or subjective judgements of experienced personnel to influence solution outcomes. An investigation of optimization techniques has been carried out which indicated that genetic algorithms offer great potential in solving the variety of problem areas involved in manufacturing systems design. This research has, therefore, concentrated on testing the use of genetic algorithms to make individual manufacturing design decisions. In particular, the ability of genetic algorithms to generate better solutions than existing techniques has been examined and their ability to overcome the range of limitations that exist with current solution techniques. IIFor each problem area, a typical solution has been coded in terms of a genetic algorithm structure, a suitable objective function constructed and experiments performed to identify the most suitable operators and operator parameter values to use. The best solution generated using these parameters has then been compared with the solution derived using a traditional solution technique. In addition, from the range of experiments undertaken the underlying relationships have been identified between problem characteristics and optimality of operator types and parameter values. The results of the research have identified that genetic algorithms could provide an improved solution technique for all manufacturing design decision areas investigated. In most areas genetic algorithms identified lower cost solutions and overcame many of the limitations of existing techniques

Sequence-Based Simulation-Optimization Framework With Application to Port Operations at Multimodal Container Terminals

It is evident in previous works that operations research and mathematical algorithms can provide optimal or near-optimal solutions, whereas simulation models can aid in predicting and studying the behavior of systems over time and monitor performance under stochastic and uncertain circumstances. Given the intensive computational effort that simulation optimization methods impose, especially for large and complex systems like container terminals, a favorable approach is to reduce the search space to decrease the amount of computation. A maritime port can consist of multiple terminals with specific functionalities and specialized equipment. A container terminal is one of several facilities in a port that involves numerous resources and entities. It is also where containers are stored and transported, making the container terminal a complex system. Problems such as berth allocation, quay and yard crane scheduling and assignment, storage yard layout configuration, container re-handling, customs and security, and risk analysis become particularly challenging. Discrete-event simulation (DES) models are typically developed for complex and stochastic systems such as container terminals to study their behavior under different scenarios and circumstances. Simulation-optimization methods have emerged as an approach to find optimal values for input variables that maximize certain output metric(s) of the simulation. Various traditional and nontraditional approaches of simulation-optimization continue to be used to aid in decision making. In this dissertation, a novel framework for simulation-optimization is developed, implemented, and validated to study the influence of using a sequence (ordering) of decision variables (resource levels) for simulation-based optimization in resource allocation problems. This approach aims to reduce the computational effort of optimizing large simulations by breaking the simulation-optimization problem into stages. Since container terminals are complex stochastic systems consisting of different areas with detailed and critical functions that may affect the output, a platform that accurately simulates such a system can be of significant analytical benefit. To implement and validate the developed framework, a large-scale complex container terminal discrete-event simulation model was developed and validated based on a real system and then used as a testing platform for various hypothesized algorithms studied in this work