Manufacturing process planning optimisation in reconfigurable multiple parts flow lines

Purpose: This paper explores the capabilities of genetic algorithms in handling optimization of the critical issues mentioned above for the purpose of manufacturing process planning in reconfigurable manufacturing activities. Two modified genetic algorithms are devised and employed to provide the best approximate process planning solution. Modifications included adapting genetic operators to the problem specific knowledge and implementing application specific heuristics to enhance the search efficiency. Design/methodology/approach: The genetic algorithm methodology implements a genetic algorithm that is augmented by application specific heuristics in order to guide the search for an optimal solution. The case study is based on the manufacturing system. Raw materials enter the system through an input stage and exit the system through an output stage. The system is composed of sixteen (16) processing modules that are arranged in four processing stages. Findings: The results indicate that the two genetic algorithms are able to converge to optimal solutions in reasonable time. A computational study shows that improved solutions can be obtained by implementing a genetic algorithm with an extended diversity control mechanism. Research limitations/implications: This paper has examined the issues of MPP optimization in a reconfigurable manufacturing framework with the help of a reconfigurable multiparts manufacturing flow line. Originality/value: The results of the case illustration have demonstrated the practical use of diversity control implemented in the MGATO technique. In comparison to MGAWTO, the implemented MGATO improves the population diversity through a customized threshold operator. It was clear that the MGATO can obtain better solution quality by foiling the tendency towards premature convergence

Genetic algorithms for the scheduling in additive manufacturing

[EN] Genetic Algorithms (GAs) are introduced to tackle the packing problem. The scheduling in Additive Manufacturing (AM) is also dealt with to set up a managed market, called “Lonja3D”. This will enable to determine an alternative tool through the combinatorial auctions, wherein the customers will be able to purchase the products at the best prices from the manufacturers. Moreover, the manufacturers will be able to optimize the production capacity and to decrease the operating costs in each case.This research has been partially financed by the project: “Lonja de Impresión 3D para la Industria 4.0 y la Empresa Digital (LONJA3D)” funded by the Regional Government of Castile and Leon and the European Regional Development Fund (ERDF, FEDER) with grant VA049P17Castillo-Rivera, S.; De Antón, J.; Del Olmo, R.; Pajares, J.; López-Paredes, A. (2020). Genetic algorithms for the scheduling in additive manufacturing. International Journal of Production Management and Engineering. 8(2):59-63. https://doi.org/10.4995/ijpme.2020.12173OJS596382Ahsan, A., Habib, A., Khoda, B. (2015). Resource based process planning for additive manufacturing. Computer-Aided Design, 69, 112-125. https://doi.org/10.1016/j.cad.2015.03.006Araújo, L., Özcan, E., Atkin, J., Baumers, M., Tuck, C., Hague, R. (2015). Toward better build volume packing in additive manufacturing: classification of existing problems and benchmarks. 26th Annual International Solid Freeform Fabrication Symposium - an Additive Manufacturing Conference, 401-410.Berman, B. (2012). 3-D printing: The new industrial revolution. Business Horizons, 55: 155-162. https://doi.org/10.1016/j.bushor.2011.11.003Canellidis, V., Dedoussis, V., Mantzouratos, N., Sofianopoulou, S. (2006). Preprocessing methodology for optimizing stereolithography apparatus build performance. Computers in Industry, 57, 424-436. https://doi.org/10.1016/j.compind.2006.02.004Chergui, A., Hadj-Hamoub, K., Vignata, F. (2018). Production scheduling and nesting in additive manufacturing. Computers & Industrial Engineering, 126, 292-301. https://doi.org/10.1016/j.cie.2018.09.048Demirel, E., Özelkan, E.C., Lim, C. (2018). Aggregate planning with flexibility requirements profile. International Journal of Production Economics, 202, 45-58. https://doi.org/10.1016/j.ijpe.2018.05.001Fera, M., Fruggiero, F., Lambiase, A., Macchiaroli, R., Todisco, V. (2018). A modified genetic algorithm for time and cost optimization of an additive manufacturing single-machine scheduling. International Journal of Industrial Engineering Computations, 9, 423-438. https://doi.org/10.5267/j.ijiec.2018.1.001Hopper, E., Turton, B. (1997). Application of genetic algorithms to packing problems - A Review. Proceedings of the 2nd Online World Conference on Soft Computing in Engineering Design and Manufacturing, Springer Verlag, London, 279-288. https://doi.org/10.1007/978-1-4471-0427-8_30Ikonen, I., Biles, W.E., Kumar, A., Wissel, J.C., Ragade, R.K. (1997). A genetic algorithm for packing three-dimensional non-convex objects having cavities and holes. ICGA, 591-598.Kim, K.H., Egbelu, P.J. (1999). Scheduling in a production environment with multiple process plans per job. International Journal of Production Research, 37, 2725-2753. https://doi.org/10.1080/002075499190491Lawrynowicz, A. (2011). Genetic algorithms for solving scheduling problems in manufacturing systems. Foundations of Management, 3(2), 7-26. https://doi.org/10.2478/v10238-012-0039-2Li, Q., Kucukkoc, I., Zhang, D. (2017). Production planning in additive manufacturing and 3D printing. Computers and Operations Research, 83, 157-172. https://doi.org/10.1016/j.cor.2017.01.013Milošević, M., Lukić, D., Đurđev, M., Vukman, J., Antić, A. (2016). Genetic Algorithms in Integrated Process Planning and Scheduling-A State of The Art Review. Proceedings in Manufacturing Systems, 11(2), 83-88.Pour, M.A., Zanardini, M., Bacchetti, A., Zanoni, S. (2016). Additive manufacturing impacts on productions and logistics systems. IFAC, 49(12), 1679-1684. https://doi.org/10.1016/j.ifacol.2016.07.822Wilhelm, W.E., Shin, H.M. (1985). Effectiveness of Alternate Operations in a Flexible Manufacturing System. International Journal of Production Research, 23(1), 65-79. https://doi.org/10.1080/00207548508904691Xirouchakis, P., Kiritsis, D., Persson, J.G. (1998). A Petri net Technique for Process Planning Cost Estimation. Annals of the CIRP, 47(1), 427-430. https://doi.org/10.1016/S0007-8506(07)62867-4Zhang, Y., Bernard, A., Gupta, R.K., Harik, R. (2014). Evaluating the design for additive manufacturing: a process planning perspective. Procedia CIRP, 21, 144-150. https://doi.org/10.1016/j.procir.2014.03.17

Process Planning Optimization In Reconfigurable Manufacturing Systems

Trends and perspectives in dynamic environments point towards a need for optimal operating levels in reconfigurable manufacturing activities. Central to the goal of meeting this need is the issue of appropriate techniques for manufacturing process planning optimization in reconfigurable manufacturing, i.e. (i) what decision making models and (ii) what computational techniques, provide an optimal manufacturing process planning solution in a multidimensional decision variables space? Conventional optimization techniques are not robust, hence; they are not suitable for handling multidimensional search spaces. On the other hand, process planning optimization for reconfigurable manufacturing is not amenable to classical modeling approaches due to the presence of complex system dynamics. Therefore, this study explores how to model reconfigurable manufacturing activities in an optimization perspective and how to develop and select appropriate non-conventional optimization techniques for reconfigurable process planning.In this study, a new approach to modeling Manufacturing Process Planning Optimization (MPPO) was developed by extending the concept of manufacturing optimization through a decoupled optimization method. The uniqueness of this approach lies in embedding an integrated scheduling function into a partially integrated process planning function in order to exploit the strategic potentials of flexibility and reconfigurability in manufacturing systems. Alternative MPPO models were constructed and variances associated with their utilization analyzed. Five (5) Alternative Algorithm Design Techniques (AADTs) were developed and investigated for suitability in providing process planning solutions suitable for reconfigurable manufacturing. The five (5) AADTs include; a variant of the simulated annealing algorithm that implements heuristic knowledge at critical decision points, two (2) cooperative search schemes based on a “loose hybridization” of the Boltzmann Machine algorithm with (i) simulated annealing, and (ii) genetic algorithm search techniques, and two (2) modified genetic algorithms. The comparative performances of the developed AADTs when tasked to solve an instance of a MPPO problem were analyzed and evaluated. In particular, the relative performances of the novel variant of simulated annealing in comparison to: (a) (i) a simulated annealing search, and (ii) a genetic search in the Boltzmann Machine Architecture, and (b) (i) a modified genetic algorithm and (ii) a genetic algorithm with a customized threshold operator that implements an innovative extension of the diversity control mechanism to gene and genome levels; were pursued in this thesis.Results show that all five (5) AADTs are capable of stable and asymptotic convergence to near optimal solutions in real time. Analysis indicates that the performances of the implemented variant of simulated annealing are comparable to those of other optimization techniques developed in this thesis. However, a computational study shows that; in comparison to the simulated annealing technique, significant improvements in optimization control performance and quality of computed solutions can be realized through implementing intelligent techniques. As evidenced by the relative performances of the implemented cooperative schemes, a genetic search is better than a simulated annealing search in the Boltzmann Machine Architecture. In addition, little performance gain can be realized through parallelism in the Boltzmann Machine Architecture. On the other hand, the superior performance of the genetic algorithm that implements an extended diversity control mechanism demonstrates that more competent genetic algorithms can be designed through customized operators. Therefore, this study has revealed that extending manufacturing optimization concepts through a decoupled optimization method is an effective modeling approach that is capable of handling complex decision scenarios in reconfigurable manufacturing activities. The approach provides a powerful decision framework for process planning optimization activities of a multidimensional nature. Such an approach can be implemented more efficiently through intelligent techniques. Hence; intelligent techniques can be utilized in manufacturing process planning optimization strategies that aim to improve operating levels in reconfigurable manufacturing with the resultant benefits of improved performance levels

Intelligent systems in manufacturing: current developments and future prospects

Global competition and rapidly changing customer requirements are demanding increasing changes in manufacturing environments. Enterprises are required to constantly redesign their products and continuously reconfigure their manufacturing systems. Traditional approaches to manufacturing systems do not fully satisfy this new situation. Many authors have proposed that artificial intelligence will bring the flexibility and efficiency needed by manufacturing systems. This paper is a review of artificial intelligence techniques used in manufacturing systems. The paper first defines the components of a simplified intelligent manufacturing systems (IMS), the different Artificial Intelligence (AI) techniques to be considered and then shows how these AI techniques are used for the components of IMS

AI and OR in management of operations: history and trends

The last decade has seen a considerable growth in the use of Artificial Intelligence (AI) for operations management with the aim of finding solutions to problems that are increasing in complexity and scale. This paper begins by setting the context for the survey through a historical perspective of OR and AI. An extensive survey of applications of AI techniques for operations management, covering a total of over 1200 papers published from 1995 to 2004 is then presented. The survey utilizes Elsevier's ScienceDirect database as a source. Hence, the survey may not cover all the relevant journals but includes a sufficiently wide range of publications to make it representative of the research in the field. The papers are categorized into four areas of operations management: (a) design, (b) scheduling, (c) process planning and control and (d) quality, maintenance and fault diagnosis. Each of the four areas is categorized in terms of the AI techniques used: genetic algorithms, case-based reasoning, knowledge-based systems, fuzzy logic and hybrid techniques. The trends over the last decade are identified, discussed with respect to expected trends and directions for future work suggested

Assembly and Disassembly Planning by using Fuzzy Logic & Genetic Algorithms

The authors propose the implementation of hybrid Fuzzy Logic-Genetic Algorithm (FL-GA) methodology to plan the automatic assembly and disassembly sequence of products. The GA-Fuzzy Logic approach is implemented onto two levels. The first level of hybridization consists of the development of a Fuzzy controller for the parameters of an assembly or disassembly planner based on GAs. This controller acts on mutation probability and crossover rate in order to adapt their values dynamically while the algorithm runs. The second level consists of the identification of theoptimal assembly or disassembly sequence by a Fuzzy function, in order to obtain a closer control of the technological knowledge of the assembly/disassembly process. Two case studies were analyzed in order to test the efficiency of the Fuzzy-GA methodologies

Solving Integrated Process Planning, Dynamic Scheduling, and Due Date Assignment Using Metaheuristic Algorithms

Because the alternative process plans have significant contributions to the production efficiency of a manufacturing system, researchers have studied the integration of manufacturing functions, which can be divided into two groups, namely, integrated process planning and scheduling (IPPS) and scheduling with due date assignment (SWDDA). Although IPPS and SWDDA are well-known and solved problems in the literature, there are limited works on integration of process planning, scheduling, and due date assignment (IPPSDDA). In this study, due date assignment function was added to IPPS in a dynamic manufacturing environment. And the studied problem was introduced as dynamic integrated process planning, scheduling, and due date assignment (DIPPSDDA). The objective function of DIPPSDDA is to minimize earliness and tardiness (E/T) and determine due dates for each job. Furthermore, four different pure metaheuristic algorithms which are genetic algorithm (GA), tabu algorithm (TA), simulated annealing (SA), and their hybrid (combination) algorithms GA/SA and GA/TA have been developed to facilitate and optimize DIPPSDDA on the 8 different sized shop floors. The performance comparisons of the algorithms for each shop floor have been given to show the efficiency and effectiveness of the algorithms used. In conclusion, computational results show that the proposed combination algorithms are competitive, give better results than pure metaheuristics, and can effectively generate good solutions for DIPPSDDA problems

Minimisation of energy consumption variance for multi-process manufacturing lines through genetic algorithm manipulation of production schedule

Typical manufacturing scheduling algorithms do not consider the energy consumption of each job, or its variance, when they generate a production schedule. This can become problematic for manufacturers when local infrastructure has limited energy distribution capabilities. In this paper, a genetic algorithm based schedule modification algorithm is presented. By referencing energy consumption models for each job, adjustments are made to the original schedule so that it produces a minimal variance in the total energy consumption in a multi-process manufacturing production line, all while operating within the constraints of the manufacturing line and individual processes. Empirical results show a significant reduction in energy consumption variance can be achieved on schedules containing multiple concurrent jobs

The relevance of outsourcing and leagile strategies in performance optimization of an integrated process planning and scheduling

Over the past few years growing global competition has forced the manufacturing industries to upgrade their old production strategies with the modern day approaches. As a result, recent interest has been developed towards finding an appropriate policy that could enable them to compete with others, and facilitate them to emerge as a market winner. Keeping in mind the abovementioned facts, in this paper the authors have proposed an integrated process planning and scheduling model inheriting the salient features of outsourcing, and leagile principles to compete in the existing market scenario. The paper also proposes a model based on leagile principles, where the integrated planning management has been practiced. In the present work a scheduling problem has been considered and overall minimization of makespan has been aimed. The paper shows the relevance of both the strategies in performance enhancement of the industries, in terms of their reduced makespan. The authors have also proposed a new hybrid Enhanced Swift Converging Simulated Annealing (ESCSA) algorithm, to solve the complex real-time scheduling problems. The proposed algorithm inherits the prominent features of the Genetic Algorithm (GA), Simulated Annealing (SA), and the Fuzzy Logic Controller (FLC). The ESCSA algorithm reduces the makespan significantly in less computational time and number of iterations. The efficacy of the proposed algorithm has been shown by comparing the results with GA, SA, Tabu, and hybrid Tabu-SA optimization methods