Minimizing the makespan in a flexible flowshop with sequence dependent setup times, uniform machines, and limited buffers

This research addresses the problem of minimizing the makespan in a flexible flowshop with sequence dependent setup times, uniform machines, and limited buffers. A mathematical model was developed to solve this problem. The problem is NP-Hard in the strong sense and only very small problems could be solved optimally. For exact methods, the computation times are long and not practical even when the problems are relatively small. Two construction heuristics were developed that could find solutions quickly. Also a simulated annealing heuristic was constructed that improved the solutions obtained from the construction heuristics. The combined heuristics could compute a good solution in a short amount of time. The heuristics were tested in three different environments: 3 stages, 4 stages, and 5 stages. To assess the quality of the solutions, a lower bound and two simple heuristics were generated for comparison purposes. The proposed heuristics showed steady improvement over the simple heuristics. When compared to the lower bounds, the heuristics performed well for the smaller environment, but the performance quality decreased as the number of stages increased. The combination of these heuristics defiantly shows promise for solving the problem

Two-Stage Vehicle Routing Problems with Profits and Buffers: Analysis and Metaheuristic Optimization Algorithms

This thesis considers the Two-Stage Vehicle Routing Problem (VRP) with Profits and Buffers, which generalizes various optimization problems that are relevant for practical applications, such as the Two-Machine Flow Shop with Buffers and the Orienteering Problem. Two optimization problems are considered for the Two-Stage VRP with Profits and Buffers, namely the minimization of total time while respecting a profit constraint and the maximization of total profit under a budget constraint. The former generalizes the makespan minimization problem for the Two-Machine Flow Shop with Buffers, whereas the latter is comparable to the problem of maximizing score in the Orienteering Problem. For the three problems, a theoretical analysis is performed regarding computational complexity, existence of optimal permutation schedules (where all vehicles traverse the same nodes in the same order) and potential gaps in attainable solution quality between permutation schedules and non-permutation schedules. The obtained theoretical results are visualized in a table that gives an overview of various subproblems belonging to the Two-Stage VRP with Profits and Buffers, their theoretical properties and how they are connected. For the Two-Machine Flow Shop with Buffers and the Orienteering Problem, two metaheuristics 2BF-ILS and VNSOP are presented that obtain favorable results in computational experiments when compared to other state-of-the-art algorithms. For the Two-Stage VRP with Profits and Buffers, an algorithmic framework for Iterative Search Algorithms with Variable Neighborhoods (ISAVaN) is proposed that generalizes aspects from 2BF-ILS as well as VNSOP. Various algorithms derived from that framework are evaluated in an experimental study. The evaluation methodology used for all computational experiments in this thesis takes the performance during the run time into account and demonstrates that algorithms for structurally different problems, which are encompassed by the Two-Stage VRP with Profits and Buffers, can be evaluated with similar methods. The results show that the most suitable choice for the components in these algorithms is dependent on the properties of the problem and the considered evaluation criteria. However, a number of similarities to algorithms that perform well for the Two-Machine Flow Shop with Buffers and the Orienteering Problem can be identified. The framework unifies these characteristics, providing a spectrum of algorithms that can be adapted to the specifics of the considered Vehicle Routing Problem.:1 Introduction 2 Background 2.1 Problem Motivation 2.2 Formal Definition of the Two-Stage VRP with Profits and Buffers 2.3 Review of Literature on Related Vehicle Routing Problems 2.3.1 Two-Stage Vehicle Routing Problems 2.3.2 Vehicle Routing Problems with Profits 2.3.3 Vehicle Routing Problems with Capacity- or Resource-based Restrictions 2.4 Preliminary Remarks on Subsequent Chapters 3 The Two-Machine Flow Shop Problem with Buffers 3.1 Review of Literature on Flow Shop Problems with Buffers 3.1.1 Algorithms and Metaheuristics for Flow Shops with Buffers 3.1.2 Two-Machine Flow Shop Problems with Buffers 3.1.3 Blocking Flow Shops 3.1.4 Non-Permutation Schedules 3.1.5 Other Extensions and Variations of Flow Shop Problems 3.2 Theoretical Properties 3.2.1 Computational Complexity 3.2.2 The Existence of Optimal Permutation Schedules 3.2.3 The Gap Between Permutation Schedules an Non-Permutation 3.3 A Modification of the NEH Heuristic 3.4 An Iterated Local Search for the Two-Machine Flow Shop Problem with Buffers 3.5 Computational Evaluation 3.5.1 Algorithms for Comparison 3.5.2 Generation of Problem Instances 3.5.3 Parameter Values 3.5.4 Comparison of 2BF-ILS with other Metaheuristics 3.5.5 Comparison of 2BF-OPT with NEH 3.6 Summary 4 The Orienteering Problem 4.1 Review of Literature on Orienteering Problems 4.2 Theoretical Properties 4.3 A Variable Neighborhood Search for the Orienteering Problem 4.4 Computational Evaluation 4.4.1 Measurement of Algorithm Performance 4.4.2 Choice of Algorithms for Comparison 4.4.3 Problem Instances 4.4.4 Parameter Values 4.4.5 Experimental Setup 4.4.6 Comparison of VNSOP with other Metaheuristics 4.5 Summary 5 The Two-Stage Vehicle Routing Problem with Profits and Buffers 5.1 Theoretical Properties of the Two-Stage VRP with Profits and Buffers 5.1.1 Computational Complexity of the General Problem 5.1.2 Existence of Permutation Schedules in the Set of Optimal Solutions 5.1.3 The Gap Between Permutation Schedules an Non-Permutation Schedules 5.1.4 Remarks on Restricted Cases 5.1.5 Overview of Theoretical Results 5.2 A Metaheuristic Framework for the Two-Stage VRP with Profits and Buffers 5.3 Experimental Results 5.3.1 Problem Instances 5.3.2 Experimental Results for O_{max R, Cmax≤B} 5.3.3 Experimental Results for O_{min Cmax, R≥Q} 5.4 Summary Bibliography List of Figures List of Tables List of Algorithm

Scheduling and discrete event control of flexible manufacturing systems based on Petri nets

A flexible manufacturing system (FMS) is a computerized production system that can simultaneously manufacture multiple types of products using various resources such as robots and multi-purpose machines. The central problems associated with design of flexible manufacturing systems are related to process planning, scheduling, coordination control, and monitoring. Many methods exist for scheduling and control of flexible manufacturing systems, although very few methods have addressed the complexity of whole FMS operations. This thesis presents a Petri net based method for deadlock-free scheduling and discrete event control of flexible manufacturing systems. A significant advantage of Petri net based methods is their powerful modeling capability. Petri nets can explicitly and concisely model the concurrent and asynchronous activities, multi-layer resource sharing, routing flexibility, limited buffers and precedence constraints in FMSs. Petri nets can also provide an explicit way for considering deadlock situations in FMSs, and thus facilitate significantly the design of a deadlock-free scheduling and control system. The contributions of this work are multifold. First, it develops a methodology for discrete event controller synthesis for flexible manufacturing systems in a timed Petri net framework. The resulting Petri nets have the desired qualitative properties of liveness, boundedness (safeness), and reversibility, which imply freedom from deadlock, no capacity overflow, and cyclic behavior, respectively. This precludes the costly mathematical analysis for these properties and reduces on-line computation overhead to avoid deadlocks. The performance and sensitivity of resulting Petri nets, thus corresponding control systems, are evaluated. Second, it introduces a hybrid heuristic search algorithm based on Petri nets for deadlock-free scheduling of flexible manufacturing systems. The issues such as deadlock, routing flexibility, multiple lot size, limited buffer size and material handling (loading/unloading) are explored. Third, it proposes a way to employ fuzzy dispatching rules in a Petri net framework for multi-criterion scheduling. Finally, it shows the effectiveness of the developed methods through several manufacturing system examples compared with benchmark dispatching rules, integer programming and Lagrangian relaxation approaches

An integrated approach for remanufacturing job shop scheduling with routing alternatives.

Remanufacturing is a practice of growing importance due to increasing environmental awareness and regulations. However, the stochastic natures inherent in the remanufacturing processes complicate its scheduling. This paper undertakes the challenge and presents a remanufacturing job shop scheduling approach by integrating alternative routing assignment and machine resource dispatching. A colored timed Petri net is introduced to model the dynamics of remanufacturing process, such as various process routings, uncertain operation times for cores, and machine resource conflicts. With the color attributes in Petri nets, two types of decision points, recovery routing selection and resource dispatching, are introduced and linked with places in CTPN model. With time attributes in Petri nets, the temporal aspect of recovery operations for cores as well as the evolution dynamics in cores\u27 operational stages is mathematically analyzed. A hybrid meta-heuristic algorithm embedded scheduling strategy over CTPN is proposed to search for the optimal recovery routings for worn cores and their recovery operation sequences on workstations, in minimizing the total production cost. The approach is demonstrated through the remanufacturing of used machine tool and its effectiveness is compared against another two cases: baseline case with fixed recovery process routings and case 2 using standard SA/MST

Improving just-in-time delivery performance of IoT-enabled flexible manufacturing systems with AGV based material transportation

Autonomous guided vehicles (AGVs) are driverless material handling systems used for transportation of pallets and line side supply of materials to provide flexibility and agility in shop-floor logistics. Scheduling of shop-floor logistics in such systems is a challenging task due to their complex nature associated with the multiple part types and alternate material transfer routings. This paper presents a decision support system capable of supporting shop-floor decision-making activities during the event of manufacturing disruptions by automatically adjusting both AGV and machine schedules in Flexible Manufacturing Systems (FMSs). The proposed system uses discrete event simulation (DES) models enhanced by the Internet-of-Things (IoT) enabled digital integration and employs a nonlinear mixed integer programming Genetic Algorithm (GA) to find near-optimal production schedules prioritising the just-in-time (JIT) material delivery performance and energy efficiency of the material transportation. The performance of the proposed system is tested on the Integrated Manufacturing and Logistics (IML) demonstrator at WMG, University of Warwick. The results showed that the developed system can find the near-optimal solutions for production schedules subjected to production anomalies in a negligible time, thereby supporting shop-floor decision-making activities effectively and rapidly

Improving just-in-time delivery performance of IoT-enabled flexible manufacturing systems with AGV based material transportation

© 2020 by the authors. Licensee MDPI, Basel, Switzerland. Autonomous guided vehicles (AGVs) are driverless material handling systems used for transportation of pallets and line side supply of materials to provide flexibility and agility in shop-floor logistics. Scheduling of shop-floor logistics in such systems is a challenging task due to their complex nature associated with the multiple part types and alternate material transfer routings. This paper presents a decision support system capable of supporting shop-floor decision-making activities during the event of manufacturing disruptions by automatically adjusting both AGV and machine schedules in Flexible Manufacturing Systems (FMSs). The proposed system uses discrete event simulation (DES) models enhanced by the Internet-of-Things (IoT) enabled digital integration and employs a nonlinear mixed integer programming Genetic Algorithm (GA) to find near-optimal production schedules prioritising the just-in-time (JIT) material delivery performance and energy efficiency of the material transportation. The performance of the proposed system is tested on the Integrated Manufacturing and Logistics (IML) demonstrator at WMG, University of Warwick. The results showed that the developed system can find the near-optimal solutions for production schedules subjected to production anomalies in a negligible time, thereby supporting shop-floor decision-making activities effectively and rapidly

Overview on: sequencing in mixed model flowshop production line with static and dynamic context

In the present work a literature overview was given on solution techniques considering basic as well as more advanced and consequently more complex arrangements of mixed model flowshops. We first analyzed the occurrence of setup time/cost; existing solution techniques are mainly focused on permutation sequences. Thereafter we discussed objectives resulting in the introduction of variety of methods allowing resequencing of jobs within the line. The possibility of resequencing within the line ranges from 1) offline or intermittent buffers, 2) parallel stations, namely flexible, hybrid or compound flowshops, 3) merging and splitting of parallel lines, 4) re-entrant flowshops, to 5) change job attributes without physically interchanging the position. In continuation the differences in the consideration of static and dynamic demand was studied. Also intermittent setups are possible, depending on the horizon and including the possibility of resequencing, four problem cases were highlighted: static, semi dynamic, nearly dynamic and dynamic case. Finally a general overview was given on existing solution methods, including exact and approximation methods. The approximation methods are furthermore divided in two cases, know as heuristics and methaheuristic