An Integrated, Evolutionary Approach to Facility Layout and Detailed Design

The unequal-area, shape constrained facility layout problem is a NP-hard combinatorial optimization problem concerned with minimizing material handling costs. An integrated methodology that incorporates a genetic algorithm and a constructive heuristic is developed to simultaneously solve the traditional block layout problem of locating and shaping departments and the detailed design problem of locating the input/output stations of departments. These problems have received much attention over the past half-century with the majority of research focused on solving them individually or sequentially. This thesis aims to show that an integrated methodology which combines the problems and solves them in parallel is preferable to sequential approaches.The complexity of the integrated layout problem is reduced through a Flexbay formulation and through pre-assigned intra-departmental flow types. A genetic algorithm with a two-tiered solution structure generates and maintains a population of block layout solutions throughout an evolutionary process. Genetic operators reproduce and alter solutions in order to generate better solutions, find new search directions, and prevent premature convergence of the algorithm. An adaptive penalty mechanism guides the search process and reduces the computational overhead of the algorithm. Through the placement of input/output stations, the optimization of a block layout's material flow network is implemented as a subroutine to the genetic algorithm. A contour distance metric is used to evaluate the costs associated with material movement between the input/output stations of departments and aids in constructing practical aisle structures. A constructive placement heuristic places the input/output stations and perturbs them until no further improvement to a layout can be realized. The integrated approach is applied to several well known problems over a comprehensive test plan. The results from the integrated approach indicate moderate variability in the solutions and considerable computational expense. To compare the integrated methodology to prior methodologies, some of the best results from the unequal-area facility layout problem are selected from prior research and the I/O optimization heuristic is applied to them. The results of the integrated approach uniformly and significantly outperform the results obtained through sequential optimization. The integrated methodology demonstrates the value of a simultaneous approach to the unequal-area facility layout problem

Simheuristic and learnheuristic algorithms for the temporary-facility location and queuing problem during population treatment or testing events

Epidemic outbreaks, such as the one generated by the coronavirus disease, have raised the need for more efficient healthcare logistics. One of the challenges that many governments have to face in such scenarios is the deployment of temporary medical facilities across a region with the purpose of providing medical services to their citizens. This work tackles this temporary-facility location and queuing problem with the goals of minimizing costs, the expected completion time, population travel and waiting times. The completion time for a facility depends on the numbers assigned to those facilities as well as stochastic arrival times. This work proposes a learnheuristic algorithm to solve the facility location and population assignment problem. Firstly a machine learning algorithm is trained using data from a queuing model (simulation module). The learnheuristic then constructs solutions using the machine learning algorithm to rapidly evaluate decisions in terms of facility completion and population waiting times. The efficiency and quality of the algorithm is demonstrated by comparison with exact and simulation-only (simheuristic) methodologies. A series of experiments are performed which explore the trade offs between solution cost, completion time, population travel and waiting times.Peer ReviewedPostprint (author's final draft

Topology Network Optimization of Facility Planning and Design Problems

The research attempts to provide a graphical theory-based approach to solve the facility layout problem. Which has generally been approached using Quadratic Assignment Problem (QAP) in the past, an algebraic method. It is a very complex problem and is part of the NP-Hard optimization class, because of the nonlinear quadratic objective function and (0,1) binary variables. The research is divided into three phases which together provide an optimal facility layout, block plan solution consisting of MHS (material handling solution) projected onto the block plan. In phase one, we solve for the position of departments in a facility based on flow and utility factor (weight for location). The position of all the departments is identified on the vertices of MPG (maximal planar graph), which maximizes the possibility of flow. We use named MPG produced in literature, throughout the research. The grouping of the department is achieved through GMAFLAD, a QSP (quadratic set packing) based optimizer. In Phase 2, the dual for the MPG’s is solved consisting of department location as per phase 1, to generate Voronoi graphs. These graphs are then, expanded by an ingenious parameter optimization formulation to achieve area fitting for individual cases. Optimization modeling software, Lingo17.0 is used for solving the parameter optimization for generating coordinates of the block plan. The plotting of coordinates for the block plan graphics is done via Autodesk inventor 2019. In phase 3, the solution for MHS is achieved using an RSMT (Rectilinear Steiner minimal tree) graph approach. The Voronoi seed coordinates produced through phase 2 results are computed by GeoSteiner package to generated the RSMT graph for projection onto the block plan (Also, done by Inventor 2019). The graphical method employed in this research, itself has complex and NP-hard problem segments in it, which have been relaxed to polynomial time complexity by fragmenting into groups and solving them in sections. Solving for MPG & RSMT are a class of NP-Hard problem, which have been restricted to N=32 here. Finally, to validate the research and its methodology a real-life case study of a shipyard building for the data set of PDVSA, Venezuela is performed and verified

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

A new integrated design framework for the facility layout problem

This thesis proposes a new integrated design framework for solving facility layout problems (FLP). The most popular existing framework, Muther\u27s Systematic Layout Planning (SLP) does not address the variety of design goals associated with facility layout problems and is highly manual and so time consuming to perform. Furthermore, the SLP framework does not help the designer select a modeling tool to use in developing design alternatives, either by defining what a requisite model would include, or explicitly suggesting ones from literature. With the advancements made in academic research and computational capabilities since the development of the SLP framework, a new framework was needed to better address varying design goals, and assist designers in the selection of appropriate models. The framework proposed here guides the designer through determination of model requirements to meet their design goals by framing the FLP in terms of Design Layers . In addition, it proposes candidate models (or methodologies) to generate analytically derived solutions for design goals such as construction of simple block layouts, or determination of input/output points and flow paths in order to create detailed block layouts. The models and methodologies proposed are shown to rapidly reach good candidate solutions to a wide range of design problems

An Application of an Unequal-Area Facilities Layout Problem with Fixed-Shape Facilities

The unequal-area facility layout problem (UA-FLP) is the problem of locating rectangular facilities on a rectangular floor space such that facilities do not overlap while optimizing some objective. The objective considered in this paper is minimizing the total distance materials travel between facilities. The UA-FLP considered in this paper considers facilities with fixed dimension and was motivated by the investigation of layout options for a production area at the Toyota Motor Manufacturing West Virginia (TMMWV) plant in Buffalo, WV, USA. This paper presents a mathematical model and a genetic algorithm for locating facilities on a continuous plant floor. More specifically, a genetic algorithm, which consists of a boundary search heuristic (BSH), a linear program, and a dual simplex method, is developed for an UA-FLP. To test the performance of the proposed technique, several test problems taken from the literature are used in the analysis. The results show that the proposed heuristic performs well with respect to solution quality and computational time

Problemas de localização-distribuição de serviços semiobnóxios: aproximações e apoio à decisão

Doutoramento em Gestão IndustrialA presente tese resulta de um trabalho de investigação cujo objectivo se centrou no problema de localização-distribuição (PLD) que pretende abordar, de forma integrada, duas actividades logísticas intimamente relacionadas: a localização de equipamentos e a distribuição de produtos. O PLD, nomeadamente a sua modelação matemática, tem sido estudado na literatura, dando origem a diversas aproximações que resultam de diferentes cenários reais. Importa portanto agrupar as diferentes variantes por forma a facilitar e potenciar a sua investigação. Após fazer uma revisão e propor uma taxonomia dos modelos de localização-distribuição, este trabalho foca-se na resolução de alguns modelos considerados como mais representativos. É feita assim a análise de dois dos PLDs mais básicos (os problema capacitados com procura nos nós e nos arcos), sendo apresentadas, para ambos, propostas de resolução. Posteriormente, é abordada a localização-distribuição de serviços semiobnóxios. Este tipo de serviços, ainda que seja necessário e indispensável para o público em geral, dada a sua natureza, exerce um efeito desagradável sobre as comunidades contíguas. Assim, aos critérios tipicamente utilizados na tomada de decisão sobre a localização destes serviços (habitualmente a minimização de custo) é necessário adicionar preocupações que reflectem a manutenção da qualidade de vida das regiões que sofrem o impacto do resultado da referida decisão. A abordagem da localização-distribuição de serviços semiobnóxios requer portanto uma análise multi-objectivo. Esta análise pode ser feita com recurso a dois métodos distintos: não interactivos e interactivos. Ambos são abordados nesta tese, com novas propostas, sendo o método interactivo proposto aplicável a outros problemas de programação inteira mista multi-objectivo. Por último, é desenvolvida uma ferramenta de apoio à decisão para os problemas abordados nesta tese, sendo apresentada a metodologia adoptada e as suas principais funcionalidades. A ferramenta desenvolvida tem grandes preocupações com a interface de utilizador, visto ser direccionada para decisores que tipicamente não têm conhecimentos sobre os modelos matemáticos subjacentes a este tipo de problemas.This thesis main objective is to address the location-routing problem (LRP) which intends to tackle, using an integrated approach, two highly related logistics activities: the location of facilities and the distribution of materials. The LRP, namely its mathematical formulation, has been studied in the literature, and several approaches have emerged, corresponding to different real-world scenarios. Therefore, it is important to identify and group the different LRP variants, in order to segment current research and foster future studies. After presenting a review and a taxonomy of location-routing models, the following research focuses on solving some of its variants. Thus, a study of two of the most basic LRPs (capacitated problems with demand either on the nodes or on the arcs) is performed, and new approaches are presented. Afterwards, the location-routing of semi-obnoxious facilities is addressed. These are facilities that, although providing useful and indispensible services, given their nature, bring about an undesirable effect to adjacent communities. Consequently, to the usual objectives when considering their location (cost minimization), new ones must be added that are able to reflect concerns regarding the quality of life of the communities impacted by the outcome of these decisions. The location-routing of semi-obnoxious facilities therefore requires to be analysed using multi-objective approaches, which can be of two types: noninteractive or interactive. Both are discussed and new methods proposed in this thesis; the proposed interactive method is suitable to other multi-objective mixed integer programming problems. Finally, a newly developed decision-support tool to address the LRP is presented (being the adopted methodology discussed, and its main functionalities shown). This tool has great concerns regarding the user interface, as it is directed at decision makers who typically don’t have specific knowledge of the underlying models of this type of problems

An Application of an Unequal-Area Facilities Layout Problem with Fixed-Shape Facilities

The unequal-area facility layout problem (UA-FLP) is the problem of locating rectangular facilities on a rectangular floor space such that facilities do not overlap while optimizing some objective. The objective considered in this paper is minimizing the total distance materials travel between facilities. The UA-FLP considered in this paper considers facilities with fixed dimension and was motivated by the investigation of layout options for a production area at the Toyota Motor Manufacturing West Virginia (TMMWV) plant in Buffalo, WV, USA. This paper presents a mathematical model and a genetic algorithm for locating facilities on a continuous plant floor. More specifically, a genetic algorithm, which consists of a boundary search heuristic (BSH), a linear program, and a dual simplex method, is developed for an UA-FLP. To test the performance of the proposed technique, several test problems taken from the literature are used in the analysis. The results show that the proposed heuristic performs well with respect to solution quality and computational time

Applying the big bang-big crunch metaheuristic to large-sized operational problems

In this study, we present an investigation of comparing the capability of a big bang-big crunch metaheuristic (BBBC) for managing operational problems including combinatorial optimization problems. The BBBC is a product of the evolution theory of the universe in physics and astronomy. Two main phases of BBBC are the big bang and the big crunch. The big bang phase involves the creation of a population of random initial solutions, while in the big crunch phase these solutions are shrunk into one elite solution exhibited by a mass center. This study looks into the BBBC’s effectiveness in assignment and scheduling problems. Where it was enhanced by incorporating an elite pool of diverse and high quality solutions; a simple descent heuristic as a local search method; implicit recombination; Euclidean distance; dynamic population size; and elitism strategies. Those strategies provide a balanced search of diverse and good quality population. The investigation is conducted by comparing the proposed BBBC with similar metaheuristics. The BBBC is tested on three different classes of combinatorial optimization problems; namely, quadratic assignment, bin packing, and job shop scheduling problems. Where the incorporated strategies have a greater impact on the BBBC's performance. Experiments showed that the BBBC maintains a good balance between diversity and quality which produces high-quality solutions, and outperforms other identical metaheuristics (e.g. swarm intelligence and evolutionary algorithms) reported in the literature

Optimizing transportation systems and logistics network configurations : From biased-randomized algorithms to fuzzy simheuristics

242 páginasTransportation and logistics (T&L) are currently highly relevant functions in any competitive industry. Locating facilities or distributing goods to hundreds or thousands of customers are activities with a high degree of complexity, regardless of whether facilities and customers are placed all over the globe or in the same city. A countless number of alternative strategic, tactical, and operational decisions can be made in T&L systems; hence, reaching an optimal solution –e.g., a solution with the minimum cost or the maximum profit– is a really difficult challenge, even by the most powerful existing computers. Approximate methods, such as heuristics, metaheuristics, and simheuristics, are then proposed to solve T&L problems. They do not guarantee optimal results, but they yield good solutions in short computational times. These characteristics become even more important when considering uncertainty conditions, since they increase T&L problems’ complexity. Modeling uncertainty implies to introduce complex mathematical formulas and procedures, however, the model realism increases and, therefore, also its reliability to represent real world situations. Stochastic approaches, which require the use of probability distributions, are one of the most employed approaches to model uncertain parameters. Alternatively, if the real world does not provide enough information to reliably estimate a probability distribution, then fuzzy logic approaches become an alternative to model uncertainty. Hence, the main objective of this thesis is to design hybrid algorithms that combine fuzzy and stochastic simulation with approximate and exact methods to solve T&L problems considering operational, tactical, and strategic decision levels. This thesis is organized following a layered structure, in which each introduced layer enriches the previous one.El transporte y la logística (T&L) son actualmente funciones de gran relevancia en cual quier industria competitiva. La localización de instalaciones o la distribución de mercancías a cientos o miles de clientes son actividades con un alto grado de complejidad, indepen dientemente de si las instalaciones y los clientes se encuentran en todo el mundo o en la misma ciudad. En los sistemas de T&L se pueden tomar un sinnúmero de decisiones al ternativas estratégicas, tácticas y operativas; por lo tanto, llegar a una solución óptima –por ejemplo, una solución con el mínimo costo o la máxima utilidad– es un desafío realmente di fícil, incluso para las computadoras más potentes que existen hoy en día. Así pues, métodos aproximados, tales como heurísticas, metaheurísticas y simheurísticas, son propuestos para resolver problemas de T&L. Estos métodos no garantizan resultados óptimos, pero ofrecen buenas soluciones en tiempos computacionales cortos. Estas características se vuelven aún más importantes cuando se consideran condiciones de incertidumbre, ya que estas aumen tan la complejidad de los problemas de T&L. Modelar la incertidumbre implica introducir fórmulas y procedimientos matemáticos complejos, sin embargo, el realismo del modelo aumenta y, por lo tanto, también su confiabilidad para representar situaciones del mundo real. Los enfoques estocásticos, que requieren el uso de distribuciones de probabilidad, son uno de los enfoques más empleados para modelar parámetros inciertos. Alternativamente, si el mundo real no proporciona suficiente información para estimar de manera confiable una distribución de probabilidad, los enfoques que hacen uso de lógica difusa se convier ten en una alternativa para modelar la incertidumbre. Así pues, el objetivo principal de esta tesis es diseñar algoritmos híbridos que combinen simulación difusa y estocástica con métodos aproximados y exactos para resolver problemas de T&L considerando niveles de decisión operativos, tácticos y estratégicos. Esta tesis se organiza siguiendo una estructura por capas, en la que cada capa introducida enriquece a la anterior. Por lo tanto, en primer lugar se exponen heurísticas y metaheurísticas sesgadas-aleatorizadas para resolver proble mas de T&L que solo incluyen parámetros determinísticos. Posteriormente, la simulación Monte Carlo se agrega a estos enfoques para modelar parámetros estocásticos. Por último, se emplean simheurísticas difusas para abordar simultáneamente la incertidumbre difusa y estocástica. Una serie de experimentos numéricos es diseñada para probar los algoritmos propuestos, utilizando instancias de referencia, instancias nuevas e instancias del mundo real. Los resultados obtenidos demuestran la eficiencia de los algoritmos diseñados, tanto en costo como en tiempo, así como su confiabilidad para resolver problemas realistas que incluyen incertidumbre y múltiples restricciones y condiciones que enriquecen todos los problemas abordados.Doctorado en Logística y Gestión de Cadenas de SuministrosDoctor en Logística y Gestión de Cadenas de Suministro