An Aggregated Optimization Model for Multi-Head SMD Placements

In this article we propose an aggregate optimization approach by formulating the multi-head SMD placement optimization problem into a mixed integer program (MIP) with the variables based on batches of components. This MIP is tractable and effective in balancing workload among placement heads, minimizing the number of nozzle exchanges, and improving handling class. The handling class which specifies the traveling speed of the robot arm, to the best of our knowledge, has been for the first time incorporated in an optimization model. While the MIP produces an optimal planning for batches of components, a new sequencing heuristics is developed in order to determine the final sequence of component placements based on the outputs of the MIP. This two-stage approach guarantees a good feasible solution to the multi-head SMD placement optimization problem. The computational performance is examined using real industrial data.Multi-head surface mounting device;Component placement;Variable placement speed

An MILP model and a hybrid evolutionary algorithm for integrated operation optimisation of multi-head surface mounting machines in PCB assembly

This paper focuses on an operation optimisation problem for a class of multi-head surface mounting machines in printed circuit board assembly lines. The problem involves five interrelated sub-problems: assigning nozzle types as well as components to heads, assigning feeders to slots and determining component pickup and placement sequences. According to the depth of making decisions, the sub-problems are first classified into two layers. Based on the classification, a two-stage mixed-integer linear programming (MILP) is developed to describe it and a two-stage problem-solving frame with a hybrid evolutionary algorithm (HEA) is proposed. In the first stage, a constructive heuristic is developed to determine the set of nozzle types assigned to each head and the total number of assembly cycles; in the second stage, constructive heuristics, an evolutionary algorithm with two evolutionary operators and a tabu search (TS) with multiple neighbourhoods are combined to solve all the sub-problems simultaneously, where the results obtained in the first stage are taken as constraints. Computational experiments show that the HEA can obtain good near-optimal solutions for small size instances when compared with an optimal solver, Cplex, and can provide better results when compared with a TS and an EA for actual instances

Algorithmic Solutions for Combinatorial Problems in Resource Management of Manufacturing Environments

This thesis studies the use of heuristic algorithms in a number of combinatorial problems that occur in various resource constrained environments. Such problems occur, for example, in manufacturing, where a restricted number of resources (tools, machines, feeder slots) are needed to perform some operations. Many of these problems turn out to be computationally intractable, and heuristic algorithms are used to provide efficient, yet sub-optimal solutions. The main goal of the present study is to build upon existing methods to create new heuristics that provide improved solutions for some of these problems. All of these problems occur in practice, and one of the motivations of our study was the request for improvements from industrial sources. We approach three different resource constrained problems. The first is the tool switching and loading problem, and occurs especially in the assembly of printed circuit boards. This problem has to be solved when an efficient, yet small primary storage is used to access resources (tools) from a less efficient (but unlimited) secondary storage area. We study various forms of the problem and provide improved heuristics for its solution. Second, the nozzle assignment problem is concerned with selecting a suitable set of vacuum nozzles for the arms of a robotic assembly machine. It turns out that this is a specialized formulation of the MINMAX resource allocation formulation of the apportionment problem and it can be solved efficiently and optimally. We construct an exact algorithm specialized for the nozzle selection and provide a proof of its optimality. Third, the problem of feeder assignment and component tape construction occurs when electronic components are inserted and certain component types cause tape movement delays that can significantly impact the efficiency of printed circuit board assembly. Here, careful selection of component slots in the feeder improves the tape movement speed. We provide a formal proof that this problem is of the same complexity as the turnpike problem (a well studied geometric optimization problem), and provide a heuristic algorithm for this problem.Siirretty Doriast

Construction of a 3D Object Recognition and Manipulation Database from Grasp Demonstrations

Object recognition and manipulation are critical for enabling robots to operate within a household environment. There are many grasp planners that can estimate grasps based on object shape, but these approaches often perform poorly because they miss key information about non-visual object characteristics, such as weight distribution, fragility of materials, and usability characteristics. Object model databases can account for this information, but existing methods for constructing 3D object recognition databases are time and resource intensive, often requiring specialized equipment, and are therefore difficult to apply to robots in the field. We present an easy-to-use system for constructing object models for 3D object recognition and manipulation made possible by advances in web robotics. The database consists of point clouds generated using a novel iterative point cloud registration algorithm, which includes the encoding of manipulation data and usability characteristics. The system requires no additional equipment other than the robot itself, and non-expert users can demonstrate grasps through an intuitive web interface with virtually no training required. We validate the system with data collected from both a crowdsourcing user study and a set of grasps demonstrated by an expert user. We show that the crowdsourced grasps can produce successful autonomous grasps, and furthermore the demonstration approach outperforms purely vision-based grasp planning approaches for a wide variety of object classes

Optimal scope of supply chain network & operations design

The increasingly complex supply chain networks and operations call for the development of decision support systems and optimization techniques that take a holistic view of supply chain issues and provide support for integrated decision-making. The economic impacts of optimized supply chain are significant and that has attracted considerable research attention since the late 1990s. This doctoral thesis focuses on developing manageable and realistic optimization models for solving four contemporary and interrelated supply chain network and operations design problems. Each requires an integrated decision-making approach for advancing supply chain effectiveness and efficiency. The first model formulates the strategic robust downsizing of a global supply chain network, which requires an integrated decision-making on resource allocation and network reconfiguration, given certain financial constraints. The second model also looks at the strategic supply chain downsizing problem but extends the first model to include product portfolio selection as a downsizing decision. The third model concerns the redesign of a warranty distribution network, which requires an integrated decision-making on strategic network redesign and tactical recovery process redesign. The fourth model simultaneously determines the operational-level decisions on job assignment and process sequence in order to improve the total throughput of a production facility unit

Optimization of product assignment to assembly lines

Dissertação de mestrado em Industrial engineering and ManagementThe work presented in this dissertation was developed in an industrial context integrated in the production control and management department of the Bosch Car Multimedia Portugal S.A – Braga automatic insertion. The problem addressed in this dissertation was finding the best distribution of product families to assign in different lines according to the physical and technical constraints of the assembly lines. In the approach of the problem, it was used tools and techniques of the Operational Research discipline through mathematical modeling, in order to analyze complex situation and obtain more efficient solutions to help in the decision-making process. Based on production data, production needs forecasts and assembly line physical availability, models with different sets of constraints and objective functions were created to present solutions that best fit the question and the specific problem of the present production context. Through specific software that suited the problem, the previously created models were solved, and the solutions were analyzed and evaluated to suit the company’s current needs and for possible and feasible implementation of the solutions.O trabalho apresentado nesta dissertação foi desenvolvido em contexto industrial integrado no departamento de planeamento e controlo de produção da área de inserção automática da Bosch Car Multimédia Portugal S.A - Braga. O problema abordado nesta dissertação foi encontrar a melhor distribuição de famílias de produtos a alocar nas diferentes linhas de produção de acordo com as suas restrições físicas e técnicas. Na abordagem do problema recorreu-se a técnicas de Investigação Operacional através de modelação matemática, para analisar situações complexas e obter soluções mais eficientes. Tendo como base dados da produção, previsões de necessidades e disponibilidade física da produção, foram criados modelos com diferentes conjuntos de restrições e funções objetivo por forma a apresentar soluções que melhor se adequassem à pergunta e ao problema específico do contexto produtivo presente. Através da utilização de software, foram resolvidos os modelos criados anteriormente, sendo que as soluções foram analisadas e avaliadas para a adequação às necessidades atuais da empresa e para a sua possível e viável implementação

Unlocking Carbon Reduction Potential with Reinforcement Learning for the Three-Dimensional Loading Capacitated Vehicle Routing Problem

Heavy goods vehicles are vital backbones of the supply chain delivery system but also contribute significantly to carbon emissions with only 60% loading efficiency in the United Kingdom. Collaborative vehicle routing has been proposed as a solution to increase efficiency, but challenges remain to make this a possibility. One key challenge is the efficient computation of viable solutions for co-loading and routing. Current operations research methods suffer from non-linear scaling with increasing problem size and are therefore bound to limited geographic areas to compute results in time for day-to-day operations. This only allows for local optima in routing and leaves global optimisation potential untouched. We develop a reinforcement learning model to solve the three-dimensional loading capacitated vehicle routing problem in approximately linear time. While this problem has been studied extensively in operations research, no publications on solving it with reinforcement learning exist. We demonstrate the favourable scaling of our reinforcement learning model and benchmark our routing performance against state-of-the-art methods. The model performs within an average gap of 3.83% to 8.10% compared to established methods. Our model not only represents a promising first step towards large-scale logistics optimisation with reinforcement learning but also lays the foundation for this research stream

Estimating the production time of a PCB assembly job without solving the optimised machine control

Production planning and control of the printed circuit board (PCB) assembly includes several decisions dealing with, for example, grouping of PCB jobs, allocation of PCB batches to machine lines, sequencing of batches and load balancing of lines. The production time of a PCB job for a given placement machine is a key factor in this context and it must be quickly and accurately estimated, possibly millions of times in a single planning task, to avoid erroneous decisions. The commonly used nominal tact time-based estimators are very rough and the machine simulators too slow. Therefore, the purpose of this study is to give better machine-specific estimators that avoid the construction the actual machine control program. Two new estimators are proposed for gantry machines, one based on the information given by the manufacturer about the operations of the placement head, and the other on the regularised least-squares regression method trained with a set of PCB placement jobs. In practical evaluation with 95 PCB jobs, the mean absolute percentage error of the first and second methods are 3.75% and 6.52%, respectively, while that of the tact time-based approach is more than 17%. This indicates a great potential of the proposed methods as production time estimators.</p