QUALITY ANALYSIS IN FLEXIBLE MANUFACTURING SYSTEMS WITH BATCH PRODUCTIONS

To improve product quality and reduce cost, batch production is often implemented in many exible manufacturing systems. However, the current literature does not provide any method to analyze the quality performance in a flexible manufacturing system with batch production. In this research, we present an analytical method with closed-form formula to evaluate the quality performance in such systems. Based on the model, we discover and investigate monotonic and non-monotonic properties in quality to provide practical guidance for operation management. To improve product quality, we introduce the notions of quality improvability with respect to product sequencing. In addition, we develop the indicators for quality improvability based on the data available on the factory floor rather than complicated calculations. We define the bottleneck sequence and bottleneck transition as the ones that impede quality in the strongest manner, investigate the sensitivity of quality performance with respect to sequences and transitions, and propose quality bottleneck sequence and transition indicators based on the measured data. Finally, we provide a case study at an automotive paint shop to show how this method is applied to improve paint quality. Moreover, we explore a potential application to reduce energy consumption and atmospheric emissions at automotive paint shops. By selecting appropriate batch and sequence policies, the paint quality can be improved and repaints can be reduced so that less material and energy will be consumed, and less atmospheric emissions will be generated. It is shown that such scheduling and control method can lead to significant energy savings and emission reduction with no extra investment nor changes to existing painting processes. The successful development of such method would open up a new area in manufacturing systems research and contribute to establish a solid foundation for an integrated study on productivity, quality and exibility. In addition, it will provide production engineers and operation managers a quantitative tool for continuous improvement on product quality in flexible manufacturing environmen

Agent and cyber-physical system based self-organizing and self-adaptive intelligent shopfloor

The increasing demand of customized production results in huge challenges to the traditional manufacturing systems. In order to allocate resources timely according to the production requirements and to reduce disturbances, a framework for the future intelligent shopfloor is proposed in this paper. The framework consists of three primary models, namely the model of smart machine agent, the self-organizing model, and the self-adaptive model. A cyber-physical system for manufacturing shopfloor based on the multiagent technology is developed to realize the above-mentioned function models. Gray relational analysis and the hierarchy conflict resolution methods were applied to achieve the self-organizing and self-adaptive capabilities, thereby improving the reconfigurability and responsiveness of the shopfloor. A prototype system is developed, which has the adequate flexibility and robustness to configure resources and to deal with disturbances effectively. This research provides a feasible method for designing an autonomous factory with exception-handling capabilities

An agent-based simulator for quantifying the cost of uncertainty in production systems

Product-mix problems, where a range of products that generate different incomes compete for a limited set of production resources, are key to the success of many organisations. In their deterministic forms, these are simple optimisation problems; however, the consideration of stochasticity may turn them into analytically and/or computationally intractable problems. Thus, simulation becomes a powerful approach for providing efficient solutions to real-world productmix problems. In this paper, we develop a simulator for exploring the cost of uncertainty in these production systems using Petri nets and agent-based techniques. Specifically, we implement a stochastic version of Goldratt’s PQ problem that incorporates uncertainty in the volume and mix of customer demand. Through statistics, we derive regression models that link the net profit to the level of variability in the volume and mix. While the net profit decreases as uncertainty grows, we find that the system is able to effectively accommodate a certain level of variability when using a Drum-Buffer-Rope mechanism. In this regard, we reveal that the system is more robust to mix than to volume uncertainty. Later, we analyse the cost-benefit trade-off of uncertainty reduction, which has important implications for professionals. This analysis may help them optimise the profitability of investments. In this regard, we observe that mitigating volume uncertainty should be given higher consideration when the costs of reducing variability are low, while the efforts are best concentrated on alleviating mix uncertainty under high costs.This article was financially supported by the State Research Agency of the Spanish Ministry of Science and Innovation (MCIN/AEI/ 10.13039/50110 0 011033), via the project SPUR, with grant ref. PID2020–117021GB-I00. In addition, the authors greatly appreciate the valuable and constructive feedback received from the Editorial team of this journal and two anonymous reviewers in the different stages of the review process

Modeling, design and scheduling of computer integrated manufacturing and demanufacturing systems

This doctoral dissertation work aims to provide a discrete-event system-based methodology for design, implementation, and operation of flexible and agile manufacturing and demanufacturing systems. After a review of the current academic and industrial activities in these fields, a Virtual Production Lines (VPLs) design methodology is proposed to facilitate a Manufacturing Execution System integrated with a shop floor system. A case study on a back-end semiconductor line is performed to demonstrate that the proposed methodology is effective to increase system throughput and decrease tardiness. An adaptive algorithm is proposed to deal with the machine failure and maintenance. To minimize the environmental impacts caused by end-of-life or faulty products, this research addresses the fundamental design and implementation issues of an integrated flexible demanufacturing system (IFDS). In virtue of the success of the VPL design and differences between disassembly and assembly, a systematic approach is developed for disassembly line design. This thesis presents a novel disassembly planning and demanufacturing scheduling method for such a system. Case studies on the disassembly of personal computers are performed illustrating how the proposed approaches work

Multi Site Coordination using a Multi-Agent System

A new approach of coordination of decisions in a multi site system is proposed. It is based this approach on a multi-agent concept and on the principle of distributed network of enterprises. For this purpose, each enterprise is defined as autonomous and performs simultaneously at the local and global levels. The basic component of our approach is a so-called Virtual Enterprise Node (VEN), where the enterprise network is represented as a set of tiers (like in a product breakdown structure). Within the network, each partner constitutes a VEN, which is in contact with several customers and suppliers. Exchanges between the VENs ensure the autonomy of decision, and guarantiee the consistency of information and material flows. Only two complementary VEN agents are necessary: one for external interactions, the Negotiator Agent (NA) and one for the planning of internal decisions, the Planner Agent (PA). If supply problems occur in the network, two other agents are defined: the Tier Negotiator Agent (TNA) working at the tier level only and the Supply Chain Mediator Agent (SCMA) working at the level of the enterprise network. These two agents are only active when the perturbation occurs. Otherwise, the VENs process the flow of information alone. With this new approach, managing enterprise network becomes much more transparent and looks like managing a simple enterprise in the network. The use of a Multi-Agent System (MAS) allows physical distribution of the decisional system, and procures a heterarchical organization structure with a decentralized control that guaranties the autonomy of each entity and the flexibility of the network

Manufacturing Systems Line Balancing using Max-Plus Algebra

In today\u27s dynamic environment, particularly the manufacturing sector, the necessity of being agile, and flexible is far greater than before. Decision makers should be equipped with effective tools, methods, and information to respond to the market\u27s rapid changes. Modelling a manufacturing system provides unique insight into its behavior and allows simulating all crucial elements that have a role in the system performance. Max-Plus Algebra is a mathematical tool that can model a Discrete Event Dynamic System in the form of linear equations. Whereas Max-Plus Algebra was introduced after the 1980s, the number of studies regarding this tool and its applications is fewer than regarding Petri Nets, Automata, Markov process, Discrete Even Simulation and Queuing models. Consequently, Max-Plus Algebra needs to be applied and tested in many systems in order to explore hidden aspects of its function and capabilities. To work effectively; the production/assembly line should be balanced. Line balancing is one of the manufacturing functions that tries to divide work equally across the production flow. Car Headlight Manufacturing Line as a Discrete Manufacturing System is considered which is a combination of manufacturing and assembly lines composed of different stations. Seven system scenarios were modeled and analyzed using Max-Plus to balance the car headlights production line. Key Performance Indicators (KPIs) are used to compare the various scenarios including Cycle Time, Average Deliver Rate, Total Processing Lead Time, Stations\u27 Utilization Rate, Idle Time, Efficiency, and Financial Analysis. FlexSim simulation software is used to validate the Max-Plus models results and its advantages and drawbacks compared with Max-Plus Algebra. This study is a unique application of Max-Plus Algebra in line balancing of a manufacturing system. Moreover, the problem size of the considered model is at least twice (12 stations) that of previous studies. In the matter of complexity, seven different scenarios are developed through the combination of parallel stations and buffers. Due to that the last scenario is included four parallel stations plus two buffers Based on the findings, the superiority of scenario 7 compared to other scenarios is proved due to its lowest system delivering first output time (14 seconds), best average delivery rate (24.5 seconds), shortest cycle time (736 seconds), shortest total processing lead time (11,534 seconds), least percentage of idle time (12%), lowest unit cost ($6.9), and highest efficiency (88%). However, Scenario 4 has the best utilization rate at 75%

Modelling and condition-based control of a flexible and hybrid disassembly system with manual and autonomous workstations using reinforcement learning

Remanufacturing includes disassembly and reassembly of used products to save natural resources and reduce emissions. While assembly is widely understood in the field of operations management, disassembly is a rather new problem in production planning and control. The latter faces the challenge of high uncertainty of type, quantity and quality conditions of returned products, leading to high volatility in remanufacturing production systems. Traditionally, disassembly is a manual labor-intensive production step that, thanks to advances in robotics and artificial intelligence, starts to be automated with autonomous workstations. Due to the diverging material flow, the application of production systems with loosely linked stations is particularly suitable and, owing to the risk of condition induced operational failures, the rise of hybrid disassembly systems that combine manual and autonomous workstations can be expected. In contrast to traditional workstations, autonomous workstations can expand their capabilities but suffer from unknown failure rates. For such adverse conditions a condition-based control for hybrid disassembly systems, based on reinforcement learning, alongside a comprehensive modeling approach is presented in this work. The method is applied to a real-world production system. By comparison with a heuristic control approach, the potential of the RL approach can be proven simulatively using two different test cases

A Strategic Approach for Bottleneck Identification in Make-To-Order Environments: A Drum-Buffer-Rope Action Research Based Case Study

Purpose: This study focused on providing a strategic perspective for the selection and exploitation of bottlenecks in make-to-order production systems, a largely unexplored field in the literature. The researchers developed a systematic decision-making process that operationalized the first two stages of Goldratt’s drum-buffer-rope methodology. This process was derived from the seminal work of Goldratt, who introduced key insights from the resource-based view and practice-based view strategic perspectives. The process also included original contributions from the authors to understand which purpose should be fulfilled, what decisions should be made and how the process should be applied in an operative way. Design/methodology/approach: Given the practical nature of the research project, action research was an appropriate methodological approach, since this approach aims to contribute to academic research while solving real-world problems. Additionally, the research process complied with necessary criteria to assure the research quality required for action research. Findings: The systematic process was successfully tested by means of a case study on a make-to-order company. This case study answered the research question regarding systematically selecting and exploiting a bottleneck to enhance competitive advantage/firm performance. Originality/value: The key contributions focused on the make-to-order environment and were as it follows: (1) four specific criteria to select the bottleneck, far beyond a load versus capacity perspective (i.e., a strategic perspective inspired by the main concepts of the resource-based view regarding the contribution of strategic resources to sustain competitive advantage). A first case study presenting a partial version of this contribution has been discussed on a previous publication of the authors (Lizarralde, Apaolaza, & Mediavilla, 2019b), which describes the case of production plant of a company dedicated to producing steel tubes by extrusion; (2) a detailed discussion on how to exploit the bottleneck aligned with the practice-based view, which recognised that practices could provide superior performance to organisations; and (3) an overarching systematic process that enables an operative deployment in the specific steps to select strategically the bottleneck and exploit this constraint according to some of Goldratt’s seminal proposals