Quantitative modelling approaches for lean manufacturing under uncertainty

[EN] Lean manufacturing (LM) applies different tools that help to eliminate waste as well as the opera-tions that do not add value to the product or processes to increase the value of each performedactivity. Here the main motivation is to study how quantitative modelling approaches can supportLM tools even under system and environment uncertainties. The main contributions of the articleare: (i) providing a systematic literature review of 99 works related to the modelling of uncertaintyin LM environments; (ii) proposing a methodology to classify the reviewed works; (iii) classifyingLM works under uncertainty; and (iv) identify quantitative models and their solution to deal withuncertainty in LM environments by identifying the main variables involved. Hence this article pro-vides a conceptual framework for future LM quantitative modelling under uncertainty as a guide foracademics, researchers and industrial practitioners. The main findings identify that LM under uncer-tainty has been empirically investigated mainly in the US, India and the UK in the automotive andaerospace manufacturing sectors using analytical and simulation models to minimise time and cost.Value stream mapping (VSM) and just in time (JIT) are the most used LM techniques to reduce wastein a context of system uncertainty.The research leading to these results received funding fromthe project 'Industrial Production and Logistics Optimizationin Industry 4.0' (i4OPT) (Ref. PROMETEO/2021/065) granted by the Valencian Regional Government; and grant PDC2022-133957-I00 funded by MCIN/AEI /10.13039/501100011033 and by European Union Next Generation EU/PRTR.Rojas, T.; Mula, J.; Sanchis, R. (2023). Quantitative modelling approaches for lean manufacturing under uncertainty. International Journal of Production Research. 1-27. https://doi.org/10.1080/00207543.2023.229313812

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

The agricultural policy simulator (AgriPoliS): an agent-based model to study structural change in agriculture (Version 1.0)

A central criticism common to agricultural economic modelling approaches for policy analysis is that they do not adequately take account of a number of characteristic factors of the agricultural sector. This concerns aspects like the immobility of land, heterogeneity of farms, interactions between farms, space, dynamic adjustment processes as well as dynamics of structural change. In brief, modelling the complexity of the system has not been at the centre of interest. In terms of modelling complex economic systems, an agent-based modelling approach is a suitable approach to quantitatively model and understand such systems in a more natural way. In the same way, this applies to the modelling of agricultural structures. In particular, agent-based models of agricultural structures allow for carrying out computer experiments to support a better understanding of the complexity of agricultural systems, structural change, and endogenous adjustment reactions in response to a policy change. This paper presents the agent-based model AgriPoliS (Agricultural Policy Simulator) which simultaneously considers a large number of individually acting farms, product markets, investment activity, as well as the land market, and a simple spatial representation. The ultimate objective of AgriPoliS is to study the interrelationship of rents, technical change, product prices, investments, production and policies, structural effects resulting from these, the analysis of the winners and losers of agricultural policy as well as the costs and efficiency of various policy measures. -- G E R M A N V E R S I O N: Ein oft genannter Kritikpunkt an vielen agrarökonomischen Politikanalysemodellen ist, dass diese nur ungenügend Bezug nehmen auf Aspekte wie die Immobilität von Boden, Heterogenität der Akteure, Interaktionen zwischen Betrieben, räumliche Bezüge, dynamische Anpassungsprozesse und Strukturwandel. Kurz, die Modellierung komplexer Wirkungszusammenhänge steht weniger oder nicht im Zentrum des Interesses. Agentenbasierte Modelle stellen einen Weg dar, das Verständnis komplexer ökonomischer Zusammenhänge zu verbessern bzw. zu quantifizieren. Insbesondere erlauben sie die Durchführung von einer Vielzahl von Computerexperimenten, mit denen Fragestellungen wie der Zusammenhang zwischen Politikmaßnahmen und Strukturwandel untersucht werden können. Basierend darauf, stellt dieser Beitrag das agentenbasierte Modell AgriPoliS (Agricultural Policy Simulator) vor. AgriPoliS ist ein räumlich-dynamisches Modell einer Agrarstruktur, in dem eine Vielzahl individuell abgebildeter landwirtschaftlicher Unternehmen in einer vereinfacht dargestellten Agrarregion agiert und beispielsweise um begrenzt verfügbare landwirtschaftliche Flächen konkurriert.Agent-based systems,Multi-agent systems,Policy analysis,Structural change,Simulation,Agentenbasierte Systeme,Politikanalyse,Multi-Agentensysteme,Strukturwandel,Simulation

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

Simulation-based optimisation of complex maintenance systems

There is a potential as well as a growing interest amongst researchers to utilise simulation in optimising maintenance systems. The state of the art in simulation-based optimisation of maintenance was established by systematically classifying the published literature and outlining main trends in modelling and optimising maintenance systems. In general, approaches to optimise maintenance varied significantly in the literature. Overall, these studies highlight the need for a framework that unifies the approach to optimising maintenance systems. Framework requirements were established through two main sources of published research. Surveys on maintenance simulation optimisation were examined to document comments on the approaches authors follow while optimising maintenance systems. In addition, advanced and future maintenance strategies were documented to ensure it can be accommodated in the proposed framework. The proposed framework was developed using a standard flowchart tool due to its familiarity and ability to depict decision structures clearly. It provides a systematic methodology that details the steps required to connect the simulation model to an optimisation engine. Not only it provides guidance in terms of formulating the optimal problem for the maintenance system at hand but it also provides support and assistance in defining the optimisation scope and investigating applicable maintenance strategies. Additionally, it considers current issues relating to maintenance systems both in research and in practice such as uncertainty, complexity and multi-objective optimisation. The proposed framework cannot be applied using existing approaches for modelling maintenance. Existing modelling approaches using simulation have a number of limitations: The maintenance system is modelled separately from other inter-related systems such as production and spare parts logistics. In addition, these approaches are used to model one maintenance strategy only. A novel approach for modelling maintenance using Discrete Event Simulation is proposed. The proposed approach enables the modelling of interactions amongst various maintenance strategies and their effects on the assets in non-identical multi-unit systems. Using the proposed framework and modelling approach, simulation-based optimisation was conducted on an academic case and two industrial cases that are varied in terms of sector, size, number of manufacturing processes and level of maintenance documentation. Following the structured framework enabled discussing and selecting the suitable optimisation scope and applicable maintenance strategies as well as formulating a customised optimal problem for each case. The results of the study suggest that over-looking the optimisation of maintenance strategies may lead to sub-optimal solutions. In addition, this research provides insights for non-conflicting objectives in maintenance systems

An Optimisation-based Framework for Complex Business Process: Healthcare Application

The Irish healthcare system is currently facing major pressures due to rising demand, caused by population growth, ageing and high expectations of service quality. This pressure on the Irish healthcare system creates a need for support from research institutions in dealing with decision areas such as resource allocation and performance measurement. While approaches such as modelling, simulation, multi-criteria decision analysis, performance management, and optimisation can – when applied skilfully – improve healthcare performance, they represent just one part of the solution. Accordingly, to achieve significant and sustainable performance, this research aims to develop a practical, yet effective, optimisation-based framework for managing complex processes in the healthcare domain. Through an extensive review of the literature on the aforementioned solution techniques, limitations of using each technique on its own are identified in order to define a practical integrated approach toward developing the proposed framework. During the framework validation phase, real-time strategies have to be optimised to solve Emergency Department performance issues in a major hospital. Results show a potential of significant reduction in patients average length of stay (i.e. 48% of average patient throughput time) whilst reducing the over-reliance on overstretched nursing resources, that resulted in an increase of staff utilisation between 7% and 10%. Given the high uncertainty in healthcare service demand, using the integrated framework allows decision makers to find optimal staff schedules that improve emergency department performance. The proposed optimum staff schedule reduces the average waiting time of patients by 57% and also contributes to reduce number of patients left without treatment to 8% instead of 17%. The developed framework has been implemented by the hospital partner with a high level of success

Life cycle cost modelling as an aircraft design decision support tool

This report summarizes the work that has been carried out as part of the FLAVIIR project, a 5 year research program looking at technologies for future unmanned air vehicles. A novel classification of aircraft product definition is utilised and a framework to estimate the life cycle cost of aircraft using the product definition is presented. The architecture to estimate the life cycle cost and the associated models are described.The acquisition costs are estimated using a hierarchical structure and a discrete simulation model is used to estimate the maintenance and operation costs. The acquisition cost model uses an object oriented approach with libraries of materials and processes integrated into the cost model. Risk analysis is performed to identify the important design parameters and uncertainty in the model. The acquisition cost model developed has the capability to estimate the costs of aircraft structures manufactured using metal-based materials as well as non-metal-based materials.The discrete event simulation model estimates the operation and maintenance costs of a fleet of aircraft using the mission characteristics, aircraft performance and the logistics data as input. The aircraft performance parameters are calculated by using aerodynamic analysis along with performance analysis models and the simulation model utilises a novel methodology to link aircraft performance with survivability analysis for estimating the maintenance costs.A framework is presented in which the cost models developed can be integrated into the conceptual design process to facilitate the comparison between different configurations. The usage of the life cycle cost framework as a decision support tool is outlined and three case studies are presented which include composites vs metals trade-off analysis, optimisation studies and web deployment for real time cost estimation. The novel contributions of this research are outlined and interesting avenues for future research that can be pursued are identified

An integrated operation and maintenance framework for offshore renewable energy

Offshore renewable devices hold a large potential as renewable energy sources, but their deployment costs are still too high compared to those of other technologies. Operation and maintenance, as well as management of the assets, are main contributors to the overall costs of the projects, and decision-support tools in this area are required to decrease the final cost of energy.\\ In this thesis a complete characterisation and optimisation framework for the operation, maintenance and assets management of an offshore renewable farm is presented. The methodology uses known approaches, based on Monte Carlo simulation for the characterisation of the key performance indicators of the offshore renewable farm, and genetic algorithms as a search heuristic for the proposal of improved strategies. These methods, coupled in an integrated framework, constitute a novel and valuable tool to support the decision-making process in this area. The methods developed consider multiple aspects for the accurate description of the problem, including considerations on the reliability of the devices and limitations on the offshore operations dictated by the properties of the maintenance assets. Mechanisms and constraints that influence the maintenance procedures are considered and used to determine the optimal strategy. The models are flexible over a range of offshore renewable technologies, and adaptable to different offshore farm sizes and layouts, as well as maintenance assets and configurations of the devices. The approaches presented demonstrate the potential for cost reduction in the operation and maintenance strategy selection, and highlight the importance of computational tools to improve the profitability of a project while ensuring that satisfactory levels of availability and reliability are preserved. Three case studies to show the benefits of application of such methodologies, as well as the validity of their implementation, are provided. Areas for further development are identified, and suggestions to improve the effectiveness of decision-making tools for the assets management of offshore renewable technologies are provided.European CommissionMojo Ocean Dynamics Ltd. T/A Mojo Maritime Lt

Optimising cost and availability estimates at the bidding stage of performance-based contracting

Performance-Based Contracting (PBC), e.g. Contracting for Availability (CfA), has been extensively applied in many industry sectors such as defence, aerospace and railway. Under PBC, complex support activities (e.g. maintenance, training, etc.) are outsourced, under mid to long term contracting arrangements, to maintain certain level of systems’ performance (e.g. availability). However, building robust cost and availability estimates is particularly challenging at the bidding stage because therei is lack of methods and limited availability of data for analysis. Driven by this contextual challenge this PhD aims to develop a process to simulate and optimise cost and availability estimates at the bidding stage of CfA. The research methodology follows a human-centred design approach, focusing on the end-user stakeholders. An interaction with seven manufacturing organisations involved in the bidding process of CfA enabled to identify the state-of-practice and the industry needs, and a review of literature in PBC and cost estimation enabled to identify the research gaps. A simulation model for cost and availability trade-off and estimation (CATECAB) has been developed, to support cost engineers during the bidding preparation. Also, a multi-objective genetic algorithm (EMOGA) has been developed to combine with the CATECAB and build a cost and availability estimation and optimisation model (CAEOCAB). Techniques such as Monte-Carlo simulation, bootstrapping resampling, multi-regression analysis and genetic algorithms have been applied. This model is able to estimate the optimal investment in the attributes that impact the availability of the systems, according to total contract cost, availability and duration targets. The validation of the models is performed by means of four case studies with twenty-one CfA scenarios, in the maritime and air domains. The outcomes indicate a representable accuracy for the estimates produced by the models, which has been considered suitable for the early stages of the bidding process

Aeronautical life-cycle mission modelling framework for conceptual design

This thesis introduces a novel framework for life cycle mission modelling during conceptual aeronautical design. The framework supports object-oriented mission definition using Geographical Information System technology. Design concepts are defined generically, enabling simulation of most aeronautical vessels and many non-aeronautical vehicles. Moreover, the framework enables modelling of entire vessel fleets, business competitors and dynamic operational changes throughout a vessel life cycle. Vessels consist of components deteriorating over time. Vessels carry payload that operates within the vessel environment.An agent-based simulation model implements most framework features. It is the first use of an agent-based simulation utilising a Geographical Information System during conceptual aeronautical design. Two case studies for unmanned aircraft design apply the simulation. The first case study explores how the simulation supports conceptual design phase decisions. It simulates four different unmanned aircraft concepts in a search-and-rescue scenario including lifeboats. The goal is to learn which design best improves life cycle search performance. It is shown how operational and geographical impacts influence design decision making by generating novel performance information. The second case study studies the simulation optimisation capability: an existing aircraft design is modified manually based on simulation outputs. First, increasing the fuel tank capacity has a negative effect on life cycle performance due to mission constraints. Therefore, mission definition becomes an optimisation parameter. Changing mission flight speeds during specific segments leads to an overall improved design