Aerospace Manufacturing Industry: A Simulation-Based Decision Support Framework for the Scheduling of Complex Hoist Lines

The hoist scheduling problem is a critical issue in the design and control of Automated Manufacturing Systems. To deal with the major complexities appearing in such problem, this work introduces an advanced simulation model to represent the short-term scheduling of complex hoist lines. The aim is to find the best jobs schedule that minimizing the makespan while maximizing throughput with no defective outputs. Several hard constraints are considered in the model: single shared hoist, heterogeneous recipes, eventual recycles flows, and no buffers between workstations. Different heuristic-based strategies are incorporated into the computer model in order to improve the solutions generated over time. The alternative solutions can be quickly evaluated by using a graphical user interface developed together with the simulation model.Fil: Basán, Natalia Paola. Consejo Nacional de Investigaciones Científicas y Técnicas. Centro Científico Tecnológico Conicet - Santa Fe. Instituto de Desarrollo Tecnológico para la Industria Química. Universidad Nacional del Litoral. Instituto de Desarrollo Tecnológico para la Industria Química; ArgentinaFil: Pulido, Raul. Universidad Politécnica de Madrid; EspañaFil: Coccola, Mariana Evangelina. Consejo Nacional de Investigaciones Científicas y Técnicas. Centro Científico Tecnológico Conicet - Santa Fe. Instituto de Desarrollo Tecnológico para la Industria Química. Universidad Nacional del Litoral. Instituto de Desarrollo Tecnológico para la Industria Química; ArgentinaFil: Mendez, Carlos Alberto. Consejo Nacional de Investigaciones Científicas y Técnicas. Centro Científico Tecnológico Conicet - Santa Fe. Instituto de Desarrollo Tecnológico para la Industria Química. Universidad Nacional del Litoral. Instituto de Desarrollo Tecnológico para la Industria Química; Argentin

Demand Reduction and Responsive Strategies for Underground Mining

This thesis presents a demand reduction and responsive strategy for underground mining operations. The thesis starts with a literature review and background research on global energy, coal mining and the energy related issues that the mining industry face everyday. The thesis then goes on to discuss underground mine electrical power systems, data acquisition, load profiling, priority ranking, load shedding and demand side management in mining. Other areas presented in this thesis are existing energy reduction techniques, including: high efficiency motors, motor speed reduction and low energy lighting. During the thesis a data acquisition system was designed and installed at a UK Coal colliery and integrated into the mines existing supervisory control and data acquisition (SCADA) system. Design and installation problems were overcome with the construction of a test meter and lab installation and testing. A detailed explanation of the system design and installation along with the data analysis of the data from the installed system. A comprehensive load profile and load characterisation system was developed by the author. The load profiling system is comprehensive allows the definition of any type of load profile. These load profiles are fixed, variable and transient load types. The loads output and electrical demand are all taken into consideration. The load characterisation system developed is also very comprehensive. The LC MATRIX is used with the load profiles and the load characteristics to define off-line schedules. A set of unique real-time decision algorithms are also developed by the author to operate the off-line schedules within the desired objective function. MATLAB Simulation is used to developed and test the systems. Results from these test are presented. Application of the developed load profiling and scheduling systems are applied to the data collected from the mine, the results of this and the cost savings are also presented

Methodological study on technology integration for sustainable manufacturing in the surface finishing industry

Today, industries explore advanced techniques to enhance their development efforts to meet the goals of sustainability due to various challenges which is caused by industrial globalization, high energy and raw material costs, increased environmental regulations and social pressures, and new technological innovations. In order for an industrial process to become sustainable, it is essential to improve the process inputs efficiency from raw materials and energy while maintaining highest productivity and quality; in addition to, minimizing waste generation and the impact on the environment. Engaging in industrial sustainability requires major efforts from decision makers to implement advanced technologies to satisfy each triple bottom line of sustainability. Due to the complexity of industrial systems and lack of quantifiable mechanisms to assess sustainability triple bottom lines, decision makers are facing a very difficult task to solve. In this research a holistic methodology for sustainability assessment and decision-making is developed, which will assist in improving the sustainability level through implementing and integrating sustainable technologies in manufacturing systems through case studies, particularly on the electroplating industry. The methodology is general but our intent is to apply it to electroplating metal substrate processes. This research is valuable in its methodological contribution for sustainability assessment, decision-making, and technology quantification via known and well established sustainability metrics to assist decision makers to identify desired technologies needed for improving overall industrial sustainability development. This methodology is applicable for any type of industrial system of any complexity, and its efficacy is demonstrated in a case study identifying desired technologies and their implementation for achieving an overall sustainable level enhancement. Moreover, a computer aided computational tool is developed for industry forecasters to assess their current industrial sustainability and determine future sustainability goals in a quantitative manner using an interactive graphical user interface. To the best of our knowledge the introduced concept of technology integrated sustainability enhancement (TISE) holistic approach is the first to be used to effectively enhance the overall industrial system sustainability by evaluating each technology or suite of technologies based on strategically selected indicators and combined benefits methodology assessment. Furthermore, an optimization based approach was introduced for a proficient sustainability assessment of industrial systems via technology integration. Another major contribution in this research is the development of an industrial sustainability assessment program using LabView software and Matlab programming tools to assess the sustainability of various technology options. The assessment results from this program provide different technology integration options and alternatives which can be compared in terms of sustainability triple bottom lines, overall sustainability performance, and the optimum solution can be identified as the one yielding to the highest sustainability value depending on budget cost limitation to implement those technologies

Performance Evaluation of Surface Mining Equipment with Particular Reference to Shovel-Dumper Mining

Surface mining is the most well-known mining around the world, and open pit mining accounts for more than 60% of all surface yield. Haulage costs represent as much as 60% of the aggregate working expense for these type of mines, so it is desirable to keep up an effective haulage framework. Equipment availability and estimation of utilization very precisely which is very important since mine manager wants to utilize their equipment as effectively as possible to get an early return of their investment as well as reducing total production cost. In present situation to achieve high production and productivity of HEMMs in opencast mines, it is desired to have high % availability and % utilization of equipment besides ensure overall equipment effectiveness as per CMPDI norms/global bench marks. OEE shows that how an equipment is utilized with its maximum effectiveness. It uses parameters like availability, performance and utilization for the estimation of equipment effectiveness. One method for effectively use of equipment in haul cycle is queuing theory. Queuing theory was developed to model systems that provide service for randomly arising demands and predict the behaviour of such systems. A queuing system is one in which customers arrive for service, wait for service if it is not immediately available, and move on to the next server or exit the system once they have been serviced. Most mining haul routes consist of four main components: loading, loaded hauling, dumping, and unloaded hauling to return to the loader. These components can be modelled together as servers in one cyclic queuing network, or independently as individual service channels. Data from a large open pit mine are analysed and applied to a multichannel queuing model representative of the loading process of the haul cycle. The outputs of the model are compared against the actual dumper data to evaluate the validity of the queuing model developed

Optimisation approaches for supply chain planning and scheduling under demand uncertainty

This work presents efficient MILP-based approaches for the planning and scheduling of multiproduct multistage continuous plants with sequence-dependent changeovers in a supply chain network under demand uncertainty and price elasticity of demand. This problem considers multiproduct plants, where several products must be produced and delivered to supply the distribution centres (DCs), while DCs are in charge of storing and delivering these products to the final markets to be sold. A hybrid discrete/continuous model is proposed for this problem by using the ideas of the Travelling Salesman Problem (TSP) and global precedence representation. In order to deal with the uncertainty, we proposed a Hierarchical Model Predictive Control (HMPC) approach for this particular problem. Despite of its efficiency, the final solution reported still could be far from the global optimum. Due to this, Local Search (LS) algorithms are developed to improve the solution of HMPC by rescheduling successive products in the current schedule. The effectiveness of the proposed solution techniques is demonstrated by solving a large-scale instance and comparing the solution with the original MPC and a classic Cutting Plane approach adapted for this work

Optimization of yard operations in container terminals from an energy efficiency approach

This Thesis addresses common operational issues related to maritime container terminals. In the last decades, containerization of maritime transportation has grown very rapidly, forcing terminal operators to cope with unprecedented volumes of containers in a continuous manner. As a consequence, terminal efficiency is always a critical factor. In the near future, operators are also expected to face increasing operational costs deriving firstly from the energy crisis and secondly from new regulations enforcing ports to become more environmentally friendly. As a consequence, operational inefficiencies deriving from periods of congestion require innovative solutions and optimization techniques to improve the efficiency and productivity in the terminal yard. This Thesis addresses such problems by introducing an electric energy consumption model that characterizes energy expenditure of yard cranes. For each gantry, trolley and hoist movement of the cranes, the model takes into account the different resistances that must be overcome during the acceleration, constant speed and deceleration phases of each movement. The energy consumption model is coupled to two different discrete event simulation models of one parallel and one perpendicular container terminals, with the goal to analyze the handling operations and optimize energy efficiency and productivity. One additional innovative aspect of the works is that they include the effect of the volume of container traffic in the analysis with the aim to assess differences in the performance of the algorithms under a range of realistic scenarios, which is usually neglected in similar studies. Finally, in addition to stacking and retrieval operations, the works also introduce housekeeping operation, which are common in the real world but often disregarded in the literature. Such operations are relevant as they may be critical in terms of achieving good productivity, but on the other hand they amount for a significant portion of the overall energy consumption. In particular, the works of the Thesis deal have four particular objectives: (1) providing such flexible and customizable numerical models of discrete event type to simulate and analyze parallel and perpendicular terminals, (2) proposing a new stacking algorithm to reduce energy expenditure and improve automatic stacking crane productivity in perpendicular terminals; (3) optimizing the dimensions of a perpendicular layout; and (4) analyzing the distribution of containers in the yard layout as a function of the moment at which space for export containers is reserved while looking at the operational costs. In the first place, results show the models are capable of characterizing in detail the energy consumption associated to crane movements in both parallel and perpendicular terminals. With respect to perpendicular terminals, the proposed stacking algorithm is capable of improving the energy efficiency up to around 20% while achieving greater productivity at the same time. In addition, results show that the dimensions of a perpendicular terminal block can be optimized so as to improve the productivity; with respect to energy consumption, although a smaller block induces lesser electrical consumption, the random nature of housekeeping operations produce a significant degree of distortion in the results, revealing that such operations constitute a promising flied for future research. Finally, considering parallel terminals, a greater degree of clustering is observed as the reservation is made earlier. When considering the associated operational costs associated to yard cranes and yard trucks, greater clustering results in more efficient use of the energy, and therefore reservation may be desirable when possible to enhance terminal productivity.Esta Tesis aborda temas operativos comunes relacionados con terminales marítimas de contenedores. En las últimas décadas, la contenerización del transporte marítimo ha crecido exponencialmente, obligando a los operadores a hacer frente a volúmenes de contenedores sin precedentes de manera continuada. Como consecuencia, la eficiencia de las operaciones es siempre un factor crítico. En un futuro próximo, los operadores también deberán afrontar crecientes costes operativos derivados de la crisis energética, y también de nuevas regulaciones que obligan a los puertos a volverse más respetuosos con el medio ambiente. Por estos motivos, las ineficiencias operativas derivadas de períodos de congestión requieren soluciones innovadoras y técnicas de optimización para mejorar la eficiencia y productividad en los patios de contenedores. Esta tesis aborda estos problemas introduciendo un modelo de consumo de energía eléctrica que caracteriza el gasto de las grúas de patio. Para cada movimiento de "gantry", "hoist" y "spreader", el modelo tiene en cuenta las diferentes resistencias que deben superarse durante las fases de aceleración, velocidad constante y deceleración del movimiento. El modelo de consumo de energía se ha acoplado a dos modelos de simulación de eventos discretos de terminales de contenedores, una paralela y otra perpendicular, con el objetivo de analizar las operaciones de manipulación y optimizar la eficiencia energética y la productividad. Otro aspecto innovador de este trabajo es que analiza el efecto del volumen de tráfico de contenedores con el objetivo de evaluar el comportamiento de los algoritmos bajo un rango de escenarios realistas, lo que generalmente no se tiene en cuenta en estudios similares. Por último, además de las operaciones de apilamiento y salida de contenedores, la tesis también considera las operaciones de reordenamiento del patio, muy comunes en el mundo real, pero que a menudo no se tienen en cuenta en la literatura. Tales operaciones pueden ser críticas para lograr una buena productividad, pero por otra parte representan una parte importante del consumo total de energía. En particular, los trabajos desarrollados en esta Tesis tienen cuatro objetivos concretos: (1) proporcionar modelos numéricos flexibles y configurables de tipo eventos discretos para simular y analizar terminales paralelas y perpendiculares, (2) proponer un nuevo algoritmo de apilamiento para reducir el gasto de energía y mejorar la productividad de la grúa automático en terminales perpendiculares; (3) optimizar las dimensiones de un bloque de una terminal perpendicular; y (4) analizar la distribución de los contenedores en la disposición del patio en función del momento en que se reserva el espacio para los contenedores de exportación. Los resultados muestran que, en primer lugar, los modelos son capaces de caracterizar en detalle el consumo de energía asociado a los movimientos de las grúas en ambos tipos de terminales. Con respecto a las terminales perpendiculares, el algoritmo de apilado propuesto es capaz de mejorar la eficiencia energética hasta aproximadamente un 20%, al tiempo que se consigue una mayor productividad. Además, los resultados muestran que las dimensiones de un bloque perpendicular pueden optimizarse para mejorar la productividad; con respecto al consumo de energía, aunque un bloque más pequeño induce un menor consumo eléctrico, la naturaleza aleatoria de las operaciones de reordenación inducen un grado significativo de distorsión en los resultados, indicando que tales operaciones pueden ser objeto de futura investigación. Por último, respecto a las terminales paralelas, a medida que se adelanta la reserva de espacio los contenedores presentan un mayor grado de agrupación, lo que redunda en un uso más eficeficiente de la energía debido a los menores costos operacionales asociados a grúas y camiones de patio, por lo que la reserva puede ser aconsejable cuando sea posible para mejorar la productividad del termina