The relevance of outsourcing and leagile strategies in performance optimization of an integrated process planning and scheduling

Over the past few years growing global competition has forced the manufacturing industries to upgrade their old production strategies with the modern day approaches. As a result, recent interest has been developed towards finding an appropriate policy that could enable them to compete with others, and facilitate them to emerge as a market winner. Keeping in mind the abovementioned facts, in this paper the authors have proposed an integrated process planning and scheduling model inheriting the salient features of outsourcing, and leagile principles to compete in the existing market scenario. The paper also proposes a model based on leagile principles, where the integrated planning management has been practiced. In the present work a scheduling problem has been considered and overall minimization of makespan has been aimed. The paper shows the relevance of both the strategies in performance enhancement of the industries, in terms of their reduced makespan. The authors have also proposed a new hybrid Enhanced Swift Converging Simulated Annealing (ESCSA) algorithm, to solve the complex real-time scheduling problems. The proposed algorithm inherits the prominent features of the Genetic Algorithm (GA), Simulated Annealing (SA), and the Fuzzy Logic Controller (FLC). The ESCSA algorithm reduces the makespan significantly in less computational time and number of iterations. The efficacy of the proposed algorithm has been shown by comparing the results with GA, SA, Tabu, and hybrid Tabu-SA optimization methods

Scheduling Jobs in Flowshops with the Introduction of Additional Machines in the Future

This is the author's peer-reviewed final manuscript, as accepted by the publisher. The published article is copyrighted by Elsevier and can be found at: http://www.journals.elsevier.com/expert-systems-with-applications/.The problem of scheduling jobs to minimize total weighted tardiness in flowshops,\ud with the possibility of evolving into hybrid flowshops in the future, is investigated in\ud this paper. As this research is guided by a real problem in industry, the flowshop\ud considered has considerable flexibility, which stimulated the development of an\ud innovative methodology for this research. Each stage of the flowshop currently has\ud one or several identical machines. However, the manufacturing company is planning\ud to introduce additional machines with different capabilities in different stages in the\ud near future. Thus, the algorithm proposed and developed for the problem is not only\ud capable of solving the current flow line configuration but also the potential new\ud configurations that may result in the future. A meta-heuristic search algorithm based\ud on Tabu search is developed to solve this NP-hard, industry-guided problem. Six\ud different initial solution finding mechanisms are proposed. A carefully planned\ud nested split-plot design is performed to test the significance of different factors and\ud their impact on the performance of the different algorithms. To the best of our\ud knowledge, this research is the first of its kind that attempts to solve an industry-guided\ud problem with the concern for future developments

Dynamic scheduling in a multi-product manufacturing system

To remain competitive in global marketplace, manufacturing companies need to improve their operational practices. One of the methods to increase competitiveness in manufacturing is by implementing proper scheduling system. This is important to enable job orders to be completed on time, minimize waiting time and maximize utilization of equipment and machineries. The dynamics of real manufacturing system are very complex in nature. Schedules developed based on deterministic algorithms are unable to effectively deal with uncertainties in demand and capacity. Significant differences can be found between planned schedules and actual schedule implementation. This study attempted to develop a scheduling system that is able to react quickly and reliably for accommodating changes in product demand and manufacturing capacity. A case study, 6 by 6 job shop scheduling problem was adapted with uncertainty elements added to the data sets. A simulation model was designed and implemented using ARENA simulation package to generate various job shop scheduling scenarios. Their performances were evaluated using scheduling rules, namely, first-in-first-out (FIFO), earliest due date (EDD), and shortest processing time (SPT). An artificial neural network (ANN) model was developed and trained using various scheduling scenarios generated by ARENA simulation. The experimental results suggest that the ANN scheduling model can provided moderately reliable prediction results for limited scenarios when predicting the number completed jobs, maximum flowtime, average machine utilization, and average length of queue. This study has provided better understanding on the effects of changes in demand and capacity on the job shop schedules. Areas for further study includes: (i) Fine tune the proposed ANN scheduling model (ii) Consider more variety of job shop environment (iii) Incorporate an expert system for interpretation of results. The theoretical framework proposed in this study can be used as a basis for further investigation

Spatial-temporal data modelling and processing for personalised decision support

The purpose of this research is to undertake the modelling of dynamic data without losing any of the temporal relationships, and to be able to predict likelihood of outcome as far in advance of actual occurrence as possible. To this end a novel computational architecture for personalised ( individualised) modelling of spatio-temporal data based on spiking neural network methods (PMeSNNr), with a three dimensional visualisation of relationships between variables is proposed. In brief, the architecture is able to transfer spatio-temporal data patterns from a multidimensional input stream into internal patterns in the spiking neural network reservoir. These patterns are then analysed to produce a personalised model for either classification or prediction dependent on the specific needs of the situation. The architecture described above was constructed using MatLab© in several individual modules linked together to form NeuCube (M1). This methodology has been applied to two real world case studies. Firstly, it has been applied to data for the prediction of stroke occurrences on an individual basis. Secondly, it has been applied to ecological data on aphid pest abundance prediction. Two main objectives for this research when judging outcomes of the modelling are accurate prediction and to have this at the earliest possible time point. The implications of these findings are not insignificant in terms of health care management and environmental control. As the case studies utilised here represent vastly different application fields, it reveals more of the potential and usefulness of NeuCube (M1) for modelling data in an integrated manner. This in turn can identify previously unknown (or less understood) interactions thus both increasing the level of reliance that can be placed on the model created, and enhancing our human understanding of the complexities of the world around us without the need for over simplification. Read less Keywords Personalised modelling; Spiking neural network; Spatial-temporal data modelling; Computational intelligence; Predictive modelling; Stroke risk predictio

Spatial-temporal data modelling and processing for personalised decision support

The purpose of this research is to undertake the modelling of dynamic data without losing any of the temporal relationships, and to be able to predict likelihood of outcome as far in advance of actual occurrence as possible. To this end a novel computational architecture for personalised ( individualised) modelling of spatio-temporal data based on spiking neural network methods (PMeSNNr), with a three dimensional visualisation of relationships between variables is proposed. In brief, the architecture is able to transfer spatio-temporal data patterns from a multidimensional input stream into internal patterns in the spiking neural network reservoir. These patterns are then analysed to produce a personalised model for either classification or prediction dependent on the specific needs of the situation. The architecture described above was constructed using MatLab© in several individual modules linked together to form NeuCube (M1). This methodology has been applied to two real world case studies. Firstly, it has been applied to data for the prediction of stroke occurrences on an individual basis. Secondly, it has been applied to ecological data on aphid pest abundance prediction. Two main objectives for this research when judging outcomes of the modelling are accurate prediction and to have this at the earliest possible time point. The implications of these findings are not insignificant in terms of health care management and environmental control. As the case studies utilised here represent vastly different application fields, it reveals more of the potential and usefulness of NeuCube (M1) for modelling data in an integrated manner. This in turn can identify previously unknown (or less understood) interactions thus both increasing the level of reliance that can be placed on the model created, and enhancing our human understanding of the complexities of the world around us without the need for over simplification. Read less Keywords Personalised modelling; Spiking neural network; Spatial-temporal data modelling; Computational intelligence; Predictive modelling; Stroke risk predictio

Common Due-Date Problem: Exact Polynomial Algorithms for a Given Job Sequence

This paper considers the problem of scheduling jobs on single and parallel machines where all the jobs possess different processing times but a common due date. There is a penalty involved with each job if it is processed earlier or later than the due date. The objective of the problem is to find the assignment of jobs to machines, the processing sequence of jobs and the time at which they are processed, which minimizes the total penalty incurred due to tardiness or earliness of the jobs. This work presents exact polynomial algorithms for optimizing a given job sequence or single and parallel machines with the run-time complexities of $O(n \log n)$ and $O(mn^2 \log n)$ respectively, where $n$ is the number of jobs and $m$ the number of machines. The algorithms take a sequence consisting of all the jobs $(J_i, i=1,2,\dots,n)$ as input and distribute the jobs to machines (for $m>1$) along with their best completion times so as to get the least possible total penalty for this sequence. We prove the optimality for the single machine case and the runtime complexities of both. Henceforth, we present the results for the benchmark instances and compare with previous work for single and parallel machine cases, up to $200$ jobs.Comment: 15th International Symposium on Symbolic and Numeric Algorithms for Scientific Computin

The Integration of Process Planning and Shop Floor Scheduling in Small Batch Part Manufacturing

In this paper we explore possibilities to cut manufacturing leadtimes and to improve delivery performance in a small batch part manufacturing shop by integrating process planning and shop floor scheduling. Using a set of initial process plans (one for each order in the shop), we exploit a resource decomposition procedure to determine schedules to determine schedules which minimize the maximum lateness, given these process plans. If the resulting schedule is still unsatisfactory, a critical path analysis is performed to select jobs as candidates for alternative process plans. In this way, an excellent due date performance can be achieved, with a minimum of process planning and scheduling effort

Scheduling of non-repetitive lean manufacturing systems under uncertainty using intelligent agent simulation

World-class manufacturing paradigms emerge from specific types of manufacturing systems with which they remain associated until they are obsolete. Since its introduction the lean paradigm is almost exclusively implemented in repetitive manufacturing systems employing flow-shop layout configurations. Due to its inherent complexity and combinatorial nature, scheduling is one application domain whereby the implementation of manufacturing philosophies and best practices is particularly challenging. The study of the limited reported attempts to extend leanness into the scheduling of non-repetitive manufacturing systems with functional shop-floor configurations confirms that these works have adopted a similar approach which aims to transform the system mainly through reconfiguration in order to increase the degree of manufacturing repetitiveness and thus facilitate the adoption of leanness. This research proposes the use of leading edge intelligent agent simulation to extend the lean principles and techniques to the scheduling of non-repetitive production environments with functional layouts and no prior reconfiguration of any form. The simulated system is a dynamic job-shop with stochastic order arrivals and processing times operating under a variety of dispatching rules. The modelled job-shop is subject to uncertainty expressed in the form of high priority orders unexpectedly arriving at the system, order cancellations and machine breakdowns. The effect of the various forms of the stochastic disruptions considered in this study on system performance prior and post the introduction of leanness is analysed in terms of a number of time, due date and work-in-progress related performance metrics

A Novel Approach to the Common Due-Date Problem on Single and Parallel Machines

This paper presents a novel idea for the general case of the Common Due-Date (CDD) scheduling problem. The problem is about scheduling a certain number of jobs on a single or parallel machines where all the jobs possess different processing times but a common due-date. The objective of the problem is to minimize the total penalty incurred due to earliness or tardiness of the job completions. This work presents exact polynomial algorithms for optimizing a given job sequence for single and identical parallel machines with the run-time complexities of $O(n \log n)$ for both cases, where $n$ is the number of jobs. Besides, we show that our approach for the parallel machine case is also suitable for non-identical parallel machines. We prove the optimality for the single machine case and the runtime complexities of both. Henceforth, we extend our approach to one particular dynamic case of the CDD and conclude the chapter with our results for the benchmark instances provided in the OR-library.Comment: Book Chapter 22 page