Expanding the Horizons of Manufacturing: Towards Wide Integration, Smart Systems and Tools

This research topic aims at enterprise-wide modeling and optimization (EWMO) through the development and application of integrated modeling, simulation and optimization methodologies, and computer-aided tools for reliable and sustainable improvement opportunities within the entire manufacturing network (raw materials, production plants, distribution, retailers, and customers) and its components. This integrated approach incorporates information from the local primary control and supervisory modules into the scheduling/planning formulation. That makes it possible to dynamically react to incidents that occur in the network components at the appropriate decision-making level, requiring fewer resources, emitting less waste, and allowing for better responsiveness in changing market requirements and operational variations, reducing cost, waste, energy consumption and environmental impact, and increasing the benefits. More recently, the exploitation of new technology integration, such as through semantic models in formal knowledge models, allows for the capture and utilization of domain knowledge, human knowledge, and expert knowledge toward comprehensive intelligent management. Otherwise, the development of advanced technologies and tools, such as cyber-physical systems, the Internet of Things, the Industrial Internet of Things, Artificial Intelligence, Big Data, Cloud Computing, Blockchain, etc., have captured the attention of manufacturing enterprises toward intelligent manufacturing systems

Simulation framework of port operation and recovery planning

This study proposes a framework of simulation tool suites for ports to evaluate their response to disaster crisis and port security policies. The focus is containerized cargos that are imported through ports in the U.S. with final destinations also in the U.S. A crisis, such as a man-made or natural disaster, may cause a delay at the seaport. The down time of ports may result in severe economic losses. Thus, when a seaport cannot normally operate, it is important to minimize the impact caused by the disrupted freight flow. Port security policies also have a significant impact on the port operation efficiency. This model developed in this study evaluates the performance of re-routing strategies under different crisis scenarios and can help the user to find an effective re-routing decision and analyze security policies of a port. This model also analyzes security policies of the simulation port

The responsive reply chain: the influence of the positioning of decoupling points

Manufacturing supply chains have been challenged by high competition, dynamic, and stochastic conditions. They have to be constantly responsive in today’s ever-changing manufacturing environment. The proper positioning of decoupling points for material flow and information flow has a significant potential for increasing responsiveness in a supply chain. Positioning the material decoupling point as close to the end consumer as possible whilst the information decoupling point is positioned upstream is the key to the industries’ ability to reduce lead time and enhance performance in the dynamic behaviour of the supply chain. [Continues.

AN APPROACH TO INVENTORY MANAGEMENT IN MASS CUSTOMIZED PRINTING PRODUCTION ENVIRONMENT

In the competitive industrial setting of present times, it is hard for the manufacturing sector of developed economies to compete with those of developing countries because of the considerably high costs associated with Labor, Material and Transportation in addition to strict Environmental Sanctions, fierce competition from Sinking industries and the ever-shifting global economic patterns. For a manufacturing industry to survive in such conditions, it must be willing to change, should be technologically superior, access multiple markets, be responsive and adapt quickly. New manufacturing concepts and Business strategies are proposed and introduced frequently. One such business/manufacturing strategy that has proved to be successful is Mass Customization. The advantage of MC companies over traditional manufacturing comes with its fair share of challenges. This thesis identifies some important challenges faced by the printing industry, which has adapted MC, and solves one of these challenging problems

Development of a decision support system for decision-based part/fixture assignment and fixture flow control = Ukusungulwa kohlelo lokuxhaswa kwezinqumo mayelana nokwabiwa kwezingxenye ezakhiwayo kanye nokuhanjiswa kwazo.

Doctoral Degree. University of KwaZulu-Natal, Durban.ABSTRACT: An intense competition in a dynamic situation has increased the requirements that must be considered in the current manufacturing systems. Among those factors, fixtures are one of the major problematic components. The cost of fixture design and manufacture contributes to 10-20% of production costs. Manufacturing firms usually use traditional methods for part/fixture assignment works. These methods are highly resource consuming and cumbersome to enumerate the available fixtures and stabilise the number of fixtures required in a system. The aim of this study was to research and develop a Decision Support System (DSS), which was useful to perform a decision-based part/fixture assignment and fixture flow control during planned production periods. The DSS was designed to assist its users to reuse/adapt the retrieved fixtures or manufacture new fixtures depending upon the state of the retrieved fixtures and the similarities between the current and retrieved cases. This DSS combined Case-Based Reasoning (CBR), fuzzy set theory, the Analytic Hierarchy Process (AHP) and Discrete-Event Simulation (DES) techniques. The Artificial Intelligence (AI) component of the DSS immensely used a fuzzy CBR system combined with the fuzzy AHP and guiding rules from general domain knowledge. The fuzzy CBR was used to represent the uncertain and imprecise values of case attributes. The fuzzy AHP was applied to elicit domain knowledge from experts to prioritise case attributes. New part orders and training samples were represented as new and prior cases respectively using an Object-Oriented (OO) method for case retrieval and decision proposal. Popular fuzzy ranking and similarity measuring approaches were utilised in the case retrieval process. A DES model was implemented to analyse the performances of the proposed solutions by the fuzzy CBR subsystem. Three scenarios were generated by this subsystem as solution alternatives that were the proposed numbers of fixtures. The performances of these scenarios were evaluated using the DES model and the best alternative was identified. The novelty of this study employed the combination of fuzzy CBR and DES methods since such kinds of combinations have not been addressed yet. A numerical example was illustrated to present the soundness of the proposed methodological approach. Keywords: Decision support systems, case-based reasoning, analytic hierarchy process, fuzzy set theory, object-oriented methods, discrete-event simulation, fixtures. IQOQA LOCWANINGO : Ukuncintisana okunezinhlelo eziguquguqukayo kulesi sikhathi samanje sekwenze ukuthi kube nezidingo ezintsha ezinhlelweni zokukhiqiza. Phakathi kwakho konke lokhu izingxenye (fixtures) zingezinye zezinto ezidala izinkinga. Intengo yokwakha uhlaka lwengxenye kanye nokuyikhiqiza kubiza amaphesenti ayi-10 kuya kwangama-20 entengo yokukhiqiza. Amafemu akhiqizayo avamise ukusebenzisa izindlela ezindala zomsebenzi wokwaba izingxenye. Lezi zindlela zidla kakhulu izinsizangqangi futhi kuthatha isikhathi eside ukubala izingxenye ezikhona nokuqinisekisa ukuthi kunesibalo esanele kulokho okumele kube yikho ohlelweni lokusebenza. Inhloso yalolu cwaningo bekungukucwaninga nokusungula i-Decision Support System (DSS) ebe lusizo ekwenzeni umsebenzi wokuthatha izinqumo ngokwabiwa kwezingxenye kanye nokuhanjiswa kwazo ngezikhathi ezimiselwe ukukhiqiza. I-DSS yakhelwa ukusiza labo abayisebenzisayo ukuze basebenzise noma bazisebenzise lapho zingakaze zisetshenziswe khona lezo zingxenye ezibuyisiwe, noma kwakhiwe ezintsha kuya ngokuthi zibuyiswe zinjani lezi ezibuyisiwe nokuthi ziyafana yini nalezo ezintsha. I-DSS isebenzise amasu ahlanganise i-Case-Based Reasoning (CBR), injulalwazi echazwa ngokuthi i-fuzzy, ne-Analytic Hierarchy Process (AHP) ne-Discrete-Event Simulation (DES). I-Artificial Intelligence (AI) eyingxenye ye-DSS isebenzise kakhulu uhlelo lwe-fuzzy CBR luhlangene ne-fuzzy AHP kulandelwa imithetho yolwazi olumayelana nohlobo lomsebenzi. I-CBR isetshenziswe ukumelela lezo zimo zamanani ezingaqondakali nezingaphelele kulezo zingxenye. I-AHP e-fuzzy yasetshenziswa ukuze kutholakale ulwazi kochwepheshe olubeka phambili lezo zingxenye. Ama-oda ezingxenye ezintsha kanye namasampuli asetshenziselwa ukuqeqesha avezwe njengamasha kanye nabekade evele ekhona ngokulandelana kusetshenziswa indlela eyaziwa ngokuthi yi-Object-Oriented (OO) method lapho kubuyiswa izinto noma kunezinqumo eziphakanyiswayo. Izindlela ezijwayelekile zokulandelanisa nokufanisa zisetshenziswe ohlelweni lokubuyisa izinto. Kusetshenziswe isu eliyi-DES ukuhlaziya ukusebenza kwezisombululo eziphakanyiswe yindlela ye-CBR e-fuzzy. Le ndlela iphinde yaveza izimo ezintathu eziphakanyiswe ukuba zibe yisisombululo esibalweni sezingxenye ezihlongozwayo. Ukusebenza kwalezi zimo kuhlungwe ngokusebenzisa indlela ye-DES kwase kuvela inqubo engcono. Ukungajwayeleki kwalolu cwaningo kusebenzise ingxube yezindlela ze-fuzzy CBR ne-DES ngoba lolu hlobo lwengxube belungakaze lusetshenziswe. Kusetshenziswe isibonelo sezibalo ekwethuleni ukusebenza kwale nqubo yokusebenza ehlongozwayo

Development of a decision support system for decision-based part/fixture assignment and fixture flow control.

Doctoral Degree. University of KwaZulu-Natal, Durban.An intense competition in a dynamic situation has increased the requirements that must be considered in the current manufacturing systems. Among those factors, fixtures are one of the major problematic components. The cost of fixture design and manufacture contributes to 10-20% of production costs. Manufacturing firms usually use traditional methods for part/fixture assignment works. These methods are highly resource consuming and cumbersome to enumerate the available fixtures and stabilise the number of fixtures required in a system. The aim of this study was to research and develop a Decision Support System (DSS), which was useful to perform a decision-based part/fixture assignment and fixture flow control during planned production periods. The DSS was designed to assist its users to reuse/adapt the retrieved fixtures or manufacture new fixtures depending upon the state of the retrieved fixtures and the similarities between the current and retrieved cases. This DSS combined Case-Based Reasoning (CBR), fuzzy set theory, the Analytic Hierarchy Process (AHP) and Discrete-Event Simulation (DES) techniques. The Artificial Intelligence (AI) component of the DSS immensely used a fuzzy CBR system combined with the fuzzy AHP and guiding rules from general domain knowledge. The fuzzy CBR was used to represent the uncertain and imprecise values of case attributes. The fuzzy AHP was applied to elicit domain knowledge from experts to prioritise case attributes. New part orders and training samples were represented as new and prior cases respectively using an Object-Oriented (OO) method for case retrieval and decision proposal. Popular fuzzy ranking and similarity measuring approaches were utilised in the case retrieval process. A DES model was implemented to analyse the performances of the proposed solutions by the fuzzy CBR subsystem. Three scenarios were generated by this subsystem as solution alternatives that were the proposed numbers of fixtures. The performances of these scenarios were evaluated using the DES model and the best alternative was identified. The novelty of this study employed the combination of fuzzy CBR and DES methods since such kinds of combinations have not been addressed yet. A numerical example was illustrated to present the soundness of the proposed methodological approach.Please refer to the PDF for author's keywords

Historia, evolución y perspectivas de futuro en la utilización de técnicas de simulación en la gestión portuaria: aplicaciones en el análisis de operaciones, estrategia y planificación portuaria

Programa Oficial de Doutoramento en Análise Económica e Estratexia Empresarial. 5033V0[Resumen] Las técnicas de simulación, tal y como hoy las conocemos, comenzaron a mediados del siglo XX; primero con la aparición del primer computador y el desarrollo del método Monte Carlo, y más tarde con el desarrollo del primer simulador de propósito específico conocido como GPS y desarrollado por Geoffrey Gordon en IBM y la publicación del primer texto completo dedicado a esta materia y llamado the Art of Simulation (K.D. Tocher, 1963). Estás técnicas han evolucionado de una manera extraordinaria y hoy en día están plenamente implementadas en diversos campos de actividad. Las instalaciones portuarias no han escapado de esta tendencia, especialmente las dedicadas al tráfico de contenedores. Efectivamente, las características intrínsecas de este sector económico, le hacen un candidato idóneo para la implementación de modelos de simulación con propósitos y alcances muy diversos. No existe, sin embargo y hasta lo que conocemos, un trabajo científico que compile y analice pormenorizadamente tanto la historia como la evolución de simulación en ambientes portuarios, ayudando a clasificar los mismos y determinar cómo estos pueden ayudar en el análisis económico de estas instalaciones y en la formulación de las oportunas estrategias empresariales. Este es el objetivo último de la presente tesis doctoral.[Resumo] As técnicas de simulación, tal e como hoxe as coñecemos, comezaron a mediados do século XX; primeiro coa aparición do computador e o desenvolvemento do método Monte Carlo e máis tarde co desenvolvemento do primeiro simulador de propósito específico coñecido como GPS e desenvolvido por Geoffrey Gordon en IBM e a publicación do primeiro texto completo dedicado a este tema chamado “A Arte da Simulación” (K.D. Tocher, 1963). Estas técnicas evolucionaron dun xeito extraordinario e hoxe en día están plenamente implementadas en diversos campos de actividade. As instalacións portuarias non escaparon desta tendencia, especialmente as dedicadas ao tráfico de contenedores. Efectivamente, as características intrínsecas deste sector económico, fanlle un candidato idóneo para a implementación de modelos de simulación con propósitos e alcances moi variados. Con todo, e ata o que coñecemos, non existe un traballo científico que compila e analiza de forma detallada tanto a historia como a evolución da simulación en estes ambientes portuarios, clasificando os mesmos e determinando como estes poden axudar na análise económica destas instalacións e na formulación das oportunas estratexias empresariais. Este é o último obxectivo da presente tese doutoral.[Abstract] Simulation, to the extend that we understand it nowadays, began in the middle of the 20th century; first with the appearance of the computer and the development of the Monte Carlo method, and later with the development of the first specific purpose simulator known as GPS developed by Geoffrey Gordon in IBM. This author published the first full text devoted to this subject “The Art of Simulation” in 1963. These techniques have evolved in an extraordinary way and nowadays they are fully implemented in different fields of activity. Port facilities have not escaped this trend, especially those dedicated to container traffic. Indeed, the intrinsic characteristics of this economic sector, make it a suitable candidate for the implementation of simulation with very different purposes and scope. However, to the best of our knowelegde, there is not a scientific work that compiles and analyzes in detail both, the history and the evolution of simulation in port environments, contributing to classify them and determine how they can help in the economic analysis of these facilities and in the formulation of different business strategies. This is the ultimate goal of this doctoral thesis

Sequence-Based Simulation-Optimization Framework With Application to Port Operations at Multimodal Container Terminals

It is evident in previous works that operations research and mathematical algorithms can provide optimal or near-optimal solutions, whereas simulation models can aid in predicting and studying the behavior of systems over time and monitor performance under stochastic and uncertain circumstances. Given the intensive computational effort that simulation optimization methods impose, especially for large and complex systems like container terminals, a favorable approach is to reduce the search space to decrease the amount of computation. A maritime port can consist of multiple terminals with specific functionalities and specialized equipment. A container terminal is one of several facilities in a port that involves numerous resources and entities. It is also where containers are stored and transported, making the container terminal a complex system. Problems such as berth allocation, quay and yard crane scheduling and assignment, storage yard layout configuration, container re-handling, customs and security, and risk analysis become particularly challenging. Discrete-event simulation (DES) models are typically developed for complex and stochastic systems such as container terminals to study their behavior under different scenarios and circumstances. Simulation-optimization methods have emerged as an approach to find optimal values for input variables that maximize certain output metric(s) of the simulation. Various traditional and nontraditional approaches of simulation-optimization continue to be used to aid in decision making. In this dissertation, a novel framework for simulation-optimization is developed, implemented, and validated to study the influence of using a sequence (ordering) of decision variables (resource levels) for simulation-based optimization in resource allocation problems. This approach aims to reduce the computational effort of optimizing large simulations by breaking the simulation-optimization problem into stages. Since container terminals are complex stochastic systems consisting of different areas with detailed and critical functions that may affect the output, a platform that accurately simulates such a system can be of significant analytical benefit. To implement and validate the developed framework, a large-scale complex container terminal discrete-event simulation model was developed and validated based on a real system and then used as a testing platform for various hypothesized algorithms studied in this work

Pelimoottorin hyödyntäminen simuloinnin visualisoinnissa

Modern game engines provide software developers with comprehensive toolsets for turning their visions into visually appealing 3D worlds. In addition to gaming industry, these frameworks can be used in creating visualizations for real-world processes. In this thesis, the concept of game engine based industrial process visualization is demonstrated in the context of automated container terminals. During the thesis project, a real-time 3D visualization tool was developed that can be used to visualize simulated terminals and actual systems. The work was commissioned by a Finnish client company, working in the cargo handling industry. The thesis document comprises of a background part and a solution part. In the background part, the most important concepts of container terminal operations are presented. The focus is then moved to the software systems that are used in the automated terminals provided by the client company. The background part contains also a review of the existing 3D applications in the container handling industry and a literature survey of various other projects, which are utilizing game engines for simulation purposes. For the practical part, a requirements analysis was performed for the visualization tool. The development platform was then chosen by comparing two of the most commonly used modern game engines: Unity and Unreal Engine. While both of the engines had their advantages and disadvantages, Unity was chosen as the development platform for several reasons: It allowed using the existing 3D models of the client company without doing any manual conversions to the files. The object model and scripting system of Unity was also regarded as intuitive and easy to use. Finally, the software framework used in Unity allowed easy integration with the software systems of the client company. The implemented application is configured by using similar XML files that are used in GUI applications of actual terminals. It communicates with the terminal automation system by using the common communication platform. Machine positions and container events are acquired real-time from the automation system. It was also proven, that the application can be extended to send messages back to the automation system. The solution was tested with a virtual container terminal, including 10,000 containers and 47 container handling machines. It was confirmed, that the application is able to handle large amount of concurrent movement without problems. However, the vast amount of objects in the terminal makes the visualization of the whole area a challenging task for a conventional PC. Further graphical optimization is required in order to provide sufficient frame rate and smooth animation in all situations