New species of hybrid pull systems

production models;control systems;simulation

Methodology for Determining the Acceptability of Given Designs in Uncertain Environments

Managers wish to verify that a particular engineering design meets their require- ments. This design's future environment will differ from the environment assumed during the design. Therefore it is crucial to determine which variations in the envi- ronment may make this design unacceptable. The proposed methodology estimates which uncertain environmental parameters are important (so managers can become pro-active) and which parameter combinations (scenarios) make the design unac- ceptable. The methodology combines simulation, bootstrapping, and metamodeling. The methodology is illustrated through a simulated manufacturing system, includ- ing fourteen uncertain parameters of the input distributions for the various arrival and service times. These parameters are investigated through sixteen scenarios, selected through a two-level fractional-factorial design. The resulting simulation In- put/Output (I/O) data are analyzed through a first-order polynomial metamodel and bootstrapping. A second experiment gives some outputs that are indeed un- acceptable. Polynomials fitted to the I/O data estimate the border line (frontier) between acceptable and unacceptable environments.Uncertainty modeling;Risk analysis;Robustness and sensitivity analysis;Simulation;Bootstrap

Customized Pull Systems for Single-Product Flow Lines

Traditionally pull production systems are managed through classic control systems such as Kanban, Conwip, or Base stock, but this paper proposes ‘customized’ pull control. Customization means that a given production line is managed through a pull control system that in principle connects each stage of that line with each preceding stage; optimization of the corresponding simulation model, however, shows which of these potential control loops are actually implemented. This novel approach may result in one of the classic systems, but it may also be another type: (1) the total line may be decomposed into several segments, each with its own classic control system (e.g., segment 1 with Kanban, segment 2 with Conwip); (2) the total line or segments may combine different classic systems; (3) the line may be controlled through a new type of system. These different pull systems are found when applying the new approach to a set of twelve production lines. These lines are configured through the application of a statistical (Plackett-Burman) design with ten factors that characterize production lines (such as line length, demand variability, and machine breakdowns).Pull production / inventory;sampling;optimization;evolutionary algorithm

Customized Pull Systems for Single-Product Flow Lines

Traditionally pull production systems are managed through classic control systems such as Kanban, Conwip, or Base stock, but this paper proposes ‘customized’ pull control. Customization means that a given production line is managed through a pull control system that in principle connects each stage of that line with each preceding stage; optimization of the corresponding simulation model, however, shows which of these potential control loops are actually implemented. This novel approach may result in one of the classic systems, but it may also be another type: (1) the total line may be decomposed into several segments, each with its own classic control system (e.g., segment 1 with Kanban, segment 2 with Conwip); (2) the total line or segments may combine different classic systems; (3) the line may be controlled through a new type of system. These different pull systems are found when applying the new approach to a set of twelve production lines. These lines are configured through the application of a statistical (Plackett-Burman) design with ten factors that characterize production lines (such as line length, demand variability, and machine breakdowns).

Real time selection of scheduling rules and knowledge extraction via dynamically controlled data mining

A new scheduling system for selecting dispatching rules in real time is developed by combining the techniques of simulation, data mining, and statistical process control charts. The proposed scheduling system extracts knowledge from data coming from the manufacturing environment by constructing a decision tree, and selects a dispatching rule from the tree for each scheduling period. In addition, the system utilises the process control charts to monitor the performance of the decision tree and dynamically updates this decision tree whenever the manufacturing conditions change. This gives the proposed system the ability to adapt itself to changes in the manufacturing environment and improve the quality of its decisions. We implement the proposed system on a job shop problem, with the objective of minimising average tardiness, to evaluate its performance. Simulation results indicate that the performance of the proposed system is considerably better than other simulation-based single-pass and multi-pass scheduling algorithms available in the literature. We also illustrate knowledge extraction by presenting a sample decision tree from our experiments. © 2010 Taylor & Francis

Flow shop rescheduling under different types of disruption

This is an Accepted Manuscript of an article published by Taylor & Francis in International Journal of Production Research on 2013, available online:http://www.tandfonline.com/10.1080/00207543.2012.666856Almost all manufacturing facilities need to use production planning and scheduling systems to increase productivity and to reduce production costs. Real-life production operations are subject to a large number of unexpected disruptions that may invalidate the original schedules. In these cases, rescheduling is essential to minimise the impact on the performance of the system. In this work we consider flow shop layouts that have seldom been studied in the rescheduling literature. We generate and employ three types of disruption that interrupt the original schedules simultaneously. We develop rescheduling algorithms to finally accomplish the twofold objective of establishing a standard framework on the one hand, and proposing rescheduling methods that seek a good trade-off between schedule quality and stability on the other.The authors would like to thank the anonymous referees for their careful and detailed comments that helped to improve the paper considerably. This work is partially financed by the Small and Medium Industry of the Generalitat Valenciana (IMPIVA) and by the European Union through the European Regional Development Fund (FEDER) inside the R + D program "Ayudas dirigidas a Institutos tecnologicos de la Red IMPIVA" during the year 2011, with project number IMDEEA/2011/142.Katragjini Prifti, K.; Vallada Regalado, E.; Ruiz García, R. (2013). Flow shop rescheduling under different types of disruption. International Journal of Production Research. 51(3):780-797. https://doi.org/10.1080/00207543.2012.666856S780797513Abumaizar, R. J., & Svestka, J. A. 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An immune algorithm for scheduling a hybrid flow shop with sequence-dependent setup times and machines with random breakdowns. International Journal of Production Research, 47(24), 6999-7027. doi:10.1080/0020754080240063