Abstract: Flexible Manufacturing System (FMS) is seen as an option for industries which want to boost productivity as well as respond quickly to an increasingly changing marketplace. FMS produces in mid variety, mid volume range and can meet the changing market demands very quickly. But still the impact of adoption of FMS on the productivity of any industry is not very clear. In this paper an attempt has been made to model the various factors affecting the productivity of FMS installation using Total Interpretive Structural Modelling (TISM) Technique.
Abstract: The Flow Shop Scheduling Problem (FSSP) is a typical problem that is faced by production planning managers in Flexible Manufacturing Systems (FMS). This problem consists in finding the optimal scheduling to carry out a set of jobs, which are processed in a set of machines or shared resources. Moreover, all the jobs are processed in the same machine sequence. As in all the scheduling problems, the makespan can be obtained by drawing the Gantt chart according to the operations order, among other alternatives. On this way, an FMS presenting the FSSP can be modeled by Petri nets (PNs), which are a powerful tool that has been used to model and analyze discrete event systems. Then, the makespan can be obtained by simulating the PN through the token game animation and incidence matrix. In this work, we present an adaptive PN to obtain the makespan of FSSP by applying PN analytical tools.
Abstract: In the age of automation and computation aiding manufacturing, it is clear that manufacturing systems have become more complex than ever before. Although technological advances provide the capability to gain more value with fewer resources, sometimes utilisation of the manufacturing capabilities available to organisations is difficult to achieve. Flexible manufacturing systems (FMS) provide a unique capability to manufacturing organisations where there is a need for product range diversification by providing line efficiency through production flexibility. This is very valuable in trend driven production set-ups or niche volume production requirements. Although FMS provides flexible and efficient facilities, its optimal set-up is key in achieving production performance. As many variables are interlinked due to the flexibility provided by the FMS, analytical calculations are not always sufficient to predict the FMS’ performance. Simulation modelling is capable of capturing the complexity and constraints associated with FMS. This paper demonstrates how discrete event simulation (DES) can address complexity in an FMS to optimise the production line performance. A case study of an automotive FMS is presented. The DES model demonstrates different configuration options depending on prioritising objectives: utilisation and throughput. Additionally, this paper provides insight into understanding the impact of system set-up constraints on the FMS performance and demonstrates the exploration into the optimal production set-up.
Abstract: This paper gives insights into the research project “InnoCyFer” (in the form of an outlook) which is funded by the German Federal Ministry of Economics and Technology. Enabling the integrated customer individual product design as well as flexible manufacturing of these products are the main objectives of the project. To achieve this, a web-based Open Innovation-Platform containing an integrated Toolkit will be developed. This toolkit enables the active integration of the customer’s creativity and potentials of innovation in the product development process. Furthermore, the project will show the chances and possibilities of customer individualized products by building and examining the continuous process from innovation through the customers to the flexible manufacturing of individual products.
Abstract: This paper deals with modeling and optimization of two NP-hard problems in production planning of flexible manufacturing system (FMS), part type selection problem and loading problem. The part type selection problem and the loading problem are strongly related and heavily influence the system’s efficiency and productivity. These problems have been modeled and solved simultaneously by using real coded genetic algorithms (RCGA) which uses an array of real numbers as chromosome representation. The novel proposed chromosome representation produces only feasible solutions which minimize a computational time needed by GA to push its population toward feasible search space or repair infeasible chromosomes. The proposed RCGA improves the FMS performance by considering two objectives, maximizing system throughput and maintaining the balance of the system (minimizing system unbalance). The resulted objective values are compared to the optimum values produced by branch-and-bound method. The experiments show that the proposed RCGA could reach near optimum solutions in a reasonable amount of time.
Abstract: Nowadays the market for industrial companies is becoming more and more globalized and highly competitive, forcing them to shorten the duration of the manufacturing system development time in order to reduce the time to market. In order to achieve this target, the hierarchical systems used in previous manufacturing systems are not enough because they cannot deal effectively with unexpected situations. To achieve flexibility in manufacturing systems, the concept of an Autonomous Decentralized Flexible Manufacturing System (AD-FMS) is useful. In this paper, we introduce a hypothetical reasoning based algorithm called the Algorithm for Future Anticipative Reasoning (AFAR) which is able to decide on a conceivable next action of an Automated Guided Vehicle (AGV) that works autonomously in the AD-FMS.
Abstract: One of the most important problems in production planning of flexible manufacturing system (FMS) is machine tool selection and operation allocation problem that directly influences the production costs and times .In this paper minimizing machining cost, set-up cost and material handling cost as a multi-objective problem in flexible manufacturing systems environment are considered. We present a 0-1 integer linear programming model for the multiobjective machine tool selection and operation allocation problem and due to the large scale nature of the problem, solving the problem to obtain optimal solution in a reasonable time is infeasible, Paretoant colony optimization (P-ACO) approach for solving the multiobjective problem in reasonable time is developed. Experimental results indicate effectiveness of the proposed algorithm for solving the problem.
Abstract: This paper and its companion (Part 2) deal with
modeling and optimization of two NP-hard problems in production
planning of flexible manufacturing system (FMS), part type selection
problem and loading problem. The part type selection problem and
the loading problem are strongly related and heavily influence the
system-s efficiency and productivity. The complexity of the problems
is harder when flexibilities of operations such as the possibility of
operation processed on alternative machines with alternative tools are
considered. These problems have been modeled and solved
simultaneously by using real coded genetic algorithms (RCGA)
which uses an array of real numbers as chromosome representation.
These real numbers can be converted into part type sequence and
machines that are used to process the part types. This first part of the
papers focuses on the modeling of the problems and discussing how
the novel chromosome representation can be applied to solve the
problems. The second part will discuss the effectiveness of the
RCGA to solve various test bed problems.
Abstract: In this paper we present our results on the performance analysis of a multi-product manufacturing line. We study the influence of external perturbations, intermediate buffer content and the number of manufacturing stages on the production tracking error of each machine in the multi-product line operated under a surplusbased production control policy. Starting by the analysis of a single machine with multiple production stages (one for each product type), we provide bounds on the production error of each stage. Then, we extend our analysis to a line of multi-stage machines, where similarly, bounds on each production tracking error for each product type, as well as buffer content are obtained. Details on performance of the closed-loop flow line model are illustrated in numerical simulations.
Abstract: Currently is characterized production engineering
together with the integration of industrial automation and robotics
such very quick view of to manufacture the products. The production
range is continuously changing, expanding and producers have to be
flexible in this regard. It means that need to offer production
possibilities, which can respond to the quick change. Engineering
product development is focused on supporting CAD software, such
systems are mainly used for product design. That manufacturers are
competitive, it should be kept procured machines made available
capable of responding to output flexibility. In response to that
problem is the development of flexible manufacturing systems,
consisting of various automated systems. The integration of flexible
manufacturing systems and subunits together with product design and
of engineering is a possible solution for this issue. Integration is
possible through the implementation of CIM systems. Such a solution
and finding a hyphen between CAD and procurement system ICIM
3000 from Festo Co. is engaged in the research project and this
contribution. This can be designed the products in CAD systems and
watch the manufacturing process from order to shipping by the
development of methods and processes of integration, This can be
modeled in CAD systems products and watch the manufacturing
process from order to shipping to develop methods and processes of
integration, which will improve support for product design
parameters by monitoring of the production process, by creating of
programs for production using the CAD and therefore accelerates the
a total of process from design to implementation.
Abstract: The aim of this study is to identify the conditions of
implementation for reconfigurability in summarizing past flexible
manufacturing systems (FMS) research by drawing overall
conclusions from many separate High Performance Manufacturing
(HPM) studies. Meta-analysis will be applied to links between HPM
programs and their practices related to FMS and manufacturing
performance with particular reference to responsiveness performance.
More specifically, an application of meta-analysis will be made with
reference to two of the main steps towards the development of an
empirically-tested theory: testing the adequacy of the measurement of
variables and testing the linkages between the variables.
Abstract: The rapid development of manufacturing and information systems has caused significant changes in manufacturing environments in recent decades. Mass production has given way to flexible manufacturing systems, in which an important characteristic is customized or "on demand" production. In this scenario, the seamless and without gaps information flow becomes a key factor for success of enterprises. In this paper we present a framework to support the mapping of features into machining workingsteps compliant with the ISO 14649 standard (known as STEP-NC). The system determines how the features can be made with the available manufacturing resources. Examples of the mapping method are presented for features such as a pocket with a general surface.
Abstract: In most study fields, a phenomenon may not be
studied directly but it will be examined indirectly by phenomenon
model. Making an accurate model of system, there is attained new
information from modeled phenomenon without any charge, danger,
etc... there have been developed more solutions for describing and
analyzing the recent complicated systems but few of them have
analyzed the performance in the range of system description. Petri
nets are of limited solutions which may make such union. Petri nets
are being applied in problems related to modeling and designing the
systems. Theory of Petri nets allow a system to model
mathematically by a Petri net and analyzing the Petri net can then
determine main information of modeled system-s structure and
dynamic. This information can be used for assessing the performance
of systems and suggesting corrections in the system. In this paper,
beside the introduction of Petri nets, a real case study will be studied
in order to show the application of generalized stochastic Petri nets in
modeling a resource sharing production system and evaluating the
efficiency of its machines and robots. The modeling tool used here is
SHARP software which calculates specific indicators helping to
make decision.
Abstract: Flexible manufacturing system is a system that is able to respond to changed conditions. In general, this flexibility is divided into two key categories and several subcategories. The first category is the so called machine flexibility which enables to make various products by the given machinery. The second category is routing flexibility enabling to execute the same operation by various machines. Flexible manufacturing systems usually consist of three main parts: CNC machine tools, transport system and control system. A higher level of flexible manufacturing systems is represented by the so called intelligent manufacturing systems.
Abstract: This research presents a fuzzy multi-objective model
for a machine selection problem in a flexible manufacturing system
of a tire company. Two main objectives are minimization of an
average machine error and minimization of the total setup time.
Conventionally, the working team uses trial and error in selecting a
pressing machine for each task due to the complexity and constraints
of the problem. So, both objectives may not satisfy. Moreover, trial
and error takes a lot of time to get the final decision. Therefore, in
this research preemptive fuzzy goal programming model is developed
for solving this multi-objective problem. The proposed model can
obtain the appropriate results that the Decision Making (DM) is
satisfied for both objectives. Besides, alternative choice can be easily
generated by varying the satisfaction level. Additionally, decision
time can be reduced by using the model, which includes all
constraints of the system to generate the solutions. A numerical
example is also illustrated to show the effectiveness of the proposed
model.
Abstract: A new approach to determine the machine layout in flexible manufacturing cell, and to find the feasible robot configuration of the robot to achieve minimum cycle time is presented in this paper. The location of the input/output location and the optimal robot configuration is obtained for all sequences of work tasks of the robot within a specified period of time. A more realistic approach has been presented to model the problem using the robot joint space. The problem is formulated as a nonlinear optimization problem and solved using Sequential Quadratic Programming algorithm.
Abstract: As product life cycle becomes less and less every day,
having flexible manufacturing processes for any companies seems more demanding. In the assembling of closures, i.e. opening parts in
car body, hemming process is the one which needs more attention. This paper focused on the robot roller hemming process and how to
reduce its cycle time by introducing a fast roller hemming process. A
robot roller hemming process of a tailgate of Saab 93 SportCombi
model is investigated as a case study in this paper. By applying task
separation, robot coordination, and robot cell configuration principles in the roller hemming process, three alternatives are
proposed, developed, and remarkable reduction in cycle times achieved [1].
Abstract: Current trends in manufacturing are characterized by
production broadening, innovation cycle shortening, and the products
having a new shape, material and functions. The production strategy
focused on time needed change from the traditional functional
production structure to flexible manufacturing cells and lines.
Production by automated manufacturing system (AMS) is one of the
most important manufacturing philosophies in the last years. The
main goals of the project we are involved in lies on building a
laboratory in which will be located a flexible manufacturing system
consisting of at least two production machines with NC control
(milling machines, lathe). These machines will be linked to a
transport system and they will be served by industrial robots. Within
this flexible manufacturing system a station for the quality control
consisting of a camera system and rack warehouse will be also
located. The design, analysis and improvement of this manufacturing
system, specially with a special focus on the communication among
devices constitute the main aims of this paper. The key determining
factors for the manufacturing system design are: the product, the
production volume, the used machines, the disposable manpower, the
disposable infrastructure and the legislative frame for the specific
cases.
Abstract: This paper discusses the applicability of the Data
Distribution Service (DDS) for the development of automated and modular manufacturing systems which require a flexible and robust
communication infrastructure. DDS is an emergent standard for datacentric publish/subscribe middleware systems that provides an
infrastructure for platform-independent many-to-many
communication. It particularly addresses the needs of real-time systems that require deterministic data transfer, have low memory
footprints and high robustness requirements. After an overview of the
standard, several aspects of DDS are related to current challenges for the development of modern manufacturing systems with distributed architectures. Finally, an example application is presented based on a modular active fixturing system to illustrate the described aspects.
Abstract: The concept of flexible manufacturing is highly
appealing in gaining a competitive edge in the market by quickly
adapting to the changing customer needs. Scheduling jobs on flexible
manufacturing systems (FMSs) is a challenging task of managing the
available flexibility on the shop floor to react to the dynamics of the
environment in real-time. In this paper, an agent-oriented scheduling
framework that can be integrated with a real or a simulated FMS is
proposed. This framework works in stochastic environments with a
dynamic model of job arrival. It supports a hierarchical cooperative
scheduling that builds on the available flexibility of the shop floor.
Testing the framework on a model of a real FMS showed the
capability of the proposed approach to overcome the drawbacks of
the conventional approaches and maintain a near optimal solution
despite the dynamics of the operational environment.