Abstract: In this research, computer simulation is used for Electronic Manufacturing Service (EMS) plant layout analysis. The current layout of this manufacturing plant is a process layout, which is not suitable due to the nature of an EMS that has high-volume and high-variety environment. Moreover, quick response and high flexibility are also needed. Then, cellular manufacturing layout design was determined for the selected group of products. Systematic layout planning (SLP) was used to analyze and design the possible cellular layouts for the factory. The cellular layout was selected based on the main criteria of the plant. Computer simulation was used to analyze and compare the performance of the proposed cellular layout and the current layout. It found that the proposed cellular layout can generate better performances than the current layout. In this research, computer simulation is used for Electronic Manufacturing Service (EMS) plant layout analysis. The current layout of this manufacturing plant is a process layout, which is not suitable due to the nature of an EMS that has high-volume and high-variety environment. Moreover, quick response and high flexibility are also needed. Then, cellular manufacturing layout design was determined for the selected group of products. Systematic layout planning (SLP) was used to analyze and design the possible cellular layouts for the factory. The cellular layout was selected based on the main criteria of the plant. Computer simulation was used to analyze and compare the performance of the proposed cellular layout and the current layout. It found that the proposed cellular layout can generate better performances than the current layout.
Abstract: Presented in this paper is a framework of a software ‘WEMax’. The WEMax is invented for analysis and simulation for manned assembly lines to sustain and improve performance of manufacturing systems. In a manufacturing system, performance, such as productivity, is a key of competitiveness for output products. However, the manned assembly lines are difficult to forecast performance, because human labors are not expectable factors by computer simulation models or mathematical models. Existing approaches to performance forecasting of the manned assembly lines are limited to matters of the human itself, such as ergonomic and workload design, and non-human-factor-relevant simulation. Consequently, an approach for the forecasting and improvement of manned assembly line performance is needed to research. As a solution of the current problem, this study proposes a framework that is for generation and simulation of virtual manned assembly lines, and the framework has been implemented as a software.
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: The planning in manufacturing system is becoming complicated day by day due to the expanding networks and shortage of skilled people to manage change. Consequently, faster lead time and rising demands for eco-efficient evaluation of manufacturing products and processes need exploitation of new and intelligent knowledge management concepts for manufacturing planning. This paper highlights motivation for incorporation of new features in the manufacturing planning system. Furthermore, it elaborates requirements for the development of intelligent knowledge management concept to support planning related decisions. Afterwards, the derived concept is presented in this paper considering two case studies. The first case study is concerned with the automotive ramp-up planning. The second case study specifies requirements for knowledge management system to support decisions in eco-efficient evaluation of manufacturing products and processes
Abstract: A reconfigurable manufacturing system (RMS) is an
advanced system designed at the outset for rapid changes in its hardware
and software components in order to quickly adjust its production
capacity and functionally. Among various operational decisions, this
study considers the scheduling problem that determines the input
sequence and schedule at the same time for a given set of parts. In
particular, we consider the practical constraints that the numbers of
pallets/fixtures are limited and hence a part can be released into the
system only when the fixture required for the part is available. To
solve the integrated input sequencing and scheduling problems, we
suggest a priority rule based approach in which the two sub-problems
are solved using a combination of priority rules. To show the effectiveness
of various rule combinations, a simulation experiment was
done on the data for a real RMS, and the test results are reported.
Abstract: In today-s competitive market, most companies
develop manufacturing systems that can help in cost reduction and
maximum quality. Human issues are an important part of
manufacturing systems, yet most companies ignore their effects on
production performance. This paper aims to developing an integrated
workforce planning system that incorporates the human being.
Therefore, a multi-objective mixed integer nonlinear programming
model is developed to determine the amount of hiring, firing,
training, overtime for each worker type. This paper considers a
workforce planning model including human aspects such as skills,
training, workers- personalities, capacity, motivation, and learning
rates. This model helps to minimize the hiring, firing, training and
overtime costs, and maximize the workers- performance. The results
indicate that the workers- differences should be considered in
workforce scheduling to generate realistic plans with minimum costs.
This paper also investigates the effects of human learning rates on the
performance of the production systems.
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: In the paper we discuss the influence of the route
flexibility degree, the open rate of operations and the production type
coefficient on makespan. The flexible job-open shop scheduling
problem FJOSP (an extension of the classical job shop scheduling) is
analyzed. For the analysis of the production process we used a
hybrid heuristic of the GRASP (greedy randomized adaptive search
procedure) with simulated annealing algorithm. Experiments with
different levels of factors have been considered and compared. The
GRASP+SA algorithm has been tested and illustrated with results for
the serial route and the parallel one.
Abstract: Development of a Robust Supply Chain for Dynamic
Operating Environment as we move further into the twenty first
century, organisations are under increasing pressure to deliver a high
product variation at a reasonable cost without compromise in quality.
In a number of cases this will take the form of a customised or high
variety low volume manufacturing system that requires prudent
management of resources, among a number of functions, to achieve
competitive advantage. Purchasing and Supply Chain management is
one of such function and due to the substantial interaction with
external elements needs to be strategically managed. This requires a
number of primary and supporting tools that will enable the
appropriate decisions to be made rapidly. This capability is
especially vital in a dynamic environment as it provides a pivotal role
in increasing the profit margin of the product. The management of
this function can be challenging by itself and even more for Small
and Medium Enterprises (SMEs) due to the limited resources and
expertise available at their disposal.
This paper discusses the development of tools and concepts
towards effectively managing the purchasing and supply chain
function. The developed tools and concepts will provide a cost
effective way of managing this function within SMEs. The paper
further shows the use of these tools within Contechs, a manufacturer
of luxury boat interiors, and the associated benefits achieved as a
result of this implementation. Finally a generic framework towards
use in such environments is presented.
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: Lean manufacturing is a production philosophy made
popular by Toyota Motor Corporation (TMC). It is globally known as
the Toyota Production System (TPS) and has the ultimate aim of
reducing cost by thoroughly eliminating wastes or muda. TPS
embraces the Just-in-time (JIT) manufacturing; achieving cost
reduction through lead time reduction. JIT manufacturing can be
achieved by implementing Pull system in the production.
Furthermore, TPS aims to improve productivity and creating
continuous flow in the production by arranging the machines and
processes in cellular configurations. This is called as Cellular
Manufacturing Systems (CMS). This paper studies on integrating the
CMS with the Pull system to establish a Big Island-Pull system
production for High Mix Low Volume (HMLV) products in an
automotive component industry. The paper will use the build-in JIT
system steps adapted from TMC to create the Pull system production
and also create a shojinka line which, according to takt time, has the
flexibility to adapt to demand changes simply by adding and taking
out manpower. This will lead to optimization in production.
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: Process planning and production scheduling play
important roles in manufacturing systems. In this paper a multiobjective
mixed integer linear programming model is presented for
the integrated planning and scheduling of multi-product. The aim is
to find a set of high-quality trade-off solutions. This is a
combinatorial optimization problem with substantially large solution
space, suggesting that it is highly difficult to find the best solutions
with the exact search method. To account for it, a PSO-based
algorithm is proposed by fully utilizing the capability of the
exploration search and fast convergence. To fit the continuous PSO
in the discrete modeled problem, a solution representation is used in
the algorithm. The numerical experiments have been performed to
demonstrate the effectiveness of the proposed algorithm.
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 current trend of increasing quality and demands
of the final product is affected by time analysis of the entire
manufacturing process. The primary requirement of manufacturing is
to produce as many products as soon as possible, at the lowest
possible cost, but of course with the highest quality. Such
requirements may be satisfied only if all the elements entering and
affecting the production cycle are in a fully functional condition.
These elements consist of sensory equipment and intelligent control
elements that are essential for building intelligent manufacturing
systems. The intelligent manufacturing paradigm includes a new
approach to production system structure design. Intelligent behaviors
are based on the monitoring of important parameters of system and
its environment. The flexible reaction to changes. The realization and
utilization of this design paradigm as an "intelligent manufacturing
system" enables the flexible system reaction to production
requirement as soon as environmental changes too. Results of these
flexible reactions are a smaller layout space, be decreasing of
production and investment costs and be increasing of productivity.
Intelligent manufacturing system itself should be a system that can
flexibly respond to changes in entering and exiting the process in
interaction with the surroundings.
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: This paper aims to study the methodology of building the knowledge of planning adequate punches in order to complete the task of strip layout for shearing processes, using progressive dies. The proposed methodology uses die design rules and characteristics of different types of punches to classify them into five groups: prior use (the punches must be used first), posterior use (must be used last), compatible use (may be used together), sequential use (certain punches must precede some others) and simultaneous use (must be used together). With these five groups of punches, the searching space of feasible designs will be greatly reduced, and superimposition becomes a more effective method of punch layout. The superimposition scheme will generate many feasible solutions, an evaluation function based on number of stages, moment balancing and strip stability is developed for helping designers to find better solutions.