Abstract: This paper considers a multi criteria cell formation
problem in Cellular Manufacturing System (CMS). Minimizing the
number of voids and exceptional elements in cells simultaneously are
two proposed objective functions. This problem is an Np-hard
problem according to the literature, and therefore, we can-t find the
optimal solution by an exact method. In this paper we developed two
ant algorithms, Ant Colony Optimization (ACO) and Max-Min Ant
System (MMAS), based on Data Envelopment Analysis (DEA). Both
of them try to find the efficient solutions based on efficiency concept
in DEA. Each artificial ant is considered as a Decision Making Unit
(DMU). For each DMU we considered two inputs, the values of
objective functions, and one output, the value of one for all of them.
In order to evaluate performance of proposed methods we provided
an experimental design with some empirical problem in three
different sizes, small, medium and large. We defined three different
criteria that show which algorithm has the best performance.
Abstract: Overhead conveyor systems satisfy by their simple
construction, wide application range and their full compatibility with
other manufacturing systems, which are designed according to
international standards. Ultra-light overhead conveyor systems are
rope-based conveying systems with individually driven vehicles. The
vehicles can move automatically on the rope and this can be realized
by energy and signals. Crossings are realized by switches. Overhead
conveyor systems are particularly used in the automotive industry but
also at post offices. Overhead conveyor systems always must be
integrated with a logistical process by finding the best way for a
cheaper material flow and in order to guarantee precise and fast
workflows. With their help, any transport can take place without
wasting ground and space, without excessive company capacity, lost
or damaged products, erroneous delivery, endless travels and without
wasting time. Ultra-light overhead conveyor systems provide optimal
material flow, which produces profit and saves time. This article
illustrates the advantages of the structure of the ultra-light overhead
conveyor systems in logistics applications and explains the steps of
their system design. After an illustration of the steps, currently
available systems on the market will be shown by means of their
technical characteristics. Due to their simple construction, demands
to an ultra-light overhead conveyor system will be illustrated.
Abstract: In this contribution is presented a complex design of
individual objects identification in the workplace of intelligent
assembly cell. Intelligent assembly cell is situated at Institute of
Manufacturing Systems and Applied Mechanics and is used for
pneumatic actuator assembly. Pneumatic actuator components are
pneumatic roller, cover, piston and spring. Two identification objects
alternatives for assembly are designed in the workplace of industrial
robot. In the contribution is evaluated and selected suitable
alternative for identification – 2D codes reader. The complex design
of individual object identification is going out of intelligent
manufacturing systems knowledge.
Intelligent assembly and manufacturing systems as systems of
new generation are gradually loaded in to the mechanical production,
when they are removeing human operation out of production process
and they also short production times.
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: Guaranteeing the availability of the required parts at
the scheduled time represents a key logistical challenge. This is
especially important when several parts are required together. This
article describes a tool that supports the positioning in the area of
conflict between low stock costs and a high service level for a
consumer.
Abstract: Activity-Based Costing (ABC) represents an
alternative paradigm to traditional cost accounting system and
it often provides more accurate cost information for decision
making such as product pricing, product mix, and make-orbuy
decisions. ABC models the causal relationships between
products and the resources used in their production and traces
the cost of products according to the activities through the use
of appropriate cost drivers. In this paper, the implementation
of the ABC in a manufacturing system is analyzed and a
comparison with the traditional cost based system in terms of
the effects on the product costs are carried out to highlight the
difference between two costing methodologies. By using this
methodology, a valuable insight into the factors that cause the
cost is provided, helping to better manage the activities of the
company.
Abstract: In this paper a multi-objective nonlinear programming
model of cellular manufacturing system is presented which minimize
the intercell movements and maximize the sum of reliability of cells.
We present a genetic approach for finding efficient solutions to the
problem of cell formation for products having multiple routings.
These methods find the non-dominated solutions and according to
decision makers prefer, the best solution will be chosen.
Abstract: This paper was aimed at developing a computer aided
design and manufacturing system for spatial cylindrical cams. In the
proposed system, a milling tool with a diameter smaller than that of the
roller, instead of the standard cutter for traditional machining process,
was used to generate the tool path for spatial cams. To verify the
feasibility of the proposed method, a multi-axis machining simulation
software was further used to simulate the practical milling operation of
spatial cams. It was observed from computer simulation that the tool
path of small-sized cutter were within the motion range of a standard
cutter, no occurrence of overcutting. Examination of a finished cam
component clearly verifies the accuracy of the tool path generated for
small-sized milling tool. It is believed that the use of small-sized cutter
for the machining of the spatial cylindrical cams can generate a better
surface morphology with higher accuracy. The improvement in
efficiency and cost for the manufacturing of the spatial cylindrical cam
can be expected through the proposed method.
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.
Abstract: This paper mathematically analyses the varying
magnitude of production loss, which may occur due to idle time (inprocess
waiting time and traveling time) on a linear walking worker
assembly line. Within this flexible and reconfigurable assembly
system, each worker travels down the line carrying out each
assembly task at each station; and each worker accomplishes the
assembly of a unit from start to finish and then travels back to the
first station to start the assembly of a new product. This strategy of
system design attempts to combine the flexibility of the U-shaped
moving worker assembly cell with the efficiency of the conventional
fixed worker assembly line. The paper aims to evaluate the effect of
idle time that may offset the labor efficiency of each walking worker
providing an insight into the mechanism of such a flexible and
reconfigurable assembly system.
Abstract: In the modern manufacturing systems, the use of
thermal cutting techniques using oxyfuel, plasma and laser have
become indispensable for the shape forming of high quality complex
components; however, the conventional chip removal production
techniques still have its widespread space in the manufacturing
industry. Both these types of machining operations require the
positioning of end effector tool at the edge where the cutting process
commences. This repositioning of the cutting tool in every machining
operation is repeated several times and is termed as non-productive
time or airtime motion. Minimization of this non-productive
machining time plays an important role in mass production with high
speed machining. As, the tool moves from one region to the other by
rapid movement and visits a meticulous region once in the whole
operation, hence the non-productive time can be minimized by
synchronizing the tool movements. In this work, this problem is
being formulated as a general travelling salesman problem (TSP) and
a genetic algorithm approach has been applied to solve the same. For
improving the efficiency of the algorithm, the GA has been
hybridized with a noble special heuristic and simulating annealing
(SA). In the present work a novel heuristic in the combination of GA
has been developed for synchronization of toolpath movements
during repositioning of the tool. A comparative analysis of new Meta
heuristic techniques with simple genetic algorithm has been
performed. The proposed metaheuristic approach shows better
performance than simple genetic algorithm for minimization of nonproductive
toolpath length. Also, the results obtained with the help of
hybrid simulated annealing genetic algorithm (HSAGA) are also
found better than the results using simple genetic algorithm only.
Abstract: This paper presents modeling and optimization of two NP-hard problems in flexible manufacturing system (FMS), part type selection problem and loading problem. Due to the complexity and extent of the problems, the paper was split into two parts. The first part of the papers has discussed the modeling of the problems and showed how the real coded genetic algorithms (RCGA) can be applied to solve the problems. This second part discusses the effectiveness of the 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: In the past years, the world has witnessed significant work in the field of Manufacturing. Special efforts have been made in the implementation of new technologies, management and control systems, among many others which have all evolved the field. Closely following all this, due to the scope of new projects and the need of turning the existing flexible ideas into more autonomous and intelligent ones, i.e.: moving toward a more intelligent manufacturing, the present paper emerges with the main aim of contributing to the analysis and a few customization issues of a new iCIM 3000 system at the IPSAM. In this process, special emphasis in made on the material flow problem. For this, besides offering a description and analysis of the system and its main parts, also some tips on how to define other possible alternative material flow scenarios and a partial analysis of the combinatorial nature of the problem are offered as well. All this is done with the intentions of relating it with the use of simulation tools, for which these have been briefly addressed with a special focus on the Witness simulation package. For a better comprehension, the previous elements are supported by a few figures and expressions which would help obtaining necessary data. Such data and others will be used in the future, when simulating the scenarios in the search of the best material flow configurations.
Abstract: Lately, significant work in the area of Intelligent
Manufacturing has become public and mainly applied within the
frame of industrial purposes. Special efforts have been made in the
implementation of new technologies, management and control
systems, among many others which have all evolved the field. Aware
of all this and due to the scope of new projects and the need of
turning the existing flexible ideas into more autonomous and
intelligent ones, i.e.: Intelligent Manufacturing, the present paper
emerges with the main aim of contributing to the design and analysis
of the material flow in either systems, cells or work stations under
this new “intelligent" denomination. For this, besides offering a
conceptual basis in some of the key points to be taken into account
and some general principles to consider in the design and analysis of
the material flow, also some tips on how to define other possible
alternative material flow scenarios and a classification of the states a
system, cell or workstation are offered as well. All this is done with
the intentions of relating it with the use of simulation tools, for which
these have been briefly addressed with a special focus on the Witness
simulation package. For a better comprehension, the previous
elements are supported by a detailed layout, other figures and a few
expressions which could help obtaining necessary data. Such data and
others will be used in the future, when simulating the scenarios in the
search of the best material flow configurations.
Abstract: This paper presents a novel two-phase hybrid optimization algorithm with hybrid genetic operators to solve the optimal control problem of a single stage hybrid manufacturing system. The proposed hybrid real coded genetic algorithm (HRCGA) is developed in such a way that a simple real coded GA acts as a base level search, which makes a quick decision to direct the search towards the optimal region, and a local search method is next employed to do fine tuning. The hybrid genetic operators involved in the proposed algorithm improve both the quality of the solution and convergence speed. The phase–1 uses conventional real coded genetic algorithm (RCGA), while optimisation by direct search and systematic reduction of the size of search region is employed in the phase – 2. A typical numerical example of an optimal control problem with the number of jobs varying from 10 to 50 is included to illustrate the efficacy of the proposed algorithm. Several statistical analyses are done to compare the validity of the proposed algorithm with the conventional RCGA and PSO techniques. Hypothesis t – test and analysis of variance (ANOVA) test are also carried out to validate the effectiveness of the proposed algorithm. The results clearly demonstrate that the proposed algorithm not only improves the quality but also is more efficient in converging to the optimal value faster. They can outperform the conventional real coded GA (RCGA) and the efficient particle swarm optimisation (PSO) algorithm in quality of the optimal solution and also in terms of convergence to the actual optimum value.
Abstract: In this paper, a particle swarm optimization (PSO)
algorithm is proposed to solve machine loading problem in flexible
manufacturing system (FMS), with bicriterion objectives of
minimizing system unbalance and maximizing system throughput in
the occurrence of technological constraints such as available
machining time and tool slots. A mathematical model is used to
select machines, assign operations and the required tools. The
performance of the PSO is tested by using 10 sample dataset and the
results are compared with the heuristics reported in the literature. The
results support that the proposed PSO is comparable with the
algorithms reported in the literature.
Abstract: In this paper is study the possibility of successfully
implementing of hollow roller concept in order to minimize inertial
mass of the large bearings, with major results in diminution of the
material consumption, increasing of power efficiency (in wind power
station area), increasing of the durability and life duration of the large
bearings systems, noise reduction in working, resistance to
vibrations, an important diminution of losses by abrasion and
reduction of the working temperature. In this purpose was developed
an original solution through which are reduced mass, inertial forces
and moments of large bearings by using of hollow rollers. The
research was made by using the method of finite element analysis
applied on software type Solidworks - Nastran. Also, is study the
possibility of rapidly changing the manufacturing system of solid and
hollow cylindrical rollers.
Abstract: As business environments are rapidly changing,
the manufacturing system must be reconfigured to adapt to
various customer needs. In order to cope with this challenge, it
is quintessential to test industrial control logic rapidly and
easily in the design time, and monitor operational behavior in
the run time of automated manufacturing system. Proposed
integrated model for virtual prototyping and operational
monitoring of industrial control logic is to improve limitations
of current ladder programming practices and general discrete
event simulation method. Each plant layout model using HMI
package and object-oriented control logic model is designed
independently and is executed simultaneously in integrated
manner to reflect design practices of automation system in the
design time. Control logic is designed and executed using UML
activity diagram without considering complicated control
behavior to deal with current trend of reconfigurable
manufacturing. After the physical installation, layout model of
virtual prototype constructed in the design time is reused for
operational monitoring of system behavior during run time.
Abstract: In today-s global and competitive market,
manufacturing companies are working hard towards improving their
production system performance. Most companies develop production
systems that can help in cost reduction. Manufacturing systems
consist of different elements including production methods,
machines, processes, control and information systems. Human issues
are an important part of manufacturing systems, yet most companies
do not pay sufficient attention to them. In this paper, a workforce
planning (WP) model is presented. A non-linear programming model
is developed in order to minimize the hiring, firing, training and
overtime costs. The purpose is to determine the number of workers
for each worker type, the number of workers trained, and the number
of overtime hours. Moreover, a decision support system (DSS) based
on the proposed model is introduced using the Excel-Lingo software
interfacing feature. This model will help to improve the interaction
between the workers, managers and the technical systems in
manufacturing.
Abstract: The existence of maximal durations drastically modifies the performance evaluation in Discrete Event Systems (DES). The same particularity may be found on systems where the associated constraints do not concern the time. For example weight measures, in chemical industry, are used in order to control the quantity of consumed raw materials. This parameter also takes a fundamental part in the product quality as the correct transformation process is based upon a given percentage of each essence. Weight regulation therefore increases the global productivity of the system by decreasing the quantity of rejected products. In this paper we present an approach based on mixing different characteristics theories, the fuzzy system and Petri net system to describe the behaviour. An industriel application on a tobacco manufacturing plant, where the critical parameter is the weight is presented as an illustration.