Abstract: Paper presents a low power, high speed, sense-amplifier based flip-flop (SAFF). The flip-flop’s power con-sumption and delay are greatly reduced by employing a new conditionally precharge sense-amplifier stage and a single-ended latch stage. Glitch-free and contention-free latch operation is achieved by using a conditional cut-off strategy. The design uses fewer transistors, has a lower clock load, and has a simple structure, all of which contribute to a near-zero setup time. When compared to previous flip-flop structures proposed for similar input/output conditions, this design’s performance and overall PDP have improved. The post layout simulation of the circuit uses 2.91µW of power and has a delay of 65.82 ps. Overall, the power-delay product has seen some enhancements. Cadence Virtuoso Designing tool with CMOS 90nm technology are used for all designs.
Abstract: Manufacturing cost and setup time are the hot topics to improve in Metal Stamping industry because material and components price are always rising up while costumer requires to cut down the component price year by year. The Single Minute Exchange of Die (SMED) is one of many methods to reduce waste in stamping industry. The Japanese Quick Die Change (QDC) dies system is one of SMED systems that could reduce both of setup time and manufacturing cost. However, this system is rarely used in stamping industries. This paper will analyze how deep the QDC dies system could reduce setup time and the manufacturing cost. The research is conducted by direct observation, simulating and comparing of QDC dies system with conventional dies system. In this research, we found that the QDC dies system could save up to 35% of manufacturing cost and reduce 70% of setup times. This simulation proved that the QDC die system is effective for cost reduction but must be applied in several parallel production processes.
Abstract: The problem of Order Acceptance and Scheduling (OAS) is defined as a joint decision of which orders to accept for processing and how to schedule them. Any linear programming model representing real-world situation involves the parameters defined by the decision maker in an uncertain way or by means of language statement. Fuzzy data can be used to incorporate vagueness in the real-life situation. In this study, a fuzzy mathematical model is proposed for a single machine OAS problem, where the orders are defined by their fuzzy due dates, fuzzy processing times, and fuzzy sequence dependent setup times. The signed distance method, one of the fuzzy ranking methods, is used to handle the fuzzy constraints in the model.
Abstract: In this paper, we introduce a flexible box erecting
machine (BEM) that swiftly and automatically transforms cardboard
into a three dimensional box. Recently, the parcel service and
home-shopping industries have grown rapidly, and there is an
increasing need for various box types to ship various products.
However, workers cannot fold thousands of boxes manually in a day.
As such, automatic BEMs are garnering greater attention. This study
takes equipment operation into consideration as well as mechanical
improvements in order to design a BEM that is able to outperform its
conventional counterparts. We analyzed six dispatching rules – First In
First Out (FIFO), Shortest Processing Time (SPT), Earliest Due Date
(EDD), Setup Avoidance, EDD + SPT, and EDD + Setup Avoidance –
to determine which one was most suitable for BEM operation.
Consequently, SPT and Setup Avoidance were found to be the most
critical rules, followed by EDD + Setup Avoidance, EDD + SPT,
EDD, and FIFO. This hierarchy was valid for both our conventional
BEM and our new flexible BEM from the viewpoint of processing
time. We believe that this research can contribute to flexible BEM
management, which has the potential to increase productivity and
convenience.
Abstract: The market competition is moving from the single
firm to the whole supply chain because of increasing competition and
growing need for operational efficiencies and customer orientation.
Supply chain management allows companies to look beyond their
organizational boundaries to develop and leverage resources and
capabilities of their supply chain partners. This creates competitive
advantages in the marketplace and because of this SCM has acquired
strategic importance. Lean Approach is a management strategy that focuses on reducing
every type of waste present in an organization. This approach is
becoming more and more popular among supply chain managers. The supply chain application of lean approach is not frequent. In
particular, it is not well studied which are the impacts of lean
approach principles in a supply chain context. In literature there are
only few studies aimed at understanding the qualitative impact of the
lean approach in supply chains. Therefore, the goal of this research
work is to study the impacts of lean principles implementation along
a supply chain. To achieve this, a simulation model of a threeechelon
multi-product supply chain has been built. Kanban system (and several priority policies) and setup time
reduction degrees are implemented in the lean-configured supply
chain to apply pull and lot-sizing decrease principles respectively. To
evaluate the benefits of lean approach, lean supply chain is compared
with an EOQ-configured supply chain. The simulation results show
that Kanban system and setup-time reduction improve inventory
stock level. They also show that logistics efforts are affected to lean
implementation degree. The paper concludes describing
performances of lean supply chain in different contexts.
Abstract: This paper presents optimization of makespan for ‘n’
jobs and ‘m’ machines flexible job shop scheduling problem with
sequence dependent setup time using genetic algorithm (GA)
approach. A restart scheme has also been applied to prevent the
premature convergence. Two case studies are taken into
consideration. Results are obtained by considering crossover
probability (pc = 0.85) and mutation probability (pm = 0.15). Five
simulation runs for each case study are taken and minimum value
among them is taken as optimal makespan. Results indicate that
optimal makespan can be achieved with more than one sequence of
jobs in a production order.
Abstract: This paper presents an application of the Single-Minute Exchange of Die (SMED) methodology to a turret punching machine in an elevators company, in Portugal. The work was developed during five months, in the ambit of a master thesis in Industrial Engineering and Management. The Lean Production tool SMED was applied to reduce setup times in order to improve the production flexibility of the machine. The main results obtained were a reduction of 64% in setup time (from 15.1 to 5.4min), 50% in work-in-process amount (from 12.8 to 6.4 days) and 99% in the distance traveled by the operator during the internal period (from 136.7 to 1.7m). These improvements correspond to gains of about €7,315.38 per year.
Abstract: Single Minute Exchange of Dies (SMED) mainly focuses on recognition of internal and external activities. It is concerned particularly with transferring internal activities into external ones in as many numbers as possible, by also minimizing the internal ones. The validity of the method and procedures are verified by an application a Styrofoam manufacturing process where setup times are critical for time reduction. Significant time savings have been achieved with minimum investment. Further, the issues related with employer safety and ergonomics principles during die exchange are noted.
Abstract: The problem of lot sizing, sequencing and scheduling
multiple products in flow line production systems has been studied
by several authors. Almost all of the researches in this area assumed
that setup times and costs are sequence –independent even though
sequence dependent setups are common in practice. In this paper we
present a new mixed integer non linear program (MINLP) and a
heuristic method to solve the problem in sequence dependent case.
Furthermore, a genetic algorithm has been developed which applies
this constructive heuristic to generate initial population. These two
proposed solution methods are compared on randomly generated
problems. Computational results show a clear superiority of our
proposed GA for majority of the test problems.
Abstract: In this paper, multi-processors job shop scheduling problems are solved by a heuristic algorithm based on the hybrid of priority dispatching rules according to an ant colony optimization algorithm. The objective function is to minimize the makespan, i.e. total completion time, in which a simultanous presence of various kinds of ferons is allowed. By using the suitable hybrid of priority dispatching rules, the process of finding the best solution will be improved. Ant colony optimization algorithm, not only promote the ability of this proposed algorithm, but also decreases the total working time because of decreasing in setup times and modifying the working production line. Thus, the similar work has the same production lines. Other advantage of this algorithm is that the similar machines (not the same) can be considered. So, these machines are able to process a job with different processing and setup times. According to this capability and from this algorithm evaluation point of view, a number of test problems are solved and the associated results are analyzed. The results show a significant decrease in throughput time. It also shows that, this algorithm is able to recognize the bottleneck machine and to schedule jobs in an efficient way.
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: We consider a typical problem in the assembly of
printed circuit boards (PCBs) in a two-machine flow shop system to
simultaneously minimize the weighted sum of weighted tardiness and
weighted flow time. The investigated problem is a group scheduling
problem in which PCBs are assembled in groups and the interest is to
find the best sequence of groups as well as the boards within each
group to minimize the objective function value. The type of setup
operation between any two board groups is characterized as carryover
sequence-dependent setup time, which exactly matches with the real
application of this problem. As a technical constraint, all of the
boards must be kitted before the assembly operation starts (kitting
operation) and by kitting staff. The main idea developed in this paper
is to completely eliminate the role of kitting staff by assigning the
task of kitting to the machine operator during the time he is idle
which is referred to as integration of internal (machine) and external
(kitting) setup times. Performing the kitting operation, which is a
preparation process of the next set of boards while the other boards
are currently being assembled, results in the boards to continuously
enter the system or have dynamic arrival times. Consequently, a
dynamic PCB assembly system is introduced for the first time in the
assembly of PCBs, which also has characteristics similar to that of
just-in-time manufacturing. The problem investigated is
computationally very complex, meaning that finding the optimal
solutions especially when the problem size gets larger is impossible.
Thus, a heuristic based on Genetic Algorithm (GA) is employed. An
example problem on the application of the GA developed is
demonstrated and also numerical results of applying the GA on
solving several instances are provided.
Abstract: This paper focuses on robust design and optimization
of industrial production wastes. Past literatures were reviewed to case
study Clamason Industries Limited (CIL) - a leading ladder-tops
manufacturer. A painstaking study of the firm-s practices at the shop
floor revealed that Over-production, Waiting time, Excess inventory,
and Defects are the major wastes that are impeding their progress and
profitability. Design expert8 software was used to apply Taguchi
robust design and response surface methodology in order to model,
analyse and optimise the wastes cost in CIL. Waiting time and overproduction
rank first and second in contributing to the costs of wastes
in CIL. For minimal wastes cost the control factors of overproduction,
waiting-time, defects and excess-inventory must be set at
0.30, 390.70, 4 and 55.70 respectively for CIL. The optimal value of
cost of wastes for the months studied was 22.3679. Finally, a
recommendation was made that for the company to enhance their
profitability and customer satisfaction, they must adopt the Shingeo
Shingo-s Single Minute Exchange of Dies (SMED), which will
immediately tackle the waste of waiting by drastically reducing their
setup time.
Abstract: Throughput is an important measure of performance of production system. Analyzing and modeling of production throughput is complex in today-s dynamic production systems due to uncertainties of production system. The main reasons are that uncertainties are materialized when the production line faces changes in setup time, machinery break down, lead time of manufacturing, and scraps. Besides, demand changes are fluctuating from time to time for each product type. These uncertainties affect the production performance. This paper proposes Bayesian inference for throughput modeling under five production uncertainties. Bayesian model utilized prior distributions related to previous information about the uncertainties where likelihood distributions are associated to the observed data. Gibbs sampling algorithm as the robust procedure of Monte Carlo Markov chain was employed for sampling unknown parameters and estimating the posterior mean of uncertainties. The Bayesian model was validated with respect to convergence and efficiency of its outputs. The results presented that the proposed Bayesian models were capable to predict the production throughput with accuracy of 98.3%.
Abstract: Flow-shop scheduling problem (FSP) deals with the
scheduling of a set of jobs that visit a set of machines in the same
order. The FSP is NP-hard, which means that an efficient algorithm
for solving the problem to optimality is unavailable. To meet the
requirements on time and to minimize the make-span performance of
large permutation flow-shop scheduling problems in which there are
sequence dependent setup times on each machine, this paper
develops one hybrid genetic algorithms (HGA). Proposed HGA
apply a modified approach to generate population of initial
chromosomes and also use an improved heuristic called the iterated
swap procedure to improve initial solutions. Also the author uses
three genetic operators to make good new offspring. The results are
compared to some recently developed heuristics and computational
experimental results show that the proposed HGA performs very
competitively with respect to accuracy and efficiency of solution.
Abstract: In this researcha particle swarm optimization (PSO)
algorithm is proposedfor no-wait flowshopsequence dependent
setuptime scheduling problem with weighted earliness-tardiness
penalties as the criterion (|,
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"
).The
smallestposition value (SPV) rule is applied to convert the continuous
value of position vector of particles in PSO to job permutations.A
timing algorithm is generated to find the optimal schedule and
calculate the objective function value of a given sequence in PSO
algorithm. Twodifferent neighborhood structures are applied to
improve the solution quality of PSO algorithm.The first one is based
on variable neighborhood search (VNS) and the second one is a
simple one with invariable structure. In order to compare the
performance of two neighborhood structures, random test problems
are generated and solved by both neighborhood
approaches.Computational results show that the VNS algorithmhas
better performance than the other one especially for the large sized
problems.