Flowshop scheduling problem with a batching machine and task compatibilities

This paper deals with the problem of task scheduling in a flowshop with two (discrete and batching) machines. Each task has to be processed by both machines. All tasks visit the machines in the same order. The first machine is a discrete machine that can process no more than one task at a time, and the second machine is a batching machine that can process several tasks per batch with the additional feature that the tasks of the same batch have to be compatible. A compatibility relation is defined between each pair of tasks, so that an undirected compatibility graph is obtained which turns out to be an interval graph. The batch processing time is equal to the maximal processing time of the tasks in this batch and all tasks of the same batch start and finish together. The aim is to make batching and sequencing decisions and minimize the makespan.     

Scheduling hybrid flowshop with parallel batching machines and compatibilities

This paper considers a two-stage hybrid flowshop problem in which the first stage contains several identical discrete machines, and the second stage contains several identical batching machines. Each discrete machine can process no more than one task at time, and each batching machine can process several tasks simultaneously in a batch with the additional feature that the tasks of the same batch have to be compatible. A compatibility relation is defined between each pair of tasks, so that an undirected compatibility graph is obtained which turns out to be an interval graph. The batch processing time is equal to the maximal processing time of the tasks in this batch, and all tasks of the same batch start and finish together. The goal is to make batching and sequencing decisions in order to minimize the makespan. Since the problem is NP-hard, we develop several heuristics along with their worst cases analysis. We also consider the case in which tasks have the same processing time on the first stage, for which a polynomial time approximation scheme (PTAS) algorithm is presented.     

Machining process sequencing with fuzzy expert system and genetic algorithms

Traditional process planning systems are usually established in a deterministic framework that can only deal with precise information. However, in a practical manufacturing environment, decision making frequently involves uncertain and imprecise information. This paper describes a fuzzy approach for solving the process selection and sequencing problem under uncertainty. The proposed approach comprises a two-stage process for machining process selection and sequencing. The two stages are called intra-feature planning and inter-feature planning, respectively. According to the feature precedence relationship of a machined part, the intra-feature planning module generates a local optimal operation sequence for each feature element. This is based on a fuzzy expert system incorporated with genetic algorithms for machining cost optimization according to the cost-tolerance relationship. Manufacturing resources such as machines, tools, and fixtures are allocated to each selected operation to form an Operation-Machine-Tool (OMT) unit in the manufacturing resources allocation module. Finally, inter-feature planning generates a global OMT sequence. A genetic algorithm with fuzzy numbers and fuzzy arithmetic is developed to solve this global sequencing problem.     

Bicriteria robotic operation allocation in a flexible manufacturing cell

Consider a manufacturing cell of two identical CNC machines and a material handling robot. Identical parts requesting the completion of a number of operations are to be produced in a cyclic scheduling environment through a flow shop type setting. The existing studies in the literature overlook the flexibility of the CNC machines by assuming that both the allocation of the operations to the machines as well as their respective processing times are fixed. Consequently, the provided results may be either suboptimal or valid under unnecessarily limiting assumptions for a flexible manufacturing cell. The allocations of the operations to the two machines and the processing time of an operation on a machine can be changed by altering the machining conditions of that machine such as the speed and the feed rate in a CNC turning machine. Such flexibilities constitute the point of origin of the current study. The allocation of the operations to the machines and the machining conditions of the machines affect the processing times which, in turn, affect the cycle time. On the other hand, the machining conditions also affect the manufacturing cost. This study is the first to consider a bicriteria model which determines the allocation of the operations to the machines, the processing times of the operations on the machines, and the robot move sequence that jointly minimize the cycle time and the total manufacturing cost. We provide algorithms for the two 1-unit cycles and test their efficiency in terms of the solution quality and the computation time by a wide range of experiments on varying design parameters.     

Makespan minimization in a no-wait flow shop problem with two batching machines

This paper deals with the problem of task scheduling in a no-wait flowshop with two batching machines. Each task has to be processed by both machines. All tasks visit the machines in the same order. Batching machines can process several tasks per batch so that all tasks of the same batch start and complete together. The batch processing time for the first machine is equal to the maximal processing time of the tasks in this batch, and for the second machine is equal to the sum of the processing times of the tasks in this batch. We assume that the capacity of any batch on the first machine is bounded, and that when a batch is completed on the first machine it is immediately transferred to the second machine. The aim is to make batching and sequencing decisions that allow the makespan to be minimized.     

Dynamic programming solution to the batching problem in just-in-time flow-shops

Mixed-model manufacturing systems are widely used by companies, in order to meet the customers’ demand for a variety of products, in an efficient way. This paper is concerned with a special class of mixed-model manufacturing systems: flow-shops. In a flow-shop, each product has to be processed by a number of machines, following a common route. We study the production smoothing problem under presence of non-zero setup and processing times which also vary among the products. We split the master problem into two sub-problems which are concerned with determining the batch sizes and production sequences, respectively. We develop a dynamic programming procedure to solve the batching problem, and suggest using an existing method from the current literature to solve the sequencing problem. We conduct a computational study and show that our solution approach is effective in meeting the JIT goals and efficient in its computational requirements.     

Intra-cell manpower transfers and cell loading in labor-intensive manufacturing cells

Labor-intensive manufacturing cells consist of simple machines and equipment that require continuous operator attendance and involvement. Operators are often re-assigned to different machines when a new product is released to the cell. The main reason for this re-assignment is to maximize the output rate of the cell by balancing the flow of products through several machines with varying capacities. In this paper, first a product-sequencing problem with the objective of minimizing the total intra-cell manpower transfers is introduced. A three-phase hierarchical methodology is proposed to solve the problem optimally. Next, manpower transfer matrix values are modified considering the distances traveled among machines. In the second part of the paper, a machine-level-based similarity coefficient that uses the number of machines as a similarity measure is discussed. Later, these coefficients are used during the cell loading process to minimize makespan and also machine and space requirements. Manpower allocation decisions are made along with scheduling decisions that are critical in most labor-intensive manufacturing cells and both approaches are illustrated with an example problem.     

Scheduling a batching machine with convex resource consumption functions

In various industries jobs undergo a batching, or burn in, process where different tasks are grouped into batches and processed simultaneously. The processing time of each batch is equal to the longest processing time among all jobs contained in the batch. All to date studies dealing with batching machines have considered fixed job processing times. However, in many real life applications job processing times are controllable through the allocation of a limited resource. The most common and realistic model assumes that there exists a non-linear and convex relationship between the amount of resource allocated to a job and its processing time. The scheduler?s task when dealing with controllable processing times is twofold. In addition to solving the sequencing problem, one must establish an optimal resource allocation policy. We combine these two widespread models on a single machine setting, showing that both the makespan and total completion time criteria can be solved in polynomial time. We then show that our proposed approach can be applied to general bi-criteria objective comprising of the makespan and the total completion time.     

Scheduling-Framework für Jobs auf parallelen Maschinen in komplexen Produktionssystemen

The paper describes a framework for parallel machine scheduling in complex manufacturing systems. Complex manufacturing systems are characterized by groups of parallel machines, machine dedications, sequence dependent setup times, batch processes, prescribed due dates of the jobs, and a diverse and over time changing product mix. In the present paper, a four-phase algorithm is suggested that covers a broad range of process conditions. The frameworks contains a first phase that deals with the formation of scheduling entities. The second phase is used to assign the scheduling entities to the parallel machines. The sequence of the scheduling entities is determined in the third phase on each single machine. The schedules are improved by the final, optional fourth phase. The paper describes software development issues, the integration of the framework into other information systems on the shopfloor, and the performance assessment of a case study.     

Minimizing total weighted tardiness on a single batch process machine with incompatible job families

The diffusion step in semiconductor wafer fabrication is very time consuming, compared to other steps in the process, and performance in this area has a significant impact on overall factory performance. Diffusion furnaces are able to process multiple lots of similar wafers at a time, and are therefore appropriately modeled as batch processing machines with incompatible job families. Due to the importance of on-time delivery in semiconductor manufacturing, we focus on minimizing the total weighted tardiness in this environment. The resulting problem is NP-Hard, and we decompose it into two sequential decision problems: assigning lots to batches followed by sequencing the batches. We develop several heuristics for these subproblems and test their performance.     

Scheduling of parallel machines with sequence-dependent batches and product incompatibilities in an automotive glass facility

This application is motivated by a complex real-world scheduling problem found in the bottleneck workstation of the production line of an automotive safety glass manufacturing facility. The scheduling problem consists of scheduling jobs (glass parts) on a number of parallel batch processing machines (furnaces), assigning each job to a batch, and sequencing the batches on each machine. The two main objectives are to maximize the utilization of the parallel machines and to minimize the delay in the completion date of each job in relation to a required due date (specific for each job). Aside from the main objectives, the output batches should also produce a balanced workload on the parallel machines, balanced job due dates within each batch, and minimal capacity loss in the batches. The scheduling problem also considers a batch capacity constraint, sequence-dependent processing times, incompatible product families, additional resources, and machine capability. We propose a two-phase heuristic approach that combines exact methods with search heuristics. The first phase comprises a four-stage mixed-integer linear program for building the batches; the second phase is based on a Greedy Randomized Adaptive Search Procedure for sequencing the batches assigned to each machine. We conducted experiments on instances with up to 100 jobs built with real data from the manufacturing facility. The results are encouraging both in terms of computing time—5 min in average—and quality of the solutions—less than 10 % relative gap from the optimal solution in the first phase and less than 5 % in the second phase. Additional experiments were conducted on randomly generated instances of small, medium, and large size.     

A modeling technique for loading and scheduling problems in FMS

In recent years, due to highly competitive market conditions, it has become necessary for manufacturing systems to have quick response times and high flexibility. Flexible manufacturing systems (FMS's) have gained attention in response to this challenge. FMS has the ability to produce a variety of parts using the same system. However this flexibility comes at the price, which is the development of efficient and effective methods for integrated production planning, and control.In this paper, we analyze the production planning problem in flexible manufacturing systems. We address the problems of part loading, tool loading, and part scheduling. We assume that there is a set of tools with known life and a set of machines that can produce a variety of parts. A batch of various part types is routed through this system with the assumption that the processing time and cost vary with the assignment of parts to different machines and assignment of various tool sets to machines. We developed a mathematical model to select machines and assign operations and the required tools to machines in order to minimize the summation of maximum completion time, material handling time, and total processing time.We first integrate and formulate loading, and routing, two of the most important FMS planning problems, as a 0–1 mixed integer programming problem. We then take the output from the integrated planning model and generate a detailed operations schedule. The results reported in this paper demonstrate the model efficiency and examine the performance of the system with respect to measures such as production rate and utilization.     

Statistical measures for quantifying task and machine heterogeneities

We study heterogeneous computing (HC) systems that consist of a set of different machines that have varying capabilities. These machines are used to execute a set of heterogeneous tasks that vary in their computational complexity. Finding the optimal mapping of tasks to machines in an HC system has been shown to be, in general, an NP-complete problem. Therefore, heuristics have been used to find near-optimal mappings. The performance of allocation heuristics can be affected significantly by factors such as task and machine heterogeneities. In this paper, we identify different statistical measures used to quantify the heterogeneity of HC systems, and show the correlation between the performance of the heuristics and these measures through simple mapping examples and synthetic data analysis. In addition, we illustrate how regression trees can be used to predict the most appropriate heuristic for an HC system based on its heterogeneity.     

The impact of OPT and TPM on the economic production quantity

In manufacturing systems, the material flow is influenced by a number of factors, such as batching policies, capacity of machines, machine breakdowns, etc. Realizing the role of batching policies and reliability of machines in production systems, a mathematical model is presented here for determining optimal batching policies with the objective of improving the speed of material flow considering machine breakdowns and batch splitting and forming. This model is employed for studying (i) the significance of total preventive maintenance (TPM); (ii) the use of the optimized production technology (OPT) concept in batching policies; and (iii) the influence of a set-up cost reduction programme on the performance of manufacturing systems. The basic criterion considered for optimizing the batch sizes is the minimization of total system cost (TSC). An example problem is solved to explain the application of the model.     

Capacity planning with ant colony optimization for TFT-LCD array manufacturing

Array manufacturing in thin film transistor-liquid crystal display (TFT-LCD) production network is characterized as a capital-intensive and capacity-constrained production system with re-entrance and batch operations. Effectively using associated machines through optimal capacity planning and order scheduling decisions is a critical issue for array manufacturing. This study develops a capacity planning system (CPS) for TFT-LCD array manufacturing. CPS uses information including master production schedule, order due date, process routing, processing time, and number of machines. In addition, CPS derives the order release time, estimated machine start and finish time, machine allocation, and order completion time to maximize machine workload, improve lateness, and eliminate setup time. This research also develops ant colony optimization (ACO) to seek the optimal order release schedule to maximize a combination of the above objectives. The preliminary experiments are first applied to identify the optimal tuning parameters of the ACO algorithm. Computational experiments are then conducted to evaluate the significance and the robustness of the proposed algorithm compared with other competitive algorithms by full factorial experimental design.     

自动导引车与机器集成调度问题研究现状

随着自动导引车（automated guided vehicles,AGV）的广泛应用,柔性制造车间中机器设备与AGV之间的协同配合日益受到重视。AGV与机器的集成调度主要研究机器分配、工序排序、搬运任务的AGV分配以及AGV路径规划。该问题是极为复杂的组合优化问题,对其研究具有重要的学术意义和应用价值。围绕问题特征,从模型与算法两个方面,对国内外最新的研究文献进行了梳理。对现有模型中的约束条件和优化目标进行了详细分类,从遗传算法、混合优化算法、仿真优化算法等五个方面综述了现有算法研究中的代表性成果。在此基础上,指出了现有研究中的不足,提出了未来的研究内容和方向。     

From human – machine interaction to human – machine cooperation

Since the 1960s, the rapid growth of information systems has led to the wide development of research on human—computer interaction (HCI) that aims at the designing of human-computer interfaces presenting ergonomic properties, such as friendliness, usability, transparency, etc. Various work situations have been covered—clerical work, computer programming, design, etc. However, they were mainly static in the sense that the user fully controls the computer. More recently, public and private organizations have engaged themselves in the enterprise of managing more and more complex and coupled systems by the means of automation. Modern machines not only process information, but also act on dynamic situations as humans have done in the past, managing stock exchange, industrial plants, aircraft, etc. These dynamic situations are not fully controlled and are affected by uncertain factors. Hence, degrees of freedom must be maintained to allow the humans and the machine to adapt to unforeseen contingencies. A human-machine cooperation (HMC) approach is necessary to address the new stakes introduced by this trend. This paper describes the possible improvement of HCI by HMC, the need for a new conception of function allocation between humans and machines, and the main problems encountered within the new forms of human—machine relationship. It proposes a conceptual framework to study HMC from a cognitive point of view in highly dynamic situations like aircraft piloting or air-traffic control, and concludes on the design of ‘cooperative’ machines.     

From human-machine interaction to human-machine cooperation

Since the 1960s, the rapid growth of information systems has led to the wide development of research on human-computer interaction (HCI) that aims at the designing of human-computer interfaces presenting ergonomic properties, such as friendliness, usability, transparency, etc. Various work situations have been covered--clerical work, computer programming, design, etc. However, they were mainly static in the sense that the user fully controls the computer. More recently, public and private organizations have engaged themselves in the enterprise of managing more and more complex and coupled systems by the means of automation. Modern machines not only process information, but also act on dynamic situations as humans have done in the past, managing stock exchange, industrial plants, aircraft, etc. These dynamic situations are not fully controlled and are affected by uncertain factors. Hence, degrees of freedom must be maintained to allow the humans and the machine to adapt to unforeseen contingencies. A human-machine cooperation (HMC) approach is necessary to address the new stakes introduced by this trend. This paper describes the possible improvement of HCI by HMC, the need for a new conception of function allocation between humans and machines, and the main problems encountered within the new forms of human-machine relationship. It proposes a conceptual framework to study HMC from a cognitive point of view in highly dynamic situations like aircraft piloting or air-traffic control, and concludes on the design of 'cooperative' machines.     

Cyber physical process monitoring systems

Manufacturing process monitoring systems is evolving from centralised bespoke applications to decentralised reconfigurable collectives. The resulting cyber-physical systems are made possible through the integration of high power computation, collaborative communication, and advanced analytics. This digital age of manufacturing is aimed at yielding the next generation of innovative intelligent machines. The focus of this research is to present the design and development of a cyber-physical process monitoring system; the components of which consist of an advanced signal processing chain for the semi-autonomous process characterisation of a CNC turning machine tool. The novelty of this decentralised system is its modularity, reconfigurability, openness, scalability, and unique functionality. The function of the decentralised system is to produce performance criteria via spindle vibration monitoring, which is correlated to the occurrence of sequential process events via motor current monitoring. Performance criteria enables the establishment of normal operating response of machining operations, and more importantly the identification of abnormalities or trends in the sensor data that can provide insight into the quality of the process ongoing. The function of each component in the signal processing chain is reviewed and investigated in an industrial case study.     

Mean value analysis of re-entrant line with batch machines and multi-class jobs

We propose an approximate approach for estimating the performance measures of the re-entrant line with single-job machines and batch machines based on the mean value analysis (MVA) technique. Multi-class jobs are assumed to be processed in predetermined routings, in which some processes may utilize the same machines in the re-entrant fashion. The performance measures of interest are the steady-state averages of the cycle time of each job class, the queue length of each buffer, and the throughput of the system. The system may not be modeled by a product form queueing network due to the inclusion of the batch machines and the multi-class jobs with different processing times. Thus, we present a methodology for approximately analyzing such a re-entrant line using the iterative procedures based upon the MVA and some heuristic adjustments. Numerical experiments show that the relative errors of the proposed method are within 5% as compared against the simulation results.Scope and purposeWe consider a re-entrant shop with multi-class jobs, in which jobs may visit some machines more than once at different stages of processing, as observed in the wafer fabrication process of semiconductor manufacturing. The re-entrant line also consists of both the single-job machine and the batch machine. The former refers to the ordinary machine processing one job at a time, and the latter means the machine processing several jobs together as a batch at a time. In this paper, we propose an approximation method based on the mean value analysis for estimating the mean cycle time of each class of jobs, the mean queue length of each buffer, and the throughput of the system.