Design of robust cellular manufacturing system for dynamic part population considering multiple processing routes using genetic algorithm

In this paper, a comprehensive mathematical model is proposed for designing robust machine cells for dynamic part production. The proposed model incorporates machine cell configuration design problem bridged with the machines allocation problem, the dynamic production problem and the part routing problem. Multiple process plans for each part and alternatives process routes for each of those plans are considered. The design of robust cell configurations is based on the selected best part process route from user specified multiple process routes for each part type considering average product demand during the planning horizon. The dynamic part demand can be satisfied from internal production having limited capacity and/or through subcontracting part operation without affecting the machine cell configuration in successive period segments of the planning horizon. A genetic algorithm based heuristic is proposed to solve the model for minimization of the overall cost considering various manufacturing aspects such as production volume, multiple process route, machine capacity, material handling and subcontracting part operation.     

考虑柔性机器检修的钢管热轧批量调度方法

本文从无缝钢管生产管理中提取并定义了周期性机器柔性检修环境下的钢管热轧批量调度问题,针对无缝钢管热轧阶段的生产特点,将其抽象为一类考虑序列相关设置成本和机器柔性检修的单机调度问题,建立了以最小化机器闲置时间和机器调整时间为优化目标的数学模型。分析闲置时间和检修时点的关系,证明了闲置时间最小化性质,结合问题特征设计了两阶段启发式算法。算法第一阶段采用最小轧机调整时间规则获取具有最小机器调整时间的初始批量轧制序列,第二阶段对初始轧制序列进行全局寻优搜索。基于实际生产数据设计了多种问题规模的对比实验,实验结果表明模型和算法对求解该类问题具有较好效果。     

A two-stage hybrid flowshop scheduling problem in machine breakdown condition

This paper considers a two-stage hybrid flowshop scheduling problem in machine breakdown condition. By machine breakdown condition we mean that the machine may not always be available during the scheduling period. Machine failure may occur with a known probability after completing a job. Probability of machine failure depends on the previous processed job. The problem to be studied has one machine at the first stage and M parallel identical machines at the second stage. The objective is to find the optimal job combinations and the optimal job schedule such that the makespan is minimized. The proposed problem is compatible with a large scope of real world situations. To solve the problem, first, we introduce one optimal approach for job precedence when there is one machine in both stages and then provide a heuristic algorithm when there are M machines in stage two. To examine the performance of the heuristic, some experiments used are provided as well.     

Models for cell loading and product sequencing in labor-intensive cells

This paper focuses on cell loading issues and product sequencing in labor-intensive cells. In labor-intensive cells, there are usually more operators than number of operations and cells usually consists of simple and light-weight machines and equipment. A three-phase methodology is proposed to deal with this problem. The objectives considered are minimizing makespan, total machine requirements, and intra-cell manpower transfers. In the first phase, optimal manpower allocation to operations is determined for each product. Then, similarity among products is established based on the similarity of operator/machine levels. The second phase involves cell loading to minimize makespan and machine requirements. Two mathematical models are developed to accomplish these tasks. One mathematical model (model A) does not allow product splitting whereas model B allows product splitting. Finally, third phase treats the product sequencing problems as traveling salesman problem (TSP) where the objective is to minimize intra-cell manpower transfers. Experimentation is performed and the results are compared with those of a heuristic procedure developed earlier. The results show that model A or model B can be chosen over the heuristic procedure.     

基于两阶段高斯过程的天线建模方法

针对高斯过程机器学习解决电磁问题,提出了两阶段高斯过程的天线建模方法,共包含两个阶段,在第一阶段,学习天线的粗细模型之间的映射关系,从而在第二阶段建立起高精度细模型的实际代替模型,在降低天线高精度输入训练数据的计算代价上效果显著。将两阶段高斯过程建模方法应用在倒F天线的优化问题和双频PIFA天线的谐振频率预测问题中,通过选取细模型数据占总训练数据的不同比例,比较它们的多种误差,从而验证该两阶段高斯过程天线建模方法的有效性和准确性。     

The modified fuzzy art and a two-stage clustering approach to cell design

This study presents a new pattern recognition neural network for clustering problems, and illustrates its use for machine cell design in group technology. The proposed algorithm involves modifications of the learning procedure and resonance test of the Fuzzy ART neural network. These modifications enable the neural network to process integer values rather than binary valued inputs or the values in the interval [0, 1], and improve the clustering performance of the neural network. A two-stage clustering approach is also developed in order to obtain an informative and intelligent decision for the problem of designing a machine cell. At the first stage, we identify the part families with very similar parts (i.e., high similarity exists in their processing requirements), and the resultant part families are input to the second stage, which forms the groups of machines. Experimental studies show that the proposed approach leads to better results in comparison with those produced by the Fuzzy ART and other similar neural network classifiers.     

A cell formation problem considering machine utilization and alternative process routes by scatter search

Cell formation (CF) is the first step in the design of cellular manufacturing systems (CMSs), which has been recognized as an effective way to enhance the productivity in a factory. There is a set of criteria on which to judge route of product, machine grouping and part family simultaneously in terms of the effective utilization of these cells. In this study, we consider four objectives simultaneously: (1) Minimizing the total fixed and variable cost including costs of purchasing, operation, and maintenance; (2) minimizing cost of intercellular movements; (3) maximizing the utilization of machines in the system; and (4) minimizing deviations among the levels of the cell utilization (i.e., balancing the workload between cells). In this paper, these objectives are first weighted by their relative importance and then a new mathematical model is presented. To solve this model, a scatter search (SS) algorithm is proposed to select a process plan for each part with the minimum cost along with forming the part family and machine grouping simultaneously. The performance of the proposed SS is compared with the Lingo 8.0 software. A number of test problems are carried out to verify the good ability of the proposed SS in terms of the solution quality and computational time. The computational results reveal that the SS finds promising results, especially in the case of large-sized problems.     

Efficient operation of natural gas transmission systems: A network-based heuristic for cyclic structures

In this paper we propose a heuristic solution procedure for fuel cost minimization on gas transmission systems with a cyclic network topology, that is, networks with at least one cycle containing two or more compressor station arcs. Our heuristic solution methodology is based on a two-stage iterative procedure. In a particular iteration, at a first stage, gas flow variables are fixed and optimal pressure variables are found via dynamic programming. At a second stage, pressure variables are fixed and an attempt is made to find a set of flow variables that improve the objective function by exploiting the underlying network structure. Empirical evidence supports the effectiveness of the proposed procedure outperforming the best existing approach to the best of our knowledge.     

An efficient heuristic for a two-stage assembly scheduling problem with batch setup times to minimize makespan

This paper considers a two-stage assembly scheduling problem of N products with setup times to minimize the makespan. In this problem, there is a machining machine which produces components in the first stage. When the required components are available, a single assembly machine can assemble these components into products in the second stage. A setup time is needed whenever the machining machine starts processing components, or the item of component is switched on the machine. The problem is formulated as a mixed integer programming model, and several properties for finding optimal solutions are developed. Moreover, an efficient heuristic based on these optimal properties is proposed. A lower bound is derived to evaluate the performance of the proposed heuristic. Computational results show that the proposed heuristic can obtain a near optimal solution in almost zero time and the average percentage deviation is only 0.478.     

The two-stage assembly scheduling problem to minimize total completion time with setup times

We address the two-stage assembly scheduling problem where there are m machines at the first stage and an assembly machine at the second stage. The objective is to schedule the available n jobs so that total completion time of all n jobs is minimized. Setup times are treated as separate from processing times. This problem is NP-hard, and therefore we present a dominance relation and propose three heuristics. The heuristics are evaluated based on randomly generated data. One of the proposed heuristics is known to be the best heuristic for the case of zero setup times while another heuristic is known to perform well for such problems. A new version of the latter heuristic, which utilizes the dominance relation, is proposed and shown to perform much better than the other two heuristics.     

Minimizing makespan in a two-stage system with flowshop and open shop

This paper studies two models of two-stage processing with flowshop at the first stage followed by open shop at the second stage. The first model involves multiple machines at the first stage and two machines at the second stage, and the other involves multiple machines at both stages. In both models, the objective is to minimize the makespan. This problem is NP-complete, for which an efficient heuristic solution algorithm is constructed and its worst-case performance guarantee is analyzed for both models. An integer programming model and a branch and bound algorithm are proposed for model 1 and a lower bound is developed for model 2 as benchmarks for the heuristic algorithms. Computational experiences show that the heuristic algorithms consistently generate good schedule and the branch and bound algorithm is much efficient than the integer-programming model.     

A heuristic method for two-stage hybrid flow shop with dedicated machines

This paper considers a two-stage hybrid flow shop scheduling problem with dedicated machines, in which the first stage contains a single common critical machine, and the second stage contains several dedicated machines. Each job must be first processed on the critical machine in stage one and depending on the job type, the job will be further processed on the dedicated machine of its type in stage two. The objective is to minimize the makespan. To solve the problem, a heuristic method based on branch and bound (B&B) algorithm is proposed. Several lower bounds are derived and four constructive heuristics are used to obtain initial upper bounds. Then, three dominance properties are employed to enhance the performance of the proposed heuristic method. Extensive computational experiments on two different problem categories each with various problem configurations are conducted. The results show that the proposed heuristic method can produce very close-to-optimal schedules for problems up to 100 jobs and five dedicated machines within 60 s. The comparisons with solutions of two other meta-heuristic methods also prove the better performance of the proposed heuristic method.     

A self-organizing neural network approach for the design of cellular manufacturing systems

The crux problem of group technology (GT) is the identification of part families requiring similar manufacturing processes and the rearrangement of machines to minimize the number of parts that visit more than one machine cell. This paper presents an improved method for part family formation, machine cell identification, bottleneck machine detection and the natural cluster generation using a self-organizing neural network. In addition, the generalization ability of the neural network makes it possible to assign the new parts to the existing machine cells without repeating the entire computational process. A computer program is developed to illustrate the effectiveness of this heuristic method by comparing it with the optimal technique for large-scale problems.     

Knowledge based approach to machine cell layout

In this paper, the machine cell layout problem is examined. A new methodology for solving the problem is proposed. The methodology involves three stages. In the first stage, an algorithm suitable for solving the machine grouping problem is utilized. In the second and third stages, mathematical programming models of the machine cell and machine layout problems are formulated and solved using suitable algorithms. The development of a knowledge based system which uses models and algorithms for solving the machine grouping and layout problems, is also outlined.     

Two-stage approach for machine-part grouping and cell layout problems

Cellular manufacturing system (CMS) which is based on the concept of group technology (GT) has been recognized as an efficient and effective way to improve the productivity in a factory. In recent years, there have been continuous research efforts to study different facet of CMS. Most of them concentrated on distinguishing the part families and machine cells either simultaneously or individually with the objective of minimizing intercellular and intracellular part movements. This is known as machine-part grouping problem (MPGP) which is a crucial process while designing CMS. Nevertheless, in reality some components may not be finished within only one cell, they have to travel to another cell(s) for further operation(s). Under this circumstance, intercellular part movement will occur. Different order/sequence of machine cells allocation may result in different total intercellular movement distance unit. It should be noted that if the production volume of each part is very large, then the total number of intercellular movement will be further larger. Therefore, the sequence of machine cells is particularly important in this aspect. With this consideration, the main aim of this work is to propose two-stage approach for solving cell formation problem as well as cell layout problem. The first stage is to identify machine cells and part families, which is the essential part of MPGP. The work in second stage is to carry out a macro-approach to study the cell formation problem with consideration of machining sequence. The impact of the sequencing for allocating the machine cells on minimizing intercellular movement distance unit will be investigated in this stage. The problem scope, which is a MPGP together with the background of cell layout problem (CLP), has been identified. Two mathematical models are formulated for MPGP and CLP respectively. The primary assumption of CLP is that it is a linear layout. The CLP is considered as a quadratic assignment problem (QAP). As MPGP and QAP are NP-hard, genetic algorithm (GA) is employed as solving algorithm. GA is a popular heuristic search technique and has proved superior performance on complex optimization problem. In addition, an industrial case study of a steel member production company has been employed to evaluate the proposed MPGP and CLP models, and the computational results are presented.     

Selection of cutting conditions for power constrained parallel machine scheduling

Most previous studies on machining optimization focused on aspects related to machining efficiency and economics, without accounting for environmental considerations. Higher cutting speed is usually desirable to maximize machining productivity, but this requires a high power load peak. In Taiwan, electricity prices rise sharply if instantaneous power demand exceeds contract capacity. Many studies over the previous decades have examined production scheduling problems. However, most such studies focused on well-defined jobs with known processing times. In addition, traditional sequencing and scheduling models focus primarily on economic objectives and largely disregard environmental issues raised by production scheduling problems. This study investigates a parallel machine scheduling problem for a manufacturing system with a bounded power demand peak. The challenge is to simultaneously determine proper cutting conditions for various jobs and assign them to machines for processing under the condition that power consumption never exceed the electricity load limit. A two-stage heuristic approach is proposed to solve the parallel machine scheduling problem with the goal of minimizing makespan. The heuristic performance is tested by distributing 20 jobs over 3 machines with four possible cutting parameter settings.     

A genetic algorithm and a simulated annealing algorithm combined with column generation technique for solving the problem of scheduling in the hybrid flowshop with additional resources

In this paper, a heuristic is proposed for solving the problem of scheduling in a two-stage flowshop with parallel unrelated machines and additional renewable resources at the first stage and a single machine at the second stage. Resource requirements are arbitrary integers. The availability of additional resources is limited at every moment. The objective is the minimization of makespan. The problem is NP-hard. The proposed heuristic combines column generation technique with a genetic algorithm (the heuristic algorithm HG) or a simulated annealing algorithm (the heuristic algorithm HS). The performance analysis is performed experimentally by comparing heuristic solutions to the lower bound on the optimal makespan. Results of the computational experiment show that both the heuristic algorithms yield good quality solutions using reasonable computation time and that HS outperforms HG for the most difficult problems.     

A multiple-vendor single-buyer integrated inventory model with a variable number of vendors

Supply chain management is concerned with the coordination of material and information flows in multi-stage production systems. A closer look at the literature reveals that previous research on the coordination of multi-stage production systems has predominantly focused on the sales side of the supply chain, whereas problems that arise on the supply side have often been neglected. This article closes this gap by studying the coordination of a supplier network in an integrated inventory model. Specifically, we consider a buyer sourcing a product from heterogeneous suppliers and tackle both the supplier selection and lot size decision with the objective to minimise total system costs. First, we provide mathematical formulations for the problem under study, and then suggest a two-stage solution procedure to derive a solution. Numerical studies indicate that our solution procedure reduces the total number of supplier combinations that have to be tested for optimality, and that it may support initiatives which aim on increasing the efficiency of the supply chain as a heuristic planning tool.     

A cellular manufacturing system based on new similarity coefficient which considers alternative routes during machine failure

A two-phase procedure for configuring a cellular manufacturing system is proposed. In Phase I, a new similarity coefficient which considers the number of alternative routes when available during machine failure is proposed. The objective of Phase I is to identify part families based on the proposed new similarity coefficient. In Phase II, a new methodology which simultaneously considers scheduling and operational aspects in the cell design during machine failure for a manufacturing environment is proposed. Phase II shows how the scheduling and operational aspects influence the resource utilization during machine failure. The objective of the proposed methodology is to minimize the total sum of inventory holding cost, early/late finish penalty cost for each part in a given period, operating cost and machine investment cost by grouping machines into cells.     

Linear models for cost‐sensitive classification

In this paper, we investigate the performance of statistical, mathematical programming and heuristic linear models for cost‐sensitive classification. In particular, we use five cost‐sensitive techniques including Fisher's discriminant analysis (DA), asymmetric misclassification cost mixed integer programming (AMC‐MIP), cost‐sensitive support vector machine (CS‐SVM), a hybrid support vector machine and mixed integer programming (SVMIP) and heuristic cost‐sensitive genetic algorithm (CGA) techniques. Using simulated datasets of varying group overlaps, data distributions and class biases, and real‐world datasets from financial and medical domains, we compare the performances of our five techniques based on overall holdout sample misclassification cost. The results of our experiments on simulated datasets indicate that when group overlap is low and data distribution is exponential, DA appears to provide superior performance. For all other situations with simulated datasets, CS‐SVM provides superior performance. In case of real‐world datasets from financial domain, CGA and AMC‐MIP hold a slight edge over the two SVM‐based classifiers. However, for medical domains with mixed continuous and discrete attributes, SVM classifiers perform better than heuristic (CGA) and AMC‐MIP classifiers. The SVMIP model is the most computationally inefficient model and poor performing model.