Design,planning, scheduling,and control problems of flexible manufacturing systems

The design and use of flexible manufacturing systems (FMSs) involve some intricate operations research problems.FMS design problems include, for example, determining the appropriate number of machine tools of each type, the capacity of the material handling system, and the size of buffers.FMS planning problems include the determination of which parts should be simultaneously machined, the optimal partition of machine tools into groups, allocations of pallets and fixtures to part types, and the assignment of operations and associated cutting tools among the limited-capacity tool magazines of the machine tools.FMS scheduling problems include determining the optimal input sequence of parts and an optimal sequence at each machine tool given the current part mix.FMS control problems are those concerned with, for example, monitoring the system to be sure that requirements and due dates are being met and that unreliability problems are taken care of. This paper defines and describes these FMS problems in detail for OR/MS researchers to work on.     

Collaboration in tool development and capacity investments in high technology manufacturing networks

The procurement of capital intensive tools for hi-tech industries is one of the most complex tasks. Astronomical amounts of capital are invested in the processing equipment. Further, there is a large effort from the original equipment manufacturer (OEM) in customizing the high capital intensive equipment to suit their production process. This problem has received little attention from the quantitative decision making literature. For the first time we analyze the problem of OEM deciding on collaborating with the tool supplier via a special type of contract which we refer as “collaboration options”. We show that there are benefits to both the OEM and the tool suppliers from the collaboration.     

Analysis of flexible manufacturing systems with priority scheduling: PMVA

A new methodology for performance analysis of flexible manufacturing systems (FMSs) with priority scheduling is presented. The analytic model developed extends the mean value analysis of closed networks of queues with multiple product types, various non-preemptive priority service disciplines, and with parallel machine stations. Performance measures derived include the expected throughput per product and per station, utilization of machines and transporters, queuing times and queue length measures for various configurations. Extensive numerical calculations have shown that the algorithm used for solving the problem converges rapidly and retains numerical stability for large models. The paper also illustrates the application of the model to a system with a mixture of FCFS and HOL disciplines which gives insights into various priority assignment policies in FMSs. Special attention was given to the problem of scheduling the robot carriers (transporters).     

The optimality of balancing workloads in certain types of flexible manufacturing systems

Symmetric mathematical programming is used to analyze the optimality of balancing workloads to maximize the expected production in a single-server closed queuing network model of a flexible manufacturing system (FMS). In particular, using generalized concavity we prove that, even though the production function is not concave, balancing workloads maximizes the expected production in certain types of m-machine FMS's with n parts in the system. Our results are compared and contrasted with previous models of production systems.     

Steady state scheduling of a flexible manufacturing system with periodic releasing and flow time constraints

This paper deals with the dynamic behaviour of an FMS when parts are released periodically. The minimal release period is induced by the most critical machine or fixture pallet type. Moreover, with a fixed period, the limited number of available pallets induces a maximal flow time for every part type. Thus, the objective of this paper is to determine a part release strategy and an activity schedule on every machine which allows to control every part flow time for steady state. An analysis method for this objective is presented in this paper. Its purpose is to obtain releasing and scheduling conditions ensuring a workshop steady state compatible with the considered constraints, especially part flow times. This method is based on the resolution of conflicts between activities processed on a common machine. This resolution uses limit times associated with each activity and it can modify these limit times. These modifications in turn can induce modifications for other activity limit times due to part routing, steady-state periodicity, and part flow time constraints. Thus, an iterative procedure has been defined. It refines steady-state feasibility conditions through limit times and sequencing conditions of activities processed on a common machine. The method is illustrated with two examples.     

An efficient method to determine the optimal configuration of a flexible manufacturing system

A frequently encountered design issue for a flexible manufacturing system (FMS) is to find the lowest cost configuration, i.e. the number of resources of each type (machines, pallets, ...), which achieves a given production rate. In this paper, an efficient method to determine this optimal configuration is presented. The FMS is modelled as a closed queueing network. The proposed procedure first derives a heuristic solution and then the optimal solution. The computational complexity for finding the optimal solution is very reasonable even for large systems, except in some extreme cases. Moreover, the heuristic solution can always be determined and is very close (and often equal) to the optimal solution. A comparison with the previous method of Vinod and Solberg shows that our method performs very well.     

A numerical method to approximate optimal production and maintenance plan in a flexible manufacturing system

The simultaneous planning of the production and the maintenance in a flexible manufacturing system is considered in this paper. The manufacturing system is composed of one machine that produces a single product. There is a preventive maintenance plan to reduce the failure rate of the machine. This paper is different from the previous researches in this area in two separate ways. First, the failure rate of the machine is supposed to be a function of its age. Second, we assume that the demand of the manufacturing product is time dependent and its rate depends on the level of advertisement on that product. The objective is to maximize the expected discounted total profit of the firm over an infinite time horizon. In the process of finding a solution to the problem, we first characterize an optimal control by introducing a set of Hamilton–Jacobi–Bellman partial differential equations. Then we realize that under practical assumptions, this set of equations can not be solved analytically. Thus to find a suboptimal control, we approximate the original stochastic optimal control model by a discrete-time deterministic optimal control problem. Then proposing a numerical method to solve the steady state Riccati equation, we approximate a suboptimal solution to the problem.     

Evaluation of entropy-based dispatching in flexible manufacturing systems

Traditionally, part dispatching has been done using static rules, rules that fail to take advantage of the dynamic nature of today’s manufacturing systems. In modern manufacturing systems, machines carry multiple tools so parts have the option of being machined at more than one machine. This flexibility, termed routing flexibility in the literature, opens up new possibilities for shop floor planners for the scheduling and dispatching of parts.     

中国引进外资与本币供应量之间数量关系

引进外资是影响中国货币供应量的重要因素之一，两者之间存在一定的数量关系。根据近年来的数据进行实证分析其结果表明：引进外资对中国通货膨胀有一定的影响，今后中国引进外资工作仍要慎行     

Grouping of parts and components in flexible manufacturing systems

In this paper, the problem of grouping of parts and components in flexible manufacturing systems is discussed. The actual grouping is done by modelling the problem as an optimal k-decomposition of weighted networks. Algorithms which are suitable for computer implementation and large problems are developed to find an initial solution and for refining this solution. Bounds on algorithm performance are constructed to give an estimate of the quality of the generated solution. A numerical example illustrates these new techniques.     

Uniformly overtaking and weakly overtaking optimal solutions in infinite-horizon optimal control: When optimal solutions are agreeable

In this paper, we investigate the relationship between two classes of optimality which have arisen in the study of dynamic optimization problems defined on an infinite-time domain. We utilize an optimal control framework to discuss our results. In particular, we establish relationships between limiting objective functional type optimality concepts, commonly known as overtaking optimality and weakly overtaking optimality, and the finite-horizon solution concepts of decision-horizon optimality and agreeable plans. Our results show that both classes of optimality are implied by corresponding uniform limiting objective functional type optimality concepts, referred to here as uniformly overtaking optimality and uniformly weakly overtaking optimality. This observation permits us to extract sufficient conditions for optimality from known sufficient conditions for overtaking and weakly overtaking optimality by strengthening their hypotheses. These results take the form of a strengthened maximum principle. Examples are given to show that the hypotheses of these results can be realized.This research was supported by the National Science Foundation, Grant No. DMS-87-00706, and by the Southern Illinois University at Carbondale, Summer Research Fellowship Program.     

Experimental investigation of real-time scheduling in flexible manufacturing systems

This paper presents a new two-phase (TP) approximate method for real-time scheduling in a flexible manufacturing system (FMS). This method combines a reduced enumeration schedule generation algorithm with a 0–1 optimization algorithm. In order to make the combined algorithm practicable, heuristic rules are introduced for the selection of jobs to be scheduled. The relative performance of the TP method vis-a-vis conventional heuristic dispatching rules such as SPT, LPT, FCFS, MWKR, and LWKR is investigated using combined process-interaction/discrete-event simulation models. An efficient experimental procedure is designed and implemented using these models, and the statistical analysis of the results is presented. For the particular case investigated, the conclusions are very encouraging. In terms of mean flow time, the TP method performs significantly better than any other tested heuristic dispatching rules. Also, the experimental results show that using global information significantly improves the FMS performance.     

Algorithms for part and machine selection in flexible manufacturing systems

Deciding whether FMS technology is viable for a given application, and if so, what machines should comprise the FMS and what parts should be produced on it, can be a difficult task. Manual methods suffice only for situations where a small number of FMS-type machines are to be considered and less than a few dozen candidate parts are to be chosen from. When both machines and parts are to be selected from a larger number of candidates, manual methods become cumbersome and time consuming, and computer-based decision aids become a necessity. This paper gives an overview of the required decision process, and then focuses on those stages for which computer-based decision aids can be used effectively. Particular decision aids are described, and case studies are cited to illustrate their motivation and use.     

Application of operational research models and techniques in flexible manufacturing systems

In this paper, classification of Flexible Manufacturing Systems (FMSs) and flexibilities is presented. It would be difficult to efficiently implement an FMS without solving its design problems. These problems, as well as a number of operations problems, are discussed. A planning and scheduling framework is developed. Based on this framework, the relevant FMS literature is discussed. Most of the tools and techniques applicable for solving FMS problems are listed. Recommendations for future researh are also presented.     

Modeling a class of state-dependent routing in flexible manufacturing systems

We develop a closed queueing network model for flexible manufacturing systems (FMSs), where parts routing follows a probabilistic shortest-queue (PSQ) scheme, i.e. parts are routed to the shortest queue (or the most empty station) with the highest probability. We allow limited local buffer at each work station. We prove that with the PSQ routing, the Markovian queue-length process satisfies time reversibility and has a product-form equilibrium distribution. An algorithm is developed to compute the solutions to the model. The model can be used as a performance evaluation tool to study FMSs.     

A Petri net approach to the modelling and analysis of flexible manufacturing systems

In this paper we present an approach for modelling and analyzing flexible manufacturing systems (FMSs) using Petri nets. In this approach, we first build a Petri net model (PNM) of the given FMS in a bottom-up fashion and then analyze important qualitative aspects of FMS behaviour such as existence/absence of deadlocks and buffer overflows. The basis for our approach is a theorem we state and prove for computing the invariants of the union of a finite number of Petri nets when the invariants of the individual nets are known. We illustrate our approach using two typical manufacturing systems: an automated transfer line and a simple FMS.A shorter version of this paper was presented at the 1st ORSA/TIMS Special Interest Conference on FMSs, University of Michigan, Ann Arbor, August 1984.     

Constructions of optimal difference systems of sets

Difference systems of sets (DSSs) are combinatorial configurations which were introduced in 1971 by Levenstein for the construction of codes for synchronization. In this paper, we present two kinds of constructions of difference systems of sets by using disjoint difference families and a special type of difference sets, respectively. As a consequence, new infinite classes of optimal DSSs are obtained.     

Numerical performance of approximate queuing formulae with application to flexible manufacturing systems

This paper calls attention to two of the more successful queuing approximation formulae — one by Kramer and one by Marchal. The analytic solution of a range of single server Erlang cases is compared to the two approximation formulae. Then a family of H₂/M/1 cases is similarly considered. Maximum errors are seen to be about three percent. The Kramer formula seems to be better when the interarrival coefficient of variation is less than 0.66 and the Marchal formula is better for larger interarrival coefficients of variation. Finally, a multiserver refinement function (the ratio of G/G/1 results to M/M/1 results) is proposed to scale M/M/s as an approximation for G/G/s. In most of these multiple channel cases, the maximum error is less than six percent. The last section of this paper presents a simple, representative FMS. It is modelled as an open queuing network. Then the approximation procedure is applied node by node to illustrate the estimation of system performance measures such as machine utilizations and throughput.