Balancing assembly lines with tabu search

Balancing assembly lines is a crucial task for manufacturing companies in order to improve productivity and minimize production costs. Despite some progress in exact methods to solve large scale problems, softwares implementing simple heuristics are still the most commonly used tools in industry. Some metaheuristics have also been proposed and shown to improve on classical heuristics but, to our knowledge, no computational experiments have been performed on real industrial applications to clearly assess their performance as well as their flexibility. Here we present a new tabu search algorithm and discuss its differences with respect to those in the literature. We then evaluate its performance on the Type I assembly line balancing problem. Finally, we test our algorithm on a real industrial data set involving 162 tasks, 264 precedence constraints, and where the assembly is carried out on a sequential line with workstations located on both sides of the conveyor, with two possible conveyor heights and no re-positioning of the product. We discuss the flexibility of the metaheuristic and its ability to solve real industrial cases.     

New formulations and solution procedures for the hop constrained network design problem

Optical fiber provides tremendous advantages in being able to carry a wide range of services including video on demand, video conferencing, distance learning, remote medical imaging, and telecommuting. The high capacities encourage carriers to create networks that are substantially sparser than previous copper based networks. A recent publication by the Telecommunications Industry Association indicated that investment in fiber optics is projected to reach $35 billion in the year 2003. Given the magnitude of investments, the design of networks becomes a very important issue. Most telecommunication companies (telcos), IT consulting companies, network equipment manufacturers and network service providers have extensive network design groups. The primary function of these groups is to design the most efficient networks both in terms of costs and performance and maintain them. These designers need flexible tools to support topological network design decisions. These decisions involve significant levels of investments in transmissions and switching facilities, and impact the resulting networks’ performance fundamentally.In this paper we study a special type of a network design problem called the hop constrained backbone network design problem. We present new mathematical programming formulations of the problem and develop an efficient solution procedure based on the linear programming relaxation. Extensive computational results across a number of networks are reported.     

Supply chain scheduling in a collaborative manufacturing mode: model construction and algorithm design

In collaborative manufacturing, the supply chain scheduling problem becomes more complex according to both multiple product demands and multiple production modes. Aiming to obtain a reasonable solution to this complexity, we analyze the characteristics of collaborative manufacturing and design some elements, including production parameters, order parameters, and network parameters. We propose four general types of collaborative manufacturing networks and then construct a supply chain scheduling model composed of the processing costs, inventory costs, and two penalty costs of the early completion costs and tardiness costs. In our model, by considering the urgency of different orders, we design a delivery time window based on the least production time and slack time. Additionally, due to the merit of continuously processing orders belonging to the same product type, we design a production cost function by using a piecewise function. To solve our model efficiently, we present a hybrid ant colony optimization (HACO) algorithm. More specifically, the Monte Carlo algorithm is incorporated into our HACO algorithm to improve the solution quality. We also design a moving window award mechanism and dynamic pheromone update strategy to improve the search efficiency and solution performance. Computational tests are conducted to evaluate the performance of the proposed method.

     

An analytical method for cost analysis in multi-stage supply chains: A stochastic network model approach

This paper studies the cost distribution characteristics in multi-stage supply chain networks. Based on the graphical evaluation and review technique, we propose a novel stochastic network mathematical model for cost distribution analysis in multi-stage supply chain networks. Further, to investigate the effects of cost components, including the procurement costs, inventory costs, shortage costs, production costs and transportation costs of supply chain members, on the total supply chain operation cost, we propose the concept of cost sensitivity and provide corresponding algorithms based on the proposed stochastic network model. Then the model is extended to analyze the cost performance of supply chain robustness under different order compensation ability scenarios and the corresponding algorithms are developed. Simulation experiment shows the effectiveness and flexibility of the proposed model, and also promotes a better understanding of the model approach and its managerial implications in cost management of supply chains.     

Designing Least-Cost Nonblocking Broadband Networks

Integrated network technologies, such as ATM, support multimedia applications with vastly different bandwidth needs, connection request rates, and holding patterns. Due to their high level of flexibility and communication rates approaching several gigabits per second, the classical network planning techniques, which rely heavily on statistical analysis, are less relevant to this new generation of networks. In this paper, we propose a new model for broadband networks and investigate the question of their optimal topology from a worst-case performance point of view. Our model is more flexible and realistic than others in the literature, and our worst-case bounds are among the first in this area. Our results include a proof of intractability for some simple versions of the network design problem and efficient approximation algorithms for designing nonblocking networks of provably small cost. More specifically, assuming some mild global traffic constraints, we show that a minimum-cost nonblockingstarnetwork achieves near-optimal cost; the cost ratio is at most 2 if switch source and sink capacities are symmetric and at most 3 when the total source and sink capacities are balanced. In the special case of unit link costs, we can show that a star network is indeed the cheapest nonblocking network.     

Intermodal shipments as recourse in logistics disruptions

This research deals with the flexibility of transportation systems when faced with disruptions. A network optimization model is used to investigate the feasibility of using intermodal shipments as recourse to disruptions in a transportation network. In a study of US interstate highways and intermodal rail networks, performance of over-the-road and intermodal shipments is compared under different disruption scenarios. The results show that the topology of US transportation system and locations of existing intermodal terminals provide required path redundancies and a strategic benefit for intermodal shipments to bypass disrupted regions with lower costs and competitive shipment times compared to rerouted road shipments.     

Analysis of multistation production systems with limited buffer capacity part 2: The decomposition method

We seek efficient techniques to evaluate the performance of multistation production systems with limited interstation buffers and station breakdown. Our ultimate objective is to develop a practical computer implementation that can be used for analysis and design. A flexible decomposition framework is developed. This approach allows the analysis of multistation production systems with various structures including series arrangements, network topologies, and rework (feedback) systems. The efficient solution techniques for the subsystems developed in Part 1 are used at each iteration of the decomposition method. It is the generality and efficiency of the subsystem model as well as the flexibility and robustness of the decomposition approach that distinguish our study from earlier work.     

Analysis of multistation production systems with limited buffer capacity part 1: The subsystem model

We seek efficient techniques to evaluate the performance of multistation production systems with limited interstation buffers and station breakdown. Our ultimate objective is to develop a practical computer implementation that can be used for analysis and design. Practically implies two design considerations: flexibility and computational efficiency. The approach must be flexible enough to be applicable to production systems with various topologies and station characteristics. These include series arrangements of production systems, as well as network topologies and rework (feedback) systems. Similarly, the technique must be computationally expedient. Our approach is based on a framework to model single-buffer subsystems to be used within a decomposition technique to evaluate the performance of the entire system. The first part presents a quasi-birth-death process model for the subsystems. Exploiting the spectral characteristics of the associated matrix polynomial, we develop a novel solution procedure for the steady-state probabilities where the computational effort is independent of the buffer size. The solution procedure is applicable to quasi birth-death processes. The efficient solution procedure developed in this part is used as a building block in decomposing and analyzing multistation production systems with various topologies in the second part of the study.     

Cyclic scheduling for F.M.S.: Modelling and evolutionary solving approach

This paper concerns the domain of flexible manufacturing systems (FMS) and focuses on the scheduling problems encountered in these systems. We have chosen the cyclic behaviour to study this problem, to reduce its complexity. This cyclic scheduling problem, whose complexity is NP-hard in the general case, aims to minimise the work in process (WIP) to satisfy economic constraints. We first recall and discuss the best known cyclic scheduling heuristics. Then, we present a two-step resolution approach. In the first step, a performance analysis is carried out; it is based on the Petri net modelling of the production process. This analysis resolves some indeterminism due to the system’s flexibility and allows a lower bound of the WIP to be obtained. In the second step, after a formal model of the scheduling problem has been given, we describe a genetic algorithm approach to find a schedule which can reach the optimal production speed while minimizing the WIP. Finally, our genetic approach is validated and compared with known heuristics on a set of test problems.     

RIGIDITY IN GLASSES AND PROTEINS

We review recent progress in applying the theory of rigidity to glassy networks and to proteins. These three dimensional systems require a generalization of Laman's theorem, which we have used to develop a technique called the Pebble Game which allows the rigid regions (containing both isostatic and overconstrained parts) and the flexible joints between them, to be found. We show that a flexibility index, which measures the local density of floppy modes, is useful in characterizing the network. A sampling of recent results is given for network glasses, where we show how the glass structure can self-organize to produce an intermediate phase that is stress-free and contains a percolating isostatic cluster. In proteins, we show how maps of the rigid regions and flexible joints, as well as maps of the flexibility index, can help to elucidate the connection between structure and function. This revised version was published online in August 2006 with corrections to the Cover Date.     

An improved part grouping model for minimizing makespan in FMS

In some flexible manufacturing systems (FMSs), limited tool magazine capacity requires grouping of parts into subsets for production. Although several studies have addressed the part grouping issue, research comparing the performance of models is scanty. Moreover, there is no congruency in the objectives of the present part grouping models and subsequent loading models. Traditionally, part grouping is addressed before machine loading. In this study, we overcome the drawbacks by proposing two models: model LM, which does not require part grouping, and model PGLRM (part grouping, loading and routing model), which requires part grouping. The performance of model LM serves as a benchmark. These two models also address machine loading and part routing issues concurrently. Model PGLRM's performance is then compared with the performance of model LM and few other existing part grouping models in terms of makespan and routing flexibility. Our analysis shows that model PGLRM not only results in a lower value of makespan but also imparts higher routing flexibility as compared to existing part grouping models.     

Optimal production strategy under demand fluctuations: Technology versus capacity

This paper provides a comparative analysis of five possible production strategies for two kinds of flexibility investment, namely flexible technology and flexible capacity, under demand fluctuations. Each strategy is underpinned by a set of operations decisions on technology level, capacity amount, production quantity, and pricing. By evaluating each strategy, we show how market uncertainty, production cost structure, operations timing, and investment costing environment affect a firm’s strategic decisions. The results show that there is no sequential effect of the two flexibility investments. We also illustrate the different ways in which flexible technology and flexible capacity affect a firm’s profit under demand fluctuations. The results reveal that compared to no flexibility investment, flexible technology investment earns the same or a higher profit for a firm, whereas flexible capacity investment can be beneficial or harmful to a firm’s profit. Moreover, we prove that higher flexibility does not guarantee more profit. Depending on the situation, the optimal strategy can be any one of the five possible strategies. We also provide the optimality conditions for each strategy.     

Distributing decision making using Java simulation across the World Wide Web

This paper describes a prototype distributed, multi-user Internet based simulation environment, written in Java, and its application to decision making. An example of its use is presented in the context of manufacturing. The motivating factor behind this work is the rapid development in computer controlled plants and systems, such as automated production lines. The growth in flexibility offered by computer control has led to increasing speed and complexity in scheduling of these systems. Making such decisions often requires the very high costs of moving expert modellers and Operational Research staff to factory sites. Following developments in computer supported concurrent working (CSCW) and concurrent engineering, it is suggested that a means for working in a geographically distributed manner is desirable. The availability of Internet based solutions, exploiting Java's distributed client server architecture makes it possible to prototype such ideas in a generally accessible manner. An environment built along those lines is described here. Its benefits are shown through a case study and ideas for future work are explored.     

技术柔性、柔性生产与柔性技术的价值

在产品市场和要素市场存在不确定性的条件下,将企业的生产行为和技术柔性水平的选择纳入一个统一框架进行分析,给出了柔性技术的价值函数及其特征.结果表明,给定技术柔性水平,柔性生产行为价值不会低于非柔性生产行为的价值;给定生产行为,柔性技术的价值不会随着其柔性增加而降低.进一步,在一定条件下,柔性生产行为比非柔性生产行为更具价值,柔性技术的价值随着其柔性水平的增加而增加.     

Flexible machine layout design for dynamic and uncertain production environments

Flexible manufacturing systems operate in a dynamic environment and face considerable uncertainty in production demands. The development of a flexible machine layout is a critical issue in creating a system that can respond effectively to these requirements. Unlike most existing methods for creating flexible layout designs, the procedure developed in this paper is not restricted to equal size machines. It optimizes the trade-offs between increased material handling costs as requirements change and machine rearrangement costs needed to adapt the layout to these changes. The proposed flexible machine layout design procedure formulates and solves a robust machine layout design problem over a rolling horizon planning time window. The formulation, details of the solution methodology, illustrative examples, and computational results are presented.     

OR in the industrial engineering of Industry 4.0: experiences from the Iberian Peninsula mirrored in CJOR

Central European Journal of Operations Research - Industry 4.0 (I4.0) implies a group of technologies, organisational concepts and management principles to improve the performance of manufacturing...     

FLEXIBLE TECHNOLOGY AND THE COST OF IMPROVING GROUNDWATER QUALITY

Contamination of groundwater by agricultural and industrial chemicals is a significant public health problem in the United States and other nations. In recent years, regulations regarding acceptable groundwater quality, particularly for drinking water, have proliferated in response to heightened public awareness of health risks. To minimize the burden on the economy of providing high-quality water, it is necessary to be creative with regard to cleanup strategies. Making treatment technology flexible can reduce the cost of improving groundwater quality by avoiding unnecessary duplication of fixed costs. We consider two types of flexibility. The first is mobility of treatment technology among locations within a single water delivery system. We calculate the costs of compliance with drinking water quality regulations when treatment technologies are fixed and when they are mobile between locations, and show that mobility has significant economic advantages. The second type of flexibility is mobility among water delivery systems, which we capture through a regional rental market for treatment devices. We show that, under certain conditions, rental markets for treatment technology can lower the costs of improving water quality.     

Constructing banking networks under decreasing costs of link formation

The structure of networks plays a central role in the behavior of financial systems and their response to policy. Real-world networks, however, are rarely directly observable: banks’ assets and liabilities are typically known, but not who is lending how much and to whom. This paper adds to the existing literature in two ways. First, it shows how to simulate realistic networks that are based on balance-sheet information. To do so, we introduce a model where links cause fixed-costs, independent of contract size; but the costs per link decrease the more connected a bank is (scale economies). Second, to approach the optimization problem, we develop a new algorithm inspired by the transportation planning literature and research in stochastic search heuristics. Computational experiments find that the resulting networks are not only consistent with the balance sheets, but also resemble real-world financial networks in their density (which is sparse but not minimally dense) and in their core-periphery and disassortative structure.

     

Queueing theory in manufacturing systems analysis and design: A classification of models for production and transfer lines

Queueing network modeling of manufacturing systems has been addressed by a large number of researchers. The purpose of this paper is to provide a bibliography of material concerned with modeling of production and transfer lines using queueing networks. Both production and transfer lines have a product-flow layout and are used in mass manufacturing. We denote production lines as flow lines with asynchronous part transfer, while transfer lines have synchronous part transfer. As well as providing a bibliography of material, a contribution of this paper is also the systematic categorization of the queueing network models based on their assumptions. This, it is hoped, will be of use to researchers of queueing networks and also manufacturing system designers. A number of suggestions are also given for further research. The basic source for this work is the book by Papadopoulos, Heavey and Browne, with the addition of the newly published papers and books (from 1992 to early 1995).     

Long term capacity decisions in uncertain markets for advanced manufacturing systems incorporating scope economies

By examining the literature in the field of manufacturing flexibility many researchers have located several form of flexibility by distinguishing them into strategic and operational flexibility forms. Furthermore, many measures and design methods have been proposed for flexible manufacturing systems. Surely scope economies are one of the most important strategic form of flexibility in manufacturing systems and their strategic impact has been acknowledged by the very beginning of the flexible manufacturing era. However, despite several researches are available to address scope economies measurement and design methodologies, very few researches investigate their economic convenience in front of dedicated manufacturing systems depending on the competitive market conditions.This paper proposes a theoretical model whose main aim is the general understanding of the convenience conditions of scope economies-based manufacturing systems. The results of the theoretical model are very interesting, because they locate market conditions that make scope economies manufacturing systems less profitable than dedicated manufacturing ones; moreover, the proposed model sets some general criteria to guide the entrepreneur in making right investment decision regarding this kind of manufacturing investments. Such results can explain the reason of many failures of flexible manufacturing systems and it suggests the use of this kind of approach to investigate other flexibility forms of manufacturing systems. The ultimate goal of this research is the construction of a Decision Support System for supporting the entrepreneur in making decision on Advanced Manufacturing Systems investment decisions.