Scheduling-Based Adaptive Operations of Handling Manipulators to Reduce Downtime in Manufacturing Systems

2020 ◽  
Author(s):  
Ryo Yonemoto ◽  
Haruhiko Suwa
Keyword(s):  
Manufacturing Systems ◽  
Material Handling ◽  
Manufacturing System ◽  
Machine Breakdowns ◽  
Physical Experiments ◽  
Scheduling Method ◽  
Catch Up ◽  
Automatic Scheduling

Abstract Unexpected interruptions in manufacturing such as machine breakdowns often incur degradation of productivity. This study aims to build an automatic scheduling method that responds to the occurrence of uncertain events flawing a schedule and catch up the planned schedule as quickly as possible. We here focus on building adaptive operations of a material handling robot according to the predetermined schedule revision policy to cope with uncertainties and to reduce the total downtime of the manufacturing system. The applicability of the proposed method is demonstrated through physical experiments.

Characteristics Analysis of Flexible Manufacturing Systems

2013 ◽  
Vol 329 ◽  
pp. 172-175
Author(s):  
Jin Feng Wang ◽  
Guang Feng Zhang ◽  
Xian Zhang Feng
Keyword(s):  
Flexible Manufacturing ◽  
Flexible Manufacturing Systems ◽  
Manufacturing Systems ◽  
Material Handling ◽  
Manufacturing Industry ◽  
Production Efficiency ◽  
Manufacturing System ◽  
Learning System ◽  
Machining Process ◽  
Characteristics Analysis

For the rigid automatic line, although its production efficiency is high, but the flexible is less in the machining process, the machine and the assembly line need be shut down to adjust or replace for machine tools, jigs, tools, and tooling equipment, etc. When the work pieces for the machining is changed. It caused a heavy workload, wasting a lot of time. Flexible Manufacturing Systems consisted of unified control system, material handling system and a set of digital control processing equipment; it is the automation machinery manufacturing system to adapt the processing object transform. It has become one of the important means of manufacturing industry to obtain the advantages of market competitiveness. This paper gives the composition, algorithm and application of learning system concept, composition, and classification, characteristics of the flexible manufacturing system, the development overview and its application are induced in this paper.

Investigating the Flexibility of a Hybrid Manufacturing System Using Simulation Approach

2013 ◽  
Vol 465-466 ◽  
pp. 672-676
Author(s):  
Ping Yu Chang
Keyword(s):  
Manufacturing Systems ◽  
Material Handling ◽  
Manufacturing System ◽  
Simulation Models ◽  
Setup Time ◽  
Simulation Approach ◽  
Key Characteristics ◽  
Manufacturing System Design ◽  
Demand Fluctuations ◽  
Manufacturing Environments

Different designs of manufacturing systems are adopted in industry today. A good manufacturing design should be flexible to compensate for uncertainties such as demand fluctuations and machine breakdowns. A new conceptual manufacturing system called Multi-Channel Manufacturing (MCM) is expected to provide flexibility and efficiency under uncertainties. This paper proposes the first approach to address the usefulness of MCM. This research tries to identify the key characteristics of MCM and the manufacturing environments for which MCM should perform well. Through simulation models, different manufacturing scenarios are analyzed and a suitable manufacturing system design for each scenario is identified. The simulation results illustrate that with limited material handling capacity and opportunities for setup time reduction, MCM can outperform other manufacturing formations.

scholarly journals Reactive Scheduling Based on Adaptive Manipulator Operations in a Job Shop Configuration with Two Machines

2021 ◽  
Vol 15 (5) ◽  
pp. 661-668
Author(s):  
Ryo Yonemoto ◽  
◽  
Haruhiko Suwa
Keyword(s):  
Machine Tools ◽  
Manufacturing Systems ◽  
Material Handling ◽  
Manufacturing System ◽  
Job Shop ◽  
Machining Processes ◽  
Operation Sequence ◽  
Machine Failure ◽  
Operation Schedule ◽  
Two Machines

Manufacturing systems are affected by uncertainties, such as machine failure or tool breakage, which result in system downtime and productivity deterioration. In machining processes, system downtime must be reduces. This study aims to establish an automated scheduling technique that flexibly responds to unforeseen events, such as machine failure, based on adaptive operations of the handling manipulator instead of an operation schedule for the machine tools. We propose an “adaptive manipulation” procedure for establishing a reactive revision policy. The reactive revision policy modifies a portion of the manipulator operation sequence, followed by the machine operation sequence. We conduct a physical scheduling simulation on a material-handling manipulator system imitating a job-shop manufacturing system. Through simulations involving machine breakdown scenarios, the applicability of the reactive revision policy based on adaptive manipulation is demonstrated.

Setting-up material handling network in manufacturing systems using graph theory

2018 ◽  
Vol 15 (1) ◽  
pp. 58-67 ◽  
Author(s):  
Shashank Gupta ◽  
Piyush Gupta
Keyword(s):  
Spanning Tree ◽  
Manufacturing Systems ◽  
Material Handling ◽  
Manufacturing System ◽  
Distance Matrix ◽  
Shop Floor ◽  
Minimal Spanning Tree ◽  
Content Type ◽  
Minimal Network ◽  
Capital Costs

Purpose Material handling (MH) is an important facility in any manufacturing system. It facilitates the transport of in-process material from one workstation (WS) to another. MH devices do imply incurring capital costs and, therefore, minimizing their deployment without compromising on smooth material flow will ensure savings in addition to the optimal use of productive shop floor space and, avoid space cluttering. The purpose of this paper is to evaluate the minimal network that connects all the WSs, therefore ensuring economic and safe manufacturing operations. Design/methodology/approach Graph theoretical approach and Prim’s algorithm for minimal spanning tree is used to evaluate the minimal span of the MH devices. The algorithm is initialized by translating the graph of WSs into a distance matrix to evaluate the minimal MH network. Findings The minimal length of the MH devices is evaluated for a typical case study. Research limitations/implications The step-by step methodology explained in the manuscript acts as a good guide for practicing operational managers. The shortcoming of the methodology is that, it presumes the use of modular MH devices that will need to be reconfigured based on dynamic changes to the manufacturing system. Practical implications The methodology is explained in detail to enable the practicing managers to use it for designing their MH networks in any manufacturing system. Originality/value There is no evidence to indicate the use of minimal spanning tree algorithm for design of MH networks in a manufacturing system. This paper attempts to fill this gap.

A methodology for the reconfiguration process in manufacturing systems

2014 ◽  
Vol 25 (6) ◽  
pp. 891-915 ◽  
Author(s):  
Ibrahim H. Garbie
Keyword(s):  
System Design ◽  
Manufacturing Systems ◽  
Material Handling ◽  
Manufacturing System ◽  
Production Systems ◽  
Systems Design ◽  
Production Volume ◽  
Plant Layout ◽  
Content Type ◽  
Handling System

Purpose – The purpose of this paper is to propose a “Reconfiguration Methodology” in manufacturing systems that they can become more economically sustainable and can operate efficiency and effectively. This methodology will allow customized flexibility and capacity not only in producing a variety of products (parts) and with changing market demands, but also in changing and reengineering the system itself. Design/methodology/approach – Reconfigurable manufacturing system (RMS) is a philosophy or strategy which was introduced during the last decade to achieve agility in manufacturing systems. Until now, the RMS philosophy was based changing activities such routing, planning, programming of machines, controlling, scheduling, and physical layout or materials handling system. But the RMS concept can be based on the needed reconfiguration level (NRL), operational status of production systems, and new circumstances (NC). The NRL measure is based on the agility level of the manufacturing systems which is based on technology, people, management, and manufacturing strategies. The components of the manufacturing system design (MSD) consist of production system design, plant layout system, and material handling system. Operational status of production systems includes machine capability (flexibility) and capacity (reliability), production volume or demand, and material handling equipment in addition to the plant layout. The NC are also consisting of new product, developing the existing ones, and changing in demand. Findings – Reconfiguration manufacturing systems from one period to another period is highly desired and is considered as a novel manufacturing philosophy and/or strategy toward creating new sustainable manufacturing systems. A new reconfiguration methodology for the manufacturing systems will be analyzed and proposed. Two Case studies will be introduced. Originality/value – The suggestion of a new methodology of reconfiguration including the NRL (configurability index) and the operational status of manufacturing systems with respect to any circumstance is highly considered. The reconfiguration methodology also provides a framework for sustainability in the manufacturing area which mainly focussed on manufacturing systems design.

scholarly journals Simultaneous Scheduling of Machines and AGVs in FMS Through Hybrid JAYA Algorithm

2019 ◽  
Vol 9 (2) ◽  
pp. 1982-1988
Keyword(s):  
Flexible Manufacturing ◽  
Manufacturing Systems ◽  
Material Handling ◽  
Manufacturing System ◽  
Response Times ◽  
Life Cycles ◽  
Jaya Algorithm ◽  
Scheduling Problems ◽  
The Right ◽  
Simultaneous Scheduling

High amount of flexibility and quick response times have become essential features of modern manufacturing systems where customers are demanding a variety of products with reduced product life cycles. Flexible manufacturing system (FMS) is the right choice to achieve these challenging tasks. The performance of FMS is dependent on the selection of scheduling policy of the manufacturing system. In Traditional scheduling problems machines are as considered alone. But material handling equipment’s are also valuable resources in FMS. The scheduling of AGVs is needed to be optimized and harmonized with machine operations. Scheduling in FMS is a well-known NP-hard problem due to considerations of material handling and machine scheduling. Many researchers addressed machine and AGVs individually. In this work an attempt is made to schedule both the machines and AGVs simultaneously. For solving these problems- a new hybrid metaheuristic JAYA algorithm (HJAYA) is proposed.

scholarly journals Simultaneous Scheduling of Machines and AGVs in FMS Through Ant Colony Optimization Algorithm

2020 ◽  
Vol 9 (3) ◽  
pp. 1392-1397
Keyword(s):  
Ant Colony Optimization ◽  
Manufacturing Systems ◽  
Material Handling ◽  
Manufacturing System ◽  
Response Times ◽  
Life Cycles ◽  
Ant Colony ◽  
Scheduling Problems ◽  
Ant Colony Optimization Algorithm ◽  
Simultaneous Scheduling

High amount of flexibility and quick response times have become essential features of modern manufacturing systems where customers are demanding a variety of products with reduced product life cycles. Flexible manufacturing system (FMS) is the right choice to achieve these challenging tasks. The performance of FMS is dependent on the selection of scheduling policy of the manufacturing system. In Traditional scheduling problems machines are as considered alone. But material handling equipment’s are also valuable resources in FMS. The scheduling of AGVs is needed to be optimized and harmonized with machine operations. Scheduling in FMS is a well-known NP-hard problem due to considerations of material handling and machine scheduling. Many researchers addressed machine and AGVs individually. In this work an attempt is made to schedule both the machines and AGVs simultaneously. For solving these problems-a new metaheuristic Ant Colony Optimization (ACO) algorithm is proposed.

scholarly journals Simultaneous Scheduling of Machines and AGVs in FMS through Simulated Annealing Algorithm

2020 ◽  
Vol 9 (4) ◽  
pp. 2235-2240
Keyword(s):  
Simulated Annealing ◽  
Flexible Manufacturing ◽  
Manufacturing Systems ◽  
Material Handling ◽  
Manufacturing System ◽  
Simulated Annealing Algorithm ◽  
Response Times ◽  
Life Cycles ◽  
Scheduling Problems ◽  
Simultaneous Scheduling

High amount of flexibility and quick response times have become essential features of modern manufacturing systems where customers are demanding a variety of products with reduced product life cycles. Flexible manufacturing system (FMS) is the right choice to achieve these challenging tasks. The performance of FMS is dependent on the selection of scheduling policy of the manufacturing system. In Traditional scheduling problems machines are as considered alone. But material handling equipment’s are also valuable resources in FMS. The scheduling of AGVs is needed to be optimized and harmonized with machine operations. Scheduling in FMS is a well-known NP-hard problem due to considerations of material handling and machine scheduling. Many researchers addressed machine and AGVs individually. In this work an attempt is made to schedule both the machines and AGVs simultaneously. For solving these problems- a new metaheuristic Simulated Annealing (SA) algorithm is proposed.

A new scheduling method for manufacturing systems

1990 ◽  
Vol 19 (1-4) ◽  
pp. 22-26 ◽  
Author(s):  
Wilfred V. Huang ◽  
Jianxin Tang
Keyword(s):  
Manufacturing Systems ◽  
Scheduling Method
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