Overview of an Adaptive Setup Planning Approach for Job Shop Operations

2009 ◽  
Author(s):  
Lihui Wang
Keyword(s):  
Decision Making ◽  
Job Shop ◽  
Planning System ◽  
Shop Floor ◽  
Setup Planning ◽  
Planning Stage ◽  
Planning Approach ◽  
Job Shop Operations

This paper presents an overview of an adaptive setup planning system that considers both the availability and capability of machines on a shop floor. It integrates scheduling functions at setup planning stage, and utilizes a two-step decision-making strategy for generating machine-neutral and machine-specific optimal setup plans. The objective is to enable adaptive setup planning for dynamic machining job shop operations. Particularly, this paper documents basic algorithms and architecture of the setup planning system for dynamically assigned machines. It is then validated through a case study.

scholarly journals Data-Driven Dispatching Rules Mining and Real-Time Decision-Making Methodology in Intelligent Manufacturing Shop Floor with Uncertainty

Sensors ◽  
2021 ◽  
Vol 21 (14) ◽  
pp. 4836
Author(s):  
Liping Zhang ◽  
Yifan Hu ◽  
Qiuhua Tang ◽  
Jie Li ◽  
Zhixiong Li
Keyword(s):  
Decision Making ◽  
Data Base ◽  
Real Time ◽  
Manufacturing Industry ◽  
Job Shop ◽  
Data Driven ◽  
Dispatching Rules ◽  
Shop Floor ◽  
Production Data ◽  
Online Decision Making

In modern manufacturing industry, the methods supporting real-time decision-making are the urgent requirement to response the uncertainty and complexity in intelligent production process. In this paper, a novel closed-loop scheduling framework is proposed to achieve real-time decision making by calling the appropriate data-driven dispatching rules at each rescheduling point. This framework contains four parts: offline training, online decision-making, data base and rules base. In the offline training part, the potential and appropriate dispatching rules with managers’ expectations are explored successfully by an improved gene expression program (IGEP) from the historical production data, not just the available or predictable information of the shop floor. In the online decision-making part, the intelligent shop floor will implement the scheduling scheme which is scheduled by the appropriate dispatching rules from rules base and store the production data into the data base. This approach is evaluated in a scenario of the intelligent job shop with random jobs arrival. Numerical experiments demonstrate that the proposed method outperformed the existing well-known single and combination dispatching rules or the discovered dispatching rules via metaheuristic algorithm in term of makespan, total flow time and tardiness.

Overview of a Distributed Process Planning Approach Targeting Manufacturing Uncertainty

2006 ◽  
Author(s):  
Lihui Wang ◽  
Ningxu Cai ◽  
Hsin-Yung Feng
Keyword(s):  
Process Planning ◽  
Job Shop ◽  
Layer Structure ◽  
Dynamic Decision Making ◽  
Machining Process ◽  
Operation Planning ◽  
Planning Approach ◽  
Job Shop Operations ◽  
Function Blocks ◽  
Distributed Process

This paper presents an overview of our DPP (distributed process planning) approach, covering DPP concept, generic machining process sequencing using enriched machining features, process plan encapsulation in function blocks, and process monitoring enabled by the function blocks. A two-layer structure of Supervisory Planning and Operation Planning is proposed in DPP to separate generic data from machine-specific ones. The supervisory planning is only performed once, in advance, at shop level, whereas the operation planning is carried out at runtime at machine level. This dynamic decision-making is facilitated by a set of resource-driven algorithms embedded in the function blocks. The internal structures of typical function blocks are also introduced in the paper. The DPP approach and algorithms are further verified through a case study before drawing conclusions. It is expected that the new approach can largely enhance the dynamism of fluctuating job shop operations.

Implementation of hybrid Kanban-CONWIP system: a case study

2017 ◽  
Vol 28 (6) ◽  
pp. 714-736 ◽  
Author(s):  
Dênis Gustavo Leonardo ◽  
Bruno Sereno ◽  
Daniel Sant Anna da Silva ◽  
Mauro Sampaio ◽  
Alexandre Augusto Massote ◽  
...  
Keyword(s):  
Control Systems ◽  
Hybrid System ◽  
Production Control ◽  
Job Shop ◽  
Lean Production ◽  
Shop Floor ◽  
Content Type ◽  
Floor Control ◽  
Low Volume

Purpose Shop floor control systems are generally major points of discussion in production planning and control literature. The purpose of this paper is to investigate how lean production control principles can be used in a make-to-order (MTO) job shop, where the volume is typically low and there is high variety. This paper examines the procedures involved in implementing a constant work-in-process (CONWIP)/Kanban hybrid system in the shop floor environment and also provides insights and guidelines on the implementation of a hybrid system in a high-variety/low-volume environment. Design/methodology/approach The authors review literature on Kanban, CONWIP, and CONWIP/Kanban hybrid systems to analyze how lean production control principles can be used in a MTO job shop. The second part focuses on the process of implementation. Using a case study of a manufacturer of electromechanical components for valve monitoring and controls, the paper describes how the operation is transformed by for more efficient shop floor control systems. Real experiments are used to compare pre- and post-improvement performance. Findings The study shows that the proposed hybrid Kanban-CONWIP system reduced the cycle time and achieved an increase of 38 percent in inventory turnover. The empirical results from this pilot study provide useful managerial insights for a benchmarking analysis of the actions to be taken into consideration by companies that have similar manufacturing systems. Research limitations/implications The statistic generalization of the results is impossible due to the use of a single case method of study. Originality/value This paper provides insights and guidelines on the implementation of a hybrid system in a high-variety/low-volume environment. The literature on real applications of hybrid CONWIP/Kanban by case study is limited.

Function-Block Enabled Job Shop Planning and Control With Uncertainty

2004 ◽  
Author(s):  
Lihui Wang ◽  
Zhenkai Liu ◽  
Weiming Shen ◽  
Sherman Lang
Keyword(s):  
Process Planning ◽  
Job Shop ◽  
Function Block ◽  
Planning And Control ◽  
Planning Approach ◽  
Job Shop Operations ◽  
Batch Sizes ◽  
Distributed Process ◽  
Generate Process ◽  
And Control

The objective of this research is to develop a methodology of distributed process planning and its execution control for job shop operations. The manufacturing processes of job shop operations are rather complex, especially at shop floors where highly mixed products in small batch sizes are handled simultaneously. In addition to the fluctuating job shop operations, unpredictable events like job delay, urgent job insertion, fixture shortage, missing tool, and even machine break-down, are regularly challenging the job shop operations. Targeting the fluctuations, this research proposes a DPP (distributed process planning) approach to generate process plans that are responsive and adaptive to the changes. In this paper, a function block enabled approach is introduced. It is expected that the new approach can largely enhance the dynamism of fluctuating job shop operations.

Dynamic Scheduling Using Immune Genetic Algorithm for Agile MES

2012 ◽  
Vol 566 ◽  
pp. 494-497
Author(s):  
Shu Xia Li ◽  
Huan Cao ◽  
Hong Bo Shan
Keyword(s):  
Genetic Algorithm ◽  
Real Time ◽  
Job Shop ◽  
Dynamic Scheduling ◽  
Job Shop Scheduling ◽  
Planning System ◽  
Shop Floor ◽  
Manufacturing Execution System ◽  
Scheduling Problems ◽  
Immune Genetic Algorithm

As a bridge links the upper enterprise planning system and the lower shop floor control system, enormous real-time information interact in shop floor, which poses great difficulty for scheduling of manufacturing execution system(MES). To meet the requirement of MES agility in the volatile information environment, dynamic scheduling becomes one of most widely used methods. In this paper, a modified immune genetic algorithm which incorporates artificial immune mechanism into genetic algorithm is presented to solve dynamic job shop scheduling problems. Owing to its good solving capability and computing speed, the algorithm could utilize real-time production information to generate predictive and reactive scheduling solutions. At last, the algorithm is applied in a MT10×10 job shop proved to be effective in obtaining better solutions than traditional genetic algorithm.

scholarly journals AN IMPLEMENTATION APPROACH TO SPATIAL PLANNING IN IRAN CASE STUDY: THE SOUTH ALBORZ MACROREGION

2017 ◽  
Vol 15 (3) ◽  
Author(s):  
Masoud Taghvaei ◽  
Hasan Beik ◽  
Nader Zali ◽  
Mitra Kasaei
Keyword(s):  
Spatial Planning ◽  
Delphi Technique ◽  
Planning System ◽  
Land Planning ◽  
Effective Factors ◽  
Sectoral Planning ◽  
Planning Approach ◽  
Implementation Approach ◽  
The Impact

Despite being in existence for over seven decades, spatial planning policies in Iran have not been implemented and no serious volition to adopt their general approaches was observed. This study identifies the effective factors of the spatial planning implementation approach in the macroregion around south Alborz. By adopting the Delphi technique, a cross-impact matrix and data analysis using MICMAC software, the impact of these factors on the non-implementation of spatial planning in Iran was investigated. The results show that the existence of a central planning system, the dominance of economic and sectoral planning, the lack of integrated land-planning system are among the effective factors in the spatial planning approach in Iran. Therefore, suitable solutions to eliminate the drawbacks are proposed.

Cell Design for Transforming the Job Shop Production Process to Lean

2014 ◽  
pp. 130-147
Author(s):  
Vladimír Modrák ◽  
Pavol Semančo
Keyword(s):  
Decision Making ◽  
Production Process ◽  
Job Shop ◽  
Cell Design ◽  
Material Flows ◽  
Rules And Principles ◽  
Manufacturing Environments ◽  
Product Layout

The transformation of production process from batch to flow can be seen as an effective way to optimize material flows in job shop manufacturing environments. This transformation can be successfully adopted only under certain specific conditions, since product layout, typical for one-piece flow production, is not always a better option than the process layout. Accordingly, decision-making rules and principles for this concern are presented in the chapter. Subsequently, a case study on these issues is offered in which methodical procedures for transformation of manufacturing of small to medium-sized lots with aim to reach one-piece flow production are described in detail.

Function Block Design to Enable Adaptive Job Shop Operations

2007 ◽  
Author(s):  
Lihui Wang ◽  
Hsi-Yung Feng ◽  
Changjin Song ◽  
Wei Jin
Keyword(s):  
Job Shop ◽  
Block Design ◽  
Shop Floor ◽  
Manufacturing Companies ◽  
New Approach ◽  
Process Plan ◽  
Function Block ◽  
Job Shop Operations ◽  
Function Blocks ◽  
Block Based

Small volume and high product-mix contribute greatly to the complexity of job shop operations. In addition, shop floor uncertainty or fluctuation is another issue regularly challenging manufacturing companies, including job delay, urgent job insertion, fixture shortage, missing tool, and even machine breakdown. Targeting the uncertainty, we propose a function block based approach to generating adaptive process plans. Enabled by the function blocks, a so-generated process plan is responsive and tolerant to an unpredictable change. This paper presents in detail how a function block is designed and what it can do during process plan execution. It is expected that this new approach can largely enhance the dynamism of fluctuating job shop operations.

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