Mission reliability-oriented integrated scheduling optimization model by combining production planning and maintenance activities

2020 ◽  
pp. 095440542097108
Author(s):  
Changchao Gu ◽  
Yihai He ◽  
Zhaoxiang Chen ◽  
Xiao Han ◽  
Di Zhou ◽  
...  
Keyword(s):  
Production Planning ◽  
Production Scheduling ◽  
Manufacturing Systems ◽  
Production Efficiency ◽  
Manufacturing System ◽  
Integrated Scheduling ◽  
Scheduling Model ◽  
Production Practice ◽  
Maintenance Activities ◽  
Scheduling Plan

Machine utilization and production efficiency of manufacturing systems can be effectively improved through reasonable production scheduling. Traditionally, production scheduling and maintenance planning are considered as two independent issues, but it may lead to a suboptimal solution that is unable to maximize the productivity of the manufacturing system. Therefore, a mission reliability-oriented integrated scheduling model that considers production planning and maintenance activities is proposed. Firstly, the mission reliability that takes into account product type and equipment performance is defined to characterize production rhythm. Secondly, the maintenance strategy based on machine degradation cumulative failure and stochastic failure is proposed to guarantee the mission reliability of the machine effectively. Thirdly, an integrated scheduling model is established with the goal of minimizing total operational time, and Genetic algorithm is tailored to find the best production scheduling plan. Finally, a case study and comparative study of the cylinder head manufacturing system are presented to demonstrate the effectiveness of the proposed method. Results show that the proposed method is more suitable for production practice than the previous production scheduling strategy.

An agent-based architecture for production scheduling in dynamic job-shop manufacturing system

2018 ◽  
Vol 66 (6) ◽  
pp. 492-502 ◽  
Author(s):  
Om Ji Shukla ◽  
Gunjan Soni ◽  
Rajesh Kumar ◽  
Sujil A
Keyword(s):  
Production Planning ◽  
Production Scheduling ◽  
Manufacturing System ◽  
Job Shop ◽  
Shop Floor ◽  
Efficient Production ◽  
Planning And Scheduling ◽  
Agent Based ◽  
Production Planning And Scheduling ◽  
Key Issues

Abstract In a highly competitive environment, effective production is one of the key issues which can be addressed by efficient production planning and scheduling in the manufacturing system. This paper develops an agent-based architecture which enables integration of production planning and scheduling. In addition, this architecture will facilitate real time production scheduling as well as provide a multi-agent system (MAS) platform on which multiple agents will interact to each other. A case study of job-shop manufacturing system (JMS) has been considered in this paper for implementing the concept of MAS. The modeling of JMS has been created in SimEvents which integrates an agent-based architecture developed by Stateflow to transform into dynamic JMS. Finally, the agent-based architecture is evaluated using utilization of each machine in the shop floor with respect to time.

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.

A Production Planning and Scheduling Architecture for Networked-Manufacturing System Based on Available-to-Promise

2011 ◽  
Vol 268-270 ◽  
pp. 292-296 ◽  
Author(s):  
Wen Hao Wang ◽  
Qiong Zhu ◽  
Jie Zhang
Keyword(s):  
Production Planning ◽  
Production Scheduling ◽  
Manufacturing System ◽  
Resource Planning ◽  
Networked Manufacturing ◽  
Planning And Scheduling ◽  
Production Planning And Scheduling ◽  
Order Management ◽  
Production Activity ◽  
Decision Making System

In the practical application of push-pull based production planning and scheduling architecture, the manufacturing system was found lacking of collaborative mechanism, especially for a networked-manufacturing environment, which requires each individual manufacturer interact and cooperate with each other for a collaborative manufacturing. This paper presents a production planning and scheduling architecture for networked-manufacturing system based on available-to-promise, which can effectively merge forecast-driven production activity with order-driven production activity, thus ensures the steady and prompt supply of material, and also cooperation and mutual benefit of individual manufacturer. This architecture consists of 1) an ATP-based order management and decision-making system, 2) a push-pull based multi-plant master production schedule collaboration model, 3) a pre-reactive collaborative replenishment model, 4) a production scheduling model of unrelated parallel machine and 5) the corresponding production planning and scheduling methods for each model. By combining the concept of ATP, this architecture can not only provide resource planning for networked-manufacturing system, but also offer quick response and promise to customer requests.

Integrated Scheduling of the Job and AGV for Flexible Manufacturing System

2011 ◽  
Vol 80-81 ◽  
pp. 1335-1339 ◽  
Author(s):  
You Long Lv ◽  
Gong Zhang ◽  
Jie Zhang ◽  
Yi Jun Dong
Keyword(s):  
Genetic Algorithm ◽  
Flexible Manufacturing ◽  
Manufacturing System ◽  
Job Scheduling ◽  
Mathematic Model ◽  
Integrated Scheduling ◽  
Scheduling Model ◽  
Problem Description ◽  
Equipment Utilization ◽  
Moving Path

Job scheduling and AGV scheduling in FMS are regarded as two independent problems by most researchers. Their isolation ignores AGV’s use conflicts in the job scheduling and leads to low average equipment utilization. We point out the necessity for the job scheduling to integrate with AGV scheduling through analyzing scheduling problem of a specific type of FMS with single AGV and single buffer area. Then a corresponding mathematic model for integrated scheduling is presented based on the problem description and constraints for scheduling. A specific FMS is adopted to validate this integrated scheduling model. Based on data from this FMS, the model is performed through genetic algorithm with appropriate parameters. And job’s processing sequences as well as AGV’s moving path are obtained from the optimal gene order. The experiment result of this scheduling model adopting genetic algorithm shows good computing efficiency and equipment utilization.

A FRAMEWORK OF SCHEDULING MODELS IN MACHINING WORKSHOP FOR GREEN MANUFACTURING

2008 ◽  
Vol 07 (02) ◽  
pp. 319-322 ◽  
Author(s):  
YAN HE ◽  
FEI LIU ◽  
JINLIANG SHI
Keyword(s):  
Environmental Impacts ◽  
Production Scheduling ◽  
Manufacturing Systems ◽  
Green Manufacturing ◽  
Resource Consumption ◽  
Schematic Model ◽  
Machining Processes ◽  
Scheduling Model ◽  
Discrete Manufacturing ◽  
Scheduling Models

Reducing environmental impacts and resource consumption in manufacturing processes is one of the important issues in green manufacturing. However, this attention has focused primarily on the activities of the design and the process planning, and the production scheduling activity has been overlooked especially for discrete manufacturing systems such as machining workshop. This paper presents a framework of the scheduling models in machining workshop that integrated resource and environmental considerations into production scheduling activities. The scheduling framework builds upon the schematic model and the analysis of resource and environmental dimensions of machining processes, and is used to guide the scheduling model construction which seeks to reduce resource consumption and environmental impacts at the operational scheduling level. The example is presented to demonstrate the application of the framework.

Research on production planning and scheduling based on improved collaborative optimization

2019 ◽  
Vol 27 (2) ◽  
pp. 99-111 ◽  
Author(s):  
Song Zheng ◽  
Jiaxin Gao ◽  
Jian Xu
Keyword(s):  
Production Planning ◽  
Production Scheduling ◽  
Production Efficiency ◽  
Collaborative Optimization ◽  
Production Plan ◽  
The Novel ◽  
Integration Algorithm ◽  
Planning And Scheduling ◽  
Integrated Optimization ◽  
Production Planning And Scheduling

The production planning is aimed at the formulation and distribution of the overall production plan, while the production scheduling focuses on the implementation of the specific production plan. It is very important to coordinate each other in order to promote the production efficiency of enterprises, but the integrated optimization of production planning and scheduling has great challenges. This article proposes the novel integrated optimization method of planning and scheduling based on improved collaborative optimization. An integrated model of planning and scheduling with collaborative optimization structure is established, and the detailed solution strategy of the novel integrated optimization algorithm is presented. At last, the simulation results show that the proposed integration algorithm of planning and scheduling is competitive in global optimization and practicality.

Advanced Cost-Efficient Production Scheduling in Hi-Tech Manufacturing Industry at Test Operation

2011 ◽  
Vol 110-116 ◽  
pp. 3922-3929 ◽  
Author(s):  
Tanaporn Sillapa-Archa ◽  
Phiphlu Thaninthanadech ◽  
Darin Smitasiri
Keyword(s):  
Production Scheduling ◽  
Product Life Cycle ◽  
Manufacturing Industry ◽  
Production Efficiency ◽  
Rapid Change ◽  
Shop Floor ◽  
Efficient Production ◽  
Manufacturing Companies ◽  
Test Operation ◽  
Scheduling Plan

Rapid change in customer demand and aggressive business competition in high technology industry has driven the need for greater performance with lower price product under short product life cycle. This stimulates semiconductor manufacturing companies to pay much more attention to their cost control and production built strategy. Bad performance in shop-floor planning results in huge inventory, poor equipment efficiency, and therefore it would jeopardize the company sustainability. Consequently, the main objectives of an effective production planning intelligence are to maximize company benefits, meet customer expectation and improve production efficiency. This paper presents an algorithm of production loading plan that balances cost, meet customer delivery request and optimize production efficiency by considering all important constrained factors in manufacturing environment, namely test cost per hour, throughput rate, machine capacity and utilization, hardware set up matrix and limitation, the number of change-over and customer delivery date. The analysis is done by comparing the performance outcome with the common scheduling rules. The result of this new planning logic solution is proved to increase the effectiveness of the production scheduling plan based on available resources on hand and complex of constraint. It also decreases human interfere causing error in planning procedure.

Optimal lockout/tagout, preventive maintenance, human error and production policies of manufacturing systems with passive redundancy

2014 ◽  
Vol 20 (4) ◽  
pp. 453-470 ◽  
Author(s):  
Behnam Emami-Mehrgani ◽  
Sylvie Nadeau ◽  
Jean-Pierre Kenné
Keyword(s):  
Preventive Maintenance ◽  
Manufacturing Systems ◽  
Human Error ◽  
Manufacturing System ◽  
System Capacity ◽  
Planning Problem ◽  
Human Reliability ◽  
Content Type ◽  
Machine Age ◽  
Maintenance Activities

Purpose – The analysis of the optimal production and preventive maintenance with lockout/tagout planning problem for a manufacturing system is presented in this paper. The considered manufacturing system consists of two non-identical machines in passive redundancy producing one type of part. These machines are subject to random breakdowns and repairs. The purpose of this paper is to minimize production, inventory, backlog and maintenance costs over an infinite planning horizon; in addition, it aims to verify the influence of human reliability on the inventory levels for illustrating the importance of human error during the maintenance and lockout/tagout activities. Design/methodology/approach – This paper is different compared to other research projects on preventive maintenance and lockout/tagout. The influence of human error on lockout/tagout as well as on preventive maintenance activities are presented in this paper. The preventive maintenance policy depends on the machine age. For the considered manufacturing system the optimality conditions are provided, and numerical methods are used to obtain machine age-dependent optimal control policies (production and preventive maintenance rates with lockout/tagout). Numerical examples and sensitivity analysis are presented to illustrate the usefulness of the proposed approach. The system capacity is described by a finite-state Markov chain. Findings – The proposed model taking into account the preventive maintenance activities with lockout/tagout and human error jointly, instead of taking into account separately. It verifies the influence of human error during preventive maintenance and lockout/tagout activities on the optimal safety stock levels using an extension of the hedging point structure. Practical implications – The model proposed in this paper might be extended to manufacturing systems, but a number of conditions must be met to make effective use of it. Originality/value – The originality of this paper is to consider the preventive maintenance activities with lockout/tagout and human error simultaneously. The control policy is obtained in order to find the solution for the considered manufacturing system. This paper also brings a new vision on the importance of human reliability during preventive maintenance and lockout/tagout activities.

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