Sharif Digital Repository

One of the basic assumptions of classical production-inventory models is that all products are of perfect quality. However, in real manufacturing situations, the production of defective items is inevitable, and a fraction of the items produced may be naturally imperfect. In fact, items may be damaged due to production and/or transportation conditions in the manufacturing process. On the other hand, some reworkable items exist among imperfect items that can be made perfect by additional processing. In addition, the classical production-inventory models assume that there is only one product in the system and that there is an unlimited amount of resources. However, in many practical situations,... 

Tool reliability is one of the most important issues in a flexible manufacturing system. If a tool fails to operate correctly, the performance of the manufacturing system is reduced, the due date may be violated, or the product quality falls behind the standards. This paper develops a bi-objective mathematical model for tool selection in a flexible manufacturing system in order to optimize both reliability and cost. The tools in these environments are considered to have increasing failure rates as they are used over time; a case closer to reality. This paper aims to evaluate the availability of different tools used in a production system, in which the reliability of a tool is dependent on... 

Companies and firms, nowadays, due to mounting competition and product diversity, seek to apply virtual cellular manufacturing systems to reduce production costs and improve quality of the products. In addition, as a result of rapid advancement of technology and the reduction of product life cycle, production systems have turned towards dynamic production environments. Dynamic cellular manufacturing environments examine multi-period planning horizon, with changing demands for the periods. A dynamic virtual cellular manufacturing system is a new production approach to help manufacturers for decision making. Here, due to variability of demand rates in different periods, which turns to flow... 

The dynamic nature of today’s manufacturing industry, which is caused by the intense global competition and constant technological advancements, requires systems that are highly adaptive and responsive to demand fluctuations. Reconfigurable manufacturing systems (RMS) enable such responsiveness through their main characteristics. This paper addresses the problem of RMS configuration design, where the demand of a single product varies throughout its production life cycle, and the system configuration must change accordingly to satisfy the required demand with minimum cost. A two-phased method is developed to handle the primary system configuration design and the necessary system... 

The dynamic nature of today’s manufacturing industry, which is caused by the intense global competition and constant technological advancements, requires systems that are highly adaptive and responsive to demand fluctuations. Reconfigurable manufacturing systems (RMS) enable such responsiveness through their main characteristics. This paper addresses the problem of RMS configuration design, where the demand of a single product varies throughout its production life cycle, and the system configuration must change accordingly to satisfy the required demand with minimum cost. A two-phased method is developed to handle the primary system configuration design and the necessary system... 

Group working has an important role in cellular manufacturing systems (CMS) as they can affect the work environment and job executions on machines. The most important factors affecting human resources are aspects of ability and interactional interest among workers in workshops. Here, we present a simple and efficient method considering these two aspects to deal with the assignment of workers to cells. We use interval type-2 fuzzy interactional interest among workers and the capability of working on machines to develop a new concept of cell formation in CMS. By using a multidepot multiple travelling salesman problem (MDmTSP) model, we assign workers to cells and then propose a mathematical... 

This paper proposes an integrated integer nonlinear programming model for a concurrent cell formation and production planning problem in a dynamic cell-manufacturing system (DCMS) with limited resources to setup cells and to procure machines. The proposed model seeks to minimise the total costs associated with the production planning and the cell construction and formation under a dynamic system. To validate the model, it is first converted to a linear programming. Then, a numerical example is presented based on which the branch and bound method is used to solve it employing the Lingo 8 software. Besides, due to NP-hardness of the problem, two meta-heuristic algorithms namely a GA and a PSO... 

In this paper, minimal paths and cuts technique is developed to handle fault tree analysis (FTA) on the critical components of industrial robots. This analysis is integrated with the reliability block diagram (RBD) approach in order to investigate the robot system reliability. The model is implemented in a complex advanced manufacturing system having autonomous guided vehicles (AGVs) as material handling devices. FTA grants cause and effects and hierarchical properties to the model. On the other hand, RBD simplifies the complex system of the AGVs for reliability evaluation. The results show that due to the filtering of the paths in a manufacturing system for AGVs, the reliability is highly... 

One of the most critical issues in manufacturing systems is the operator management. In this paper, the operator assignment problem is studied within a cellular manufacturing system. The most important novelty of this research is the consideration of operator learning and forgetting effects simultaneously. The skill level of an operator can be increased/decreased based on the time spent on a machine. Moreover, the issues related to operators like hiring, firing, and salaries are considered in the proposed model. The parameters are considered to be uncertain in this model, and a robust optimization approach is developed to handle it. Using this approach, the model solution remains feasible... 

In the new competitive dynamic market, manufacturing success and survival are becoming more and more difficult to ensure. In other words, getting the right product with low cost and high quality is not the only key to success. New requirements such as production responsiveness and flexibility should be considered. Reconfigurable Manufacturing System. (RMS) is a new paradigm that enables manufacturing systems to achieve rapid response to market demand. The effectiveness of an RMS depends on implementing key characteristics and capabilities of RMS in system design stage and benefiting from them in utilisation stage. In this paper, we introduced a methodology to adjust rapidly and productively... 

Cell formation and cellular layout design are the two main steps in designing a cellular manufacturing system (CMS). In this paper, we will present an integrated methodology based on a new concept of similarity coefficients and the use of simulated annealing (SA) as an optimization tool. In comparison with the previous works, the proposed methodology takes into account relevant production data, such as alternative process routings and the production volumes of parts. The SA-based optimization tool is parallel in nature and, hence, can reduce the computation time significantly, so it is capable of handling large-scale problems. Finally, the SA-based procedure is compared with a genetic... 

In this paper, optimal production and maintenance planning of a flexible manufacturing system under a time variant demand is considered. There is a preventive maintenance plan to reduce the failure rate of the machine. It is assumed that the failure rate of the machine is a function of its age and its maintenance rate. It is, also, assumed that the demand of the manufacturing product is time dependent and its rate depends on the level of the advertisement on that product, The objective is to maximize the expected discounted total profit of the firm over an infinite time horizon. To solve this optimization problem, first, an optimal control is characterized by a set of Hamilton-Jacobi-Bellman... 

We propose a cost estimation model based on a fuzzy rule backpropagation network, configuring the rules to estimate the cost under uncertainty. A multiple linear regression analysis is applied to analyze the rules and identify the effective rules for cost estimation. Then, using a dynamic programming approach, we determine the optimal path of the manufacturing network. Finally, an application of this model is illustrated through a numerical example showing the effectiveness of the proposed model for solving the cost estimation problem under uncertainty  

We describe an intelligent co-simulator for real time production control of a complex flexible manufacturing system (CFMS) having machine and tool flexibility. The manufacturing processes associated with the CFMS are complicated with each operation being possibly done by several machining centers. The co-simulator design approach is built upon the theory of dynamic meta-model based supervisory control with the cooperation of its own embedded intelligent blocks. The system is implemented by coupling of the centralized simulation controller (CSC) and real-time simulator for enforcing dynamic strategies of shop floor control. The posteriori adaptive co-simulator is equipped with a concurrent... 

This paper is seeking to design a dynamic cellular manufacturing system (DCMS). Area of multi-objective optimization is attractive not only for offering new opportunities for defining problem, but it helps us to extend and solve the anonymous problem. So a new multi-objective mixed integer model is presented for DCMS. The proposed model considers some real-world critical conditions in lean production which are neglected in similar studies in the literature. This model solves the part and machine grouping simultaneously with labor assignment to minimize the cost of various terms like reassignment cost of human resource, over time cost of equipments and labors, and maximize utilization rate of... 

We propose an approach for finding an optimal path in a flexible jobshop manufacturing system considering two criteria of time and cost. With rise in demands, advancement in technology, and increase in production capacity, the need for more shops persists. Therefore, a flexible jobshop system has more than one shop with the same duty. The difference among shops with the same duty is in their machines with various specifications. A network is configured in which the nodes are considered to be the shops with arcs representing the paths among the shops. An Automated Guided Vehicle (AGV) functions as a material handling device through the manufacturing network. To account for uncertainty, we... 

The emergence of the globalization paradigm in manufacturing industry has changed the markets’ circumstances, and accordingly manufacturing systems need to be compatibilized with these situations. There are many solutions to assist manufacturing systems for this purpose. Computerized systems and their related solutions were being the most attractive ones for manufacturing systems in recent decade. Developing such systems and exploiting from the advantages of such solutions requires a consistent foundation. Computer Integrated Manufacturing (CIM) emerged as a philosophy to provide such foundation, and to assist the computerized manufacturing solutions. Despite of the high potentials of the... 

Intense global competition, dynamic product variations, and rapid technological developments force manufacturing systems to adapt and respond quickly to various changes in the market. Such responsiveness could be achieved through new paradigms such as Reconfigurable manufacturing systems (RMS). In this paper, the problem of configuration design for a scalable reconfigurable RMS that produces different products of a part family is addressed. In order to handle demand fluctuations of products throughout their lifecycles with minimum cost, RMS configurations must change as well. Two different approaches are developed for addressing the system configuration design in different periods. Both...