Design Of Flexible Manufacturing Systems Research Articles

FMS design model with multiple objectives using compromise programming

There has been a great change in manufacturing systems toward computer-controlled flexible manufacturing systems (FMS). The design and operation of the FMS involve intricate and interconnected decisions that result in the maximum performance of the system. However, the design and operational decisions have been made separately in consideration of a single-system performance measure. This paper presents a method for simultaneously determining design and control parameters of an FMS with the multiple performance objectives via full-factorial design of experiments, regression analysis and compromise programming. For a numerical example, the SIMAN simulator models a hypothetical FMS with six workstations. Eight design and control parameters are simultaneously determined by compromising four performance measures that are formulated using regression analysis.

The development of intelligent decision support tools to aid the design of flexible manufacturing systems

The design of flexible manufacturing systems (FMSs) is an essential but costly process. Although FMS design appears to be an excellent area for applying artificial intelligence (AI) and computer simulation techniques, to date there have been limited investigations on integrating AI with the modular simulation software available for FMS design. In this paper an integrated approach for the automatic design of FMS is reported, which uses simulation and multi-criteria decision-making techniques. The design process consists of the construction and testing of alternative designs using simulation methods. The selection of the most suitable design (based on the multi-criteria decision-making technique, the analytic hierarchy process (AHP)) is employed to analyze the output from the FMS simulation models. Intelligent tools (such as expert systems, fuzzy systems and neural networks), are developed for supporting the FMS design process. Active X technique is used for the actual integration of the FMS automatic design process and the intelligent decision support process.

Optimal design for flexible manufacturing systems: generalized analytical methods

Advanced manufacturing systems such as Flexible Manufacturing Systems (FMSs) are capital-intensive. Designing functional yet cost-effective FMSs is a challenging task because it involves the solution of a complex series of interrelated problems. In this paper, we study a design problem for FMSs that consist of multiple types of machines. Using closed queueing network models for FMSs, this problem seeks the minimum cost design subject to meeting throughput requirements. The design decisions include the number of machine groups, the number of machines for each group, the workload allocation among machine groups, the number of pallets, the number of transporters, and the batch size. Since these design decisions are highly interdependent, we present the optimum and heuristic methods that simultaneously determine them. To our knowledge, these methods are the most general analytical methods for FMS design. Development of the heuristic methods is crucial because of the time-consuming nature of the optimum method as the number of machine types increases. Computational results show that the heuristic methods are both effective and efficient.

An object-oriented rule-based framework for the specification of flexible manufacturing systems

The design of flexible manufacturing systems (FMSs) requires an effective system specification method, which is flexible to cope with redesigns as a result of requirement changes. In order to facilitate the design of such systems, object-oriented methods are increasingly adopted. However, they only provide limited support to system integration and the explicit specification of operational policies. In this connection, an object-oriented rule-based specification framework is proposed to incorporate a rule model into an object-oriented specification, to analyze and design the global processes and operational policies of FMSs. The application of this framework is illustrated via the specification of a typical vehicle-based FMS.

Agent-based design of holonic manufacturing systems

This article presents a new approach to the design of the architecture of a computer-integrated manufacturing (CIM) system. It starts with presenting the basic ideas of novel approaches which are best characterised as fractal or holonic models for the design of flexible manufacturing systems (FMS). The article discusses hierarchical and decentralised concepts for the design of such systems and argues that software agents are the ideal means for their implementation. The agent architecture InteRRaP for agent design is presented and is used to describe a planning and control architecture for a CIM system, which is separated into the layer of the production planning and control system, the shop floor control systems, the flexible cell control layer, the autonomous system layer, and the machine control layer. Two application scenarios are described at the end of the article and results are reported which were obtained from experiments with the implementations for these application scenarios. While one of these scenarios — a model of an FMS — is more research-oriented, the second one — optimisation of a production line — is directly related to an industrial real-world setting.

Axiomatic design of flexible manufacturing systems

One of the major requirements of agile manufacturing strategies for the 21st century is to introduce intelligent information technology into manufacturing. The main contribution of this paper is an innovative new FMS design methodology. The operation-driven FMS design methodology is introduced, as the concept of concurrent product and process development is being widely used to enhance the productivity and quality of manufacturing. The new FMS design theory is developed from axiomatic design theory established by Suh (1990). The general design theory based on two design axioms and a set of theorems and corollaries is concretized for the FMS design. The proposed methodology works well as an effective decision support system for FMS designers in determining the appropriate FMS configuration at the design stage. This is illustrated via a successful implementation exercise resulting in configuring FMS in real manufacturing settings.

A systemic and integrated approach to flexible manufacturing systems design

Flexible manufacturing systems (FMS) design is a complex problem which is concerned with the selection from a wide variety of available system configurations and control strategy alternatives in the light of several criteria (costs, production, flexibility etc.), many of which are difficult to quantify. Although there is a reasonable number of currently available modelling tools to be applied in FMS design, they are based on an erroneous approach, in which design is considered as a separated, local and myopic activity. Design is divided into isolated and unconnected subproblems whose individual solutions may result in a poor global solution. This paper describes a methodology of analysis and evaluation of FMS design competitive alternatives. It examines the use of an integrated, systemic, global, and user‐centred approach for solving the FMS design problem.

Incremental modeling and verification of flexible manufacturing systems

An FMS is a typical real-time concurrent system composed of a number of computer-controlled machine tools, automated material handling and storage systems that operate as an integrated system under the control of host computer(s). The growing demand for higher performance and flexibility in these systems and the interlocking factors of concurrency, deadline-driven activities, and real-time decision making pose a significant challenge to FMS design, especially in terms of control and scheduling. A formal engineering approach that helps handle the complexity and dynamics of FMS modeling, design and analysis is needed. A real-time architectural specification (RAS) model and its application in the modeling of flexible manufacturing system (FMS) are presented. RAS combines mature operational and descriptive formal methods, in particular time Petri nets (TPN) and real-time computational tree logic (RTCTL), to form an integrated system model for architectural specification and analysis of real-time concurrent systems such as FMS. The contribution of RAS is twofold: First, it provides a formal system to systematically maintain a strong correlation between (real-time) requirements and design and to verify the conformance of the design to the requirements, which helps enhance traceability and thus to help us to achieve high assurance in design. Second, it offers better scalability in modeling and analysis, which provides an effective way to deal with complexity in the application of formal methods. These two features together make RAS a suitable model for the design of FMS.

Display proximity and coding type in the design of flexible manufacturing interfaces

In order to meet the strict demands of today's volatile market, many manufacturers have implemented Flexible Manufacturing Systems (FMSs), computer-integrated systems with highly interconnected components that need to be tightly synchronized. FMSs have greater complexity and require higher capital investment than traditional manufacturing systems, but can provide reduced labor costs, higher product quality and reduced lead times. Unfortunately, many FMSs have not lived up to these expectations due to difficulties in design and implementation. FMSs require a fluid integration of human and machine components to optimize scheduling and part routing. This integration can only be achieved through substantial consideration of human factor issues. The presentation of information to the FMS operator can be rendered in many ways. Current research in cognitive engineering and human factors provides some guidance, but very few studies have focused on the complex interactions typical of human input into FMS. This study investigated two critical parameters of information display design on the operation of an FMS. Participants operated a real-time simulated FMS. They were instructed to optimize three criteria that quantify FMS performance: Percent machine utilization, number of parts completed late and average lateness. Information on part process plans, machine states and system status was presented either graphically or alphanumerically. In each condition, the information from multiple sources was either integrated using the same coding configuration or separated into distinct displays. The results provide insight into the design of displays for complex cognitive tasks such as FMS control. Some additional conclusions about FMS design are also presented.

Optimal design for flexible manufacturing systems: generalized analytical methods

Advanced manufacturing systems such as Flexible Manufacturing Systems (FMSs) are capital-intensive. Designing functional yet cost-effective FMSs is a challenging task because it involves the solution of a complex series of interrelated problems. In this paper, we study a design problem for FMSs that consist of multiple types of machines. Using closed queueing network models for FMSs, this problem seeks the minimum cost design subject to meeting throughput requirements. The design decisions include the number of machine groups, the number of machines for each group, the workload allocation among machine groups, the number of pallets, the number of transporters, and the batch size. Since these design decisions are highly interdependent, we present the optimum and heuristic methods that simultaneously determine them. To our knowledge, these methods are the most general analytical methods for FMS design. Development of the heuristic methods is crucial because of the time-consuming nature of the optimum method as the number of machine types increases. Computational results show that the heuristic methods are both effective and efficient.

ExpertFlex: A knowledge-based system for flexible manufacturing system design

ExpertFlex: A knowledge-based system for flexible manufacturing system design

IDSSFLEX: an intelligent DSS for the design and evaluation of flexible manufacturing systems

IDSSFLEX: an intelligent DSS for the design and evaluation of flexible manufacturing systems

IDSSFLEX: an intelligent DSS for the design and evaluation of flexible manufacturing systems

This paper describes IDSSFLEX, a computer system for the analysis and evaluation of Flexible Manufacturing System (FMS) design configurations. IDSSFLEX is an intelligent decision support system which selects from among several configurations and control strategy alternatives of design, the most appropriate one for a specific case. In order to accomplish such an objective, the system presents simultaneously the following features: ability to quantify subjective factors, ability to account for individual preferences, and ability to cope with multiple criteria decision making. A case study illustrates the effectiveness of the computer system.

IDSSFlex: An Intelligent DSS for the Design and Evaluation of Flexible Manufacturing Systems

IDSSFlex: An Intelligent DSS for the Design and Evaluation of Flexible Manufacturing Systems

On Agents, Holons and the Design of Flexible Manufacturing Systems

The goal of the paper is to present and discuss approaches for the design of flexible manufacturing systems on different levels. In particular the Leuven development proposal for manufacturing holons will be compared to the AWIC design proposal for multi-agent systems. Eventually the flexibility of the AWIC-method will be demonstrated by revisiting two agent based solutions of the job shop scheduling problem as proposed by Rozenberg and Sycara.

Modelling and design of flexible manufacturing systems using SADT and Petri nets tools

This paper describes an approach to manufacturing systems design that allows automatic generation of controller logic from a high level system design specification. The high level system design specification was developed using SADT method and Design/IDEF software package. The interface is based on a number of transformation rules from an IDEF0 specification into a Petri net. A standard qualitative analysis and simulation of the Petri net is used to determine if the manufacturing system will operate in the desired manner.

A new FMS simulator with object-oriented-programming techniques

With the advance of research, design and operation of flexible manufacturing systems (FMS), new requirements have been presented for FMS simulators. These new requirements are high modelling efficiency, high model validity and credibility, more user-friendly features, real control and scheduling logic similar to a real FMS, and effective and correct analysis of results, etc. In this paper, a new FMS simulator (FMSSIM) based on object-oriented-programming (OOP) and some new techniques is introduced. The new techniques include: (i) fully interactive graphical modelling technique, with which the simulation modelling only needs 2–4 h to complete and the model data are highly consistent and accurate; (ii) real FMS-like simulation control and scheduling, with which various control and scheduling algorithms such as AI-based heuristic scheduling can be easily implemented; (iii) the Intelligent Evaluator, with which the efficiency and accuracy of the evaluation process can be improved. Practical use has shown that the FMSSIM has a good performance in modelling, operation and evaluation, meeting the new requirements for a modern FMS simulator.

Identifications of part families and bottleneck parts in cellular manufacturing

The formation of machine‐part families is an important task in the design of cellular and flexible manufacturing systems. The formation results in the creation of many benefits for manufacturing systems. Among the many methods utilized in machine‐cells formation, the similarity coefficient method (SCM) is most widely used. When SCM is used, the rearrangement of machine and part components is required to form machine‐part families. This process of rearrangement has been considered as being subjective and difficult and may result in improper assignments to parts families, resulting in a negation of benefits promised. This paper presents an effective algorithm to identify part‐families and bottleneck‐parts, given machine groupings, rather than addressing the machine grouping problem in general.

Intelligent decision support system for flexible manufacturing system design

The aim of this paper is to develop a new methodology of analysis and evaluation of Flexible Manufacturing System (FMS) design configurations. It examines the use of an integrated, systemic, global and user oriented approach for the complex problem of selecting among several configuration alternatives the most suitable for a specific case. The methodology is implemented using the Decision Support System framework, offering an objective tool to help managers and engineers during the design stage of the development cycle of these manufacturing systems. A case study illustrates the effectiveness of the developed methodology.

Tools for Design and Optimal Control of Production Line and Flexible Manufacturing Systems

Abstract Flexible manufacturing system (FMS) is a net of workstations interconnected by ways which are followed by products. This paper introduces the factors which influence the design and control of FMS and shows by using the Petri nets and Markovian decision process the FMS modelling and simulation.