Flexible Manufacturing Systems Research Articles

An Algorithm for Part Input Sequencing of Flexible Manufacturing Systems with Machine Disruption

Because disruption happens unpredictably and generates serious impact in supply chain and production environments in the real world, it is important to develop approaches to handle disruption. This paper investigates disruption handling in part input sequencing of flexible manufacturing systems (FMSs). An algorithm is proposed for FMS part input sequencing to handle machine breakage. Evaluation is performed for the proposed algorithm by simulation experiments and result analyses. Finally, conclusions are summarized with managerial implications discussed and further research works suggested.

The Impact of Industrial Robot Applications on Global Value Chains Division Position

This paper surveys the GVC division position across forty-five countries and fourteen manufacturing sub-sectors during the period from 1999 to 2018 to illustrate the impact of applications of industrial robots on the GVC position. The study proves that an increasing level of utilization of industrial robots significantly improves the GVC division position in the manufacturing sector. By automating repetitive and precision tasks, robots enhance efficiency and productivity, therefore allowing deeper specialization in specific stages of the manufacturing process. This technological progress allows for a more connected global production network and hence better integration into GVC. The study also evaluates the spillover effects across value chains and the moderating impact of industrial agglomeration on smart manufacturing.The empirical results show that the application of industrial robots enhances productivity and encourages innovation in related sectors, thereby driving downstream industry growth and promoting industry specialization.Despite the improvement in GVC division positions, robots also contribute to making global value chains more diversified and resilient. Flexible and adaptive manufacturing systems can adapt to disruptions, such as pandemics and geopolitical tensions, ensuring continuity in production and increasing stability and competitiveness in smart manufacturing systems.

Dynamic workload balancing to part input sequencing for integrated scheduling decision-making of flexible manufacturing systems

Flexible manufacturing systems (FMSs) are crucial in contemporary manufacturing environments because they provide the required agility and adaptability to face volatile customer demands. Balancing workload among different work stations of an FMS is essential to ensure optimal resource utilization, minimize idle times, and improve overall system performance. This research is aimed to study the application of dynamic workload balancing to part input sequencing for integrated FMS scheduling decision-making. In this work, we propose an online algorithm that balances workload dynamically in FMSs. A mathematical model of FMS scheduling integration is presented. The proposed approach schedules tasks not only on machines but also on the robot responsible for part movement within a shop floor. The proposed approach is evaluated in two aspects of comparison and analysis. Data analysis is made by simulation experiment and statistical analysis. Conclusions with managerial implications for practical applications and future research suggestions are provided.

Smart design and additive manufacturing of bending tools to improve production flexibility

For the automotive industry, especially on the part of Tier 1 and Tier 2 suppliers, the future will be about maintaining sovereignty in the form of technology openness and accelerating digitization. The product portfolio, which is generally passed on by OEMs to suppliers for production, often includes body parts that cannot always be manufactured economically with the prevailing production technology. The reason for this is a high diversity of model-variants, which requires smaller batches. To this end, highly flexible large-series production cells for body sheet components that can be scaled in all dimensions are being developed and tested. For the first time, they will make it possible to redesign the process planning in series production on a component-specific basis. The aim is to reduce production costs for new, geometrically different component variants. The basic components of the flexible manufacturing system are, firstly, new flexible forming technologies which have the potential to produce typical vehicle part geometries. Secondly, a process generator develops the corresponding production plan. A digital mapping of the manufacturing processes enables the selection of cost-, efficiency-, flexibility- and resilience-optimized production chains depending on the number of parts. Established manufacturing processes to produce car body components are supplemented in the cell by flexible processes such as 3D swivel bending. As a use case for flexible manufacturing, a concept for Rapid Tooling of 3D swivel bending tools is developed. In the flexible manufacturing system to be developed, a method of a standardized process sequence to produce forming tools within 24 h has been lacking to date. For this purpose, the concept of an automated design is being developed in which a reconfigurable tool body can be sliced into sheet metal stripes The active tool surface is additively manufactured after the tool has been packaged using LMD and adapted to individual requirements. The goal in the application of Rapid Tooling is to reduce lead times and development costs through a largely automated tool design and lead time-optimized manufacturing concept.

Development and Application of Digital Twin Control in Flexible Manufacturing Systems

Flexible manufacturing systems (FMS) are highly adaptable production systems capable of producing a wide range of products in varying quantities. While this flexibility caters to evolving market demands, it also introduces complex scheduling and control challenges, making it difficult to optimize productivity, quality, and energy efficiency. This paper explores the application of digital twin technology to tackle these challenges and enhance FMS optimization and control. A digital twin, constructed by integrating simulation models, data acquisition, and machine learning algorithms, was employed to replicate the behavior of a real-world FMS. This digital twin enabled real-time dynamic optimization and adaptive control of manufacturing operations, facilitating informed decision making and proactive adjustments to optimize resource utilization and process efficiency. Computational experiments were conducted to evaluate the digital twin implementation on an FMS equipped with robotic material handling, CNC machines, and automated inspection. Results demonstrated that the digital twin significantly improved FMS performance. Productivity was enhanced by 14.53% compared to conventional methods, energy consumption was reduced by 13.9%, and quality was increased by 15.8% through intelligent machine coordination. The dynamic optimization and closed-loop control capabilities of the digital twin significantly improved overall equipment effectiveness. This research highlights the transformative potential of digital twins in smart manufacturing systems, paving the way for enhanced productivity, energy efficiency, and defect reduction. The digital twin paradigm offers valuable capabilities in modeling, prediction, optimization, and control, laying the foundation for next-generation FMS.

A two-stage solution approach for scheduling flexible manufacturing systems with multi-fixturing pallets

A two-stage solution approach for scheduling flexible manufacturing systems with multi-fixturing pallets

Effect of Layout Discretization on the Performance of Zone Control-Based Multi-AGV Traffic Management Systems

Automatic Guided Vehicles (AGVs) are widely used in flexible manufacturing systems for material handling inside the factory. Traffic management strategies, required to guarantee a conflict-free operation of the overall fleet, discretize the workspace of the AGVs and use the resulting graph model for route planning and execution. In zone control approaches, AGVs move from node to node on a permit basis, with limitations on the allowed number of AGVs at a time in each area of the graph to prevent and/or resolve deadlocks and conflicts. Hence, for an optimal implementation of traffic controllers in real manufacturing systems, it is essential to understand how the layout discretization influences the performance of the AGV network. This paper analyzes its effect in grid-like shaped workspaces by using a representative zone control algorithm and a recently developed improvement of it. Realistic numerical experiments on different layouts reveal that denser discretizations do not yield faster executions or increase in throughput, while lower control periods in the permit system entail significant performance uplifts.

Design and Implementation of Multi-Configuration Rolling Machine

For decades, metal corrugated sheets have usually been manufactured using conventional roll-forming machines with lower and upper rollers or a die and a press as the main shaping elements. However, these machines and their related processes present economic disadvantages because of additional expenses required to improve and manage forming tools. To overcome these drawbacks, reconfigurable machines, such as dedicated and flexible manufacturing systems, were used as alternatives; they possess high flexibility for accomplishing forming processes. Reconfigurable machines are designed around a particular family of manufactured outcomes, allowing for high system flexibility. In light of the latest developments in reconfigurable machine design, this study proposes a new sheet metal forming roller called the discrete multi disk roller (MDR) as an alternative to the traditional roller design. Unlike existing processes, the MDR minimises production costs associated with material loss and effectively decreases forming errors. Furthermore, it utilises multi-disk as reconfigurable rollers. The technique and applicable procedure of the MDR are described, and wavy sheets with different dimensions and shapes are formed to verify the applicability of the reconfigurable roller, a critical component in the forming process. Thirteen parts with different configuration profiles were produced using the proposed MDR machine.

Multi-attribute and predictive cascaded fuzzy system for the AGV dispatching in a flexible manufacturing system

Multi-attribute and predictive cascaded fuzzy system for the AGV dispatching in a flexible manufacturing system

Path detectability verification for time-dependent systems with application to flexible manufacturing systems

This paper addresses the path detectability verification problem for time-dependent systems modeled by time labeled Petri nets (TLPNs). To capture the information precisely, it may not be sufficient to estimate the current state by resorting to the partial system observation, and it is usually crucial to decide the path of a system to reach the current state. Path detectability characterizes a time-dependent system whose current state and the corresponding path can be uniquely determined after a real-time observation (RTO). Revised state class graphs (RSCGs) are proposed to capture the time information for the evolution of the RTO in a TLPN system. We demonstrate the time information overlap problem in the RSCG, i.e., several paths are associated with the same observable events and the same time instants, which leads to such paths that cannot be distinguished. The nodes required to be computed in the proposed RSCGs are always less or equal to those of the modified state class graphs reported in the literature, since the enumeration of all the states is avoided. Based on the RSCG, an RSCG observer is formulated to address the time information overlap problem and capture the number of such paths in the TLPN system. The efficiency analysis of this verification method is provided. In this paper, the results are applied to a real production system, exposing the practical value of the reported method.

Digital Twin-Driven Dynamic Scheduling of Flexible Manufacturing System in the Context of Smart Factory Producing Brass Accessories

This study aims to deal with a dynamic scheduling problem of a real Flow Shop follow-up of an assembly process considering the specific constraints and requirements of a brass accessories manufacturing (BAM) company. We basically set up a Digital Twin-driven dynamic scheduling approach for Industry 4.0 by addressing uncertainties of machine availability. In fact, the setup of this Digital Twin (DT) is the outcome of the combination of both optimization and simulation. For the first step, we have elaborated a Mixed Integer Linear Programming (MILP) scheduling model by taking into account the dedicated requisites of our case study. Concerning simulation, a 3D simulation platform of a workshop producing brass accessories controlled by a Cyber-Physical Production System (CPPS) has been developed, in our previous work, including constraints and stochastic aspects. The simulation constraints are difficult or impossible to be modeled in the MILP model. These designs are integrated with the real workshop to construct the Digital Twin. The proposed tool enables the rescheduling of production orders based on machine disturbances and unpredictability. Validation scenarios have been designed and conducted to highlight the efficacy of the Digital Twin approach utilizing the brass accessories case study. We are confident that this represents the initial endeavor addressing the optimization of production rescheduling in a flow shop follow-up of a mixed assembly system.

A multi-objective brain storm optimization for integrated distributed flexible job shop and distribution problems

Production and distribution are critical components of the furniture supply chain, and achieving optimal performance through their integration has become a vital focus for both the academic and business communities. Moreover, as economic globalization progresses, distributed manufacturing has become a pioneering production technique. Via leveraging a distributed flexible manufacturing system, mass flexible production at lower costs can be achieved. To this end, this study presents an integrated distributed flexible job shop and distribution problem to minimize makespan and total tardiness. In our research, a set of custom furniture orders from different customers are processed among flexible job shops and then delivered by vehicles to customers as the due date. To distinctly show the presented problem, a mixed integer mathematical programming model is created, and a multi-objective brain storm optimization method is introduced considering the problem's features. In comparison to the other three advanced methods, the superiority of the algorithm created is showcased. The findings of the experiments demonstrate that the constructed model and the introduced algorithm have remarkable competitiveness in addressing the problem being examined.

A FRAMEWORK FOR LEAN MANUFACTURING IMPLEMENTATION IN THE TEXTILE INDUSTRY: A RESEARCH STUDY

This study investigates the implementation of lean manufacturing in the textile industry, focusing on its potential to enhance efficiency, reduce waste, and improve product quality. Lean manufacturing principles, including Just-In-Time (JIT) production, Kanban systems, value stream mapping, 5S workplace organization, and continuous improvement (Kaizen), have been widely recognized for their effectiveness in various manufacturing sectors. However, their application in the textile industry remains underexplored. Through a systematic literature review of 60 review papers and empirical analysis involving case studies, interviews, and surveys with industry experts, managers, and workers, this research identifies the significant benefits of lean practices in textile manufacturing. The findings reveal substantial efficiency gains, waste reduction, and quality improvements among companies adopting lean principles. Nevertheless, the study also highlights several industry-specific challenges, such as high variability in raw materials, complex production processes, and market pressures from fast fashion. These challenges necessitate tailored approaches and effective change management strategies for successful lean integration. Additionally, the research emphasizes the need for investment in advanced technologies and flexible manufacturing systems to enhance responsiveness to market changes. The study concludes that despite the challenges, lean manufacturing offers valuable strategies for textile companies aiming to improve their competitiveness and sustainability in the global market. This research contributes to the growing body of knowledge on lean manufacturing and provides practical insights for textile manufacturers seeking to adopt and optimize lean practices.

A Branch and Bound Algorithm for Scheduling of Flexible Manufacturing Systems

A Branch and Bound Algorithm for Scheduling of Flexible Manufacturing Systems

Petri Nets Modeling of a Flexible Manufacturing System

In a world where industrial mechatronic systems evolve daily, the intensity of these requirements influences the maximization of efficiency, the optimization of the safety of the working environment including humans,and the increase of the quality of services. This is why industrial computing is becoming a necessity for manufacturers and even researchers working on innovative and creative subjects. This paper deals with theanalysis and the modeling of a flexible manufacturing system. Firstly, the study of the system engineering then presented the composition of the studied system. Second, we present an application of a modeling based on Petri Nets. Finally, the last presentconclusion and future work

Hierarchical online automated planning for a flexible manufacturing system

Task planning and action planning for workshop machines are essential for modern manufacturing. Traditionally, these two problems are solved independently with elaborate manual methods. However, personalized customization introduces more dynamic exogenous events into the manufacturing system, and it is then impossible to consider all possible dynamic scenarios manually. This paper focuses on online automated planning, generating new plans automatically in response to new dynamic situations. We first formulate the planning problem for a flexible manufacturing system as a fully observable nondeterministic planning problem. Second, a hierarchical automated online planning approach is presented. Finally, the effectiveness of the proposed approach is verified by an ARIAC 2022 competition environment.

НАУКОВО-МЕТОДИЧНІ ЗАСАДИ РЕСТРУКТУРИЗАЦІЇ ВИРОБНИЧОГО ПРОЦЕСУ

Batch production is typical for engineering enterprises connected with aeronautical engineering manufacturing. One of its main problems is the need to periodically change the production pattern which arises as a result of the instability of the products range, changes in volume of series, moral and physical wear of technological equipment. Such a change is carried out in the course of reconstruction and technical re-equipment in order to improve the efficiency of material flows.The main characteristics of material flows are determined by a spatial component of a flexible manufacturing system pattern, set by the machine tools laying according to the organization of batch process. The bulk of the cost of final product manufacturing is associated with the arrangement of material flows. In order to reduce the total costs it is necessary to improve the pattern of production by establishing a technology-oriented machine tools laying. In this case, there is a need to develop scientific and methodological basis of restructuring the manufacturing process.One of the most effective approaches to the design of machine building plants with a batch type of manufacturing is the use of program-target method based on the methodology of choosing the best technological solutions.Modern methodology of batch technologies design is based on the system approach to the analysis and synthesis of the basic structure of the manufacturing processes, which allows to apply mathematical simulation.The orientation of each of the sites on the end result leads to a substantial reduction of manufacturing costs, which significantly simplifies solving problems of division and coordination of labor on the principles of self-organization and self-regulation.The proposed mathematical model of manufacturing costs optimization is designed in accordance with all the aforementioned principles. The problem being solved is multiobjective. That is why the mathematical model has several goal functions them requiring finding peak values and some of them requiring finding the bottom values.The model can be applied in organizing the aeronautical engineering manufacturing, which requires effective remounting during the change of product range thus ensuring the required flexibility of manufacturing.

Optimal Strategy of Unreliable Flexible Production System Using Information System

Background: Optimization approaches and a models can be applied for critical production systems that experience equipment failure, repair delays and product quality control in order to maximize the total profit. We can cite, as an example, flexible manufacturing systems. Methods: Our methodology involves developing a decision model integrated with an information system to coordinate various system operations, ensuring timely response to customer requests. The module of the information system is provided to optimally manage the production flow and parts ordering according to machine availability. The objective is to determine the optimal order thresholds of part batches that maximize the total profit. Results: Numerical results are provided to analyze the influence of system reliability and uncertainty on decision variables, offering insights into the system’s performance and robustness. By using our method, the advancement of the flexible production systems is carried out by addressing key operational challenges and optimizing production processes for enhanced efficiency and profitability. Conclusions: To achieve this, an optimization algorithm is employed to identify optimal solutions that enhance profitability.

Research on Shortest Path BFS Strategy in Multi-AGV Scheduling System

With the increasing maturity of automated guided vehicles (AGV) technology and the widespread application of flexible manufacturing systems, enhancing the efficiency of AGVs in complex environments has become crucial. This paper analyzes the challenges of path planning and scheduling in multi-AGV systems, introduces a map-based path search algorithm, and proposes the BFS algorithm for shortest path planning. Through optimization using the breadth-first search (BFS) algorithm, efficient scheduling of multiple AGVs in complex environments is achieved. In addition, this paper validated the effectiveness of the proposed method in a production workshop experiment. The experimental results show that the BFS algorithm can quickly search for the shortest path, reduce the running time of AGVs, and significantly improve the performance of multi-AGV scheduling systems.

A Research Paper on Flexible Manufacturing System Simulator for Technical Institutes

Today’s scenario of manufacturing activities is toward automation. To provide practical exposure and better understand, there is need of automated machines in the technical institutes. Due to financial& space constraints, most of the institutes is not having automated machines for the demonstration. This comprehensive review navigates the landscape of Flexible Manufacturing Systems (FMS), dissecting scheduling rules, design, and simulation methodologies, and the integration of advanced technologies. The motor control systems, microcontroller applications, and robotic process automation contribute to a holistic understanding of FMS evolution. This synthesis serves as a roadmap for researchers and practitioners, fostering adaptability and responsiveness in modern manufacturing. FMS is the highest automation in manufacturing industry and work on group technology concept. In this project, the authors are planning to design and develop FMS Simulator for technical institute. This helps students to understand group technology concept, automated vehicle system, automated material handling system, working of automated transfer line, industrial robot and so on. This proposed initiative aligns with the broader goals of academics – to produce graduates who are not only well- versed in theoretical concepts but also equipped with the practical skills demanded by industry The utilization of an FMS with educational purposes started in the academic year 2011–2012 and still remains active. Here, the most illustrative FPs are expounded, and successful academic outcomes are reported. In addition, a set of initial considerations based on the experience acquired by the FMS is provided.