An Estimation of Distribution Algorithm for Part Cell Formation Problem

In automated batch type production systems, machine-part cell formation problems (CFP) have long drawn attention of researchers. The objective of CFP in cellular manufacturing system (CMS) is to identity machine cells and part families in order to minimize the intercellular movements of parts as well as maximize the utilization of machines. Optimum cell formation results reduction in total production times, in-process inventories, material handling cost, labor cost/times, paper works, number of machine set-ups, set-up times. It also simplifies process plans, management and improves product quality, productivity, utilization of resources. Since the modern manufacturing machines are generally multifunctional, so the processing of parts can be performed by number of alternative routes. The objectives of this study is to determine the optimal processing route and balanced machine cells (to minimize cell load variation) incorporation with parts volume, process sequence for minimum intercellular movements of parts. A genetic algorithm metaheuristic approach is presented for a benchmark CFP. Computational results show that the proposed approach gives better result comparatively with the well-known existing methods in terms of total intercellular movements.

Group technology (GT) is a manufacturing philosophy that attempts to reduce production cost by reducing the material handling and transportation cost. The GT cell formation by any known algorithm/heuristics results in much intercell movement known as exceptional elements. In such cases, fractional cell formation using reminder cells can be adopted successfully to minimize the number of exceptional elements. The fractional cell formation problem is solved using modified adaptive resonance theory1 network (ART1). The input to the modified ART1 is machine-part incidence matrix comprising of the binary digits 0 and 1. This method is applied to the known benchmarked problems found in the literature and it is found to be equal or superior to other algorithms in terms of minimizing the number of the exceptional elements. The relative merits of using this method with respect to other known algorithms/heuristics in terms of computational speed and consistency are presented.

Modeling of a manufacturing cell design problem with fuzzy multi-objective parametric programming

The primary objective of group technology (GT) is to enhance the productivity in the batch manufacturing environment. The GT cell formation problem is solved using modified binary adaptive resonance theory networks known as ART1. The input to the modified ART1 is a machine-part incidence matrix comprised of the binary digits “0” and “1”. And the outputs are the list of part families and the corresponding part list, machine cells and their corresponding list of machines, and the number of exceptional elements. This method is applied to the known benchmarked problems found in the literature and it is found to outperform other algorithms in terms of minimizing the number of the exceptional elements. The relative merits of using this method with respect to other known algorithms/heuristics in terms of computational speed and consistency are presented .

In manufacturing, the machine-part cell formation (MPCF) problem addresses the issues surrounding the formation of part families based on the processing requirements of the components, and the identification of machine groups based on their ability to process specific part families. Past research has shown that one key aspect of attaining efficient groupings of parts and machines is the block-diagonalization of the given machine-part (MP) incidence matrix. This paper presents and tests a grouping genetic algorithm (GGA) for solving the MPCF problem and gauges the quality of the GGA's solutions using the measurements of efficiency (Chandrasekharan and Rajagopalan 1986a) and efficacy (Kumar and Chandrasekharan 1990). The GGA in this study, CF-GGA, a grouping genetic algorithm for the cell formation problem, performs very well when applied to a variety of problems from the literature. With a minimal number of parameters and a straightforward encoding, CF-GGA is able to match solutions with several highly complex algorithms and heuristics that were previously employed to solve these problems.

Impact of the replacement heuristic in a grouping genetic algorithm

This paper considers the machine-part clustering under the assumption of alternative process plans for each part. Kusiak's p-median model of part family formation dealing with the problem has critical disadvantages in that the model requires too many binary variables and constraints and the number of part families must be known in advance. Furthermore, the solution quality of the model in terms of the number of exceptional elements is poor for ill-structured problems. Motivated by Viswanathan's work, this paper proposes two new p- median models using new measures of similarity between machine pairs: one with the prespecified number of cells and the other without the prespecified number of cells. Computational experience shows the applicability of new p-median models of machine cell formation over Kusiak's model.

The estimation of distribution algorithm (EDA) has recently emerged as a promising alternative to traditional evolutionary algorithms for solving combinatorial optimisation problems. This paper presents a novel two-phase simulation-based EDA (TPSB-EDA) for minimising the makespan of a hybrid flow shop under stochastic processing times. To address the stochastic scheduling problem efficiently, the proposed TPSB-EDA incorporates a two-phase simulation model to estimate the performance of candidate solutions. In this model, an optimal back propagation network is firstly applied to identify a set of roughly good solutions, and then the selected solutions are further evaluated by a discrete-event simulation algorithm. Moreover, an annealing selection mechanism (ASM) is adopted to preserve the population diversity of EDA. Different from the selection operators of common EDAs, the ASM uses Boltzmann probability in the annealing algorithm to select part of population to establish the probabilistic model. Computation results indicate that the TPSB-EDA provides good solutions in the aspects of solution quality and computational efficiency.

CLASS: An algorithm for cellular manufacturing system and layout design using sequence data

Additive manufacturing (AM) has impacted the manufacturing of complex three-dimensional objects in multiple materials for a wide array of applications. However, additive manufacturing, as an upcoming field, lacks automated and specific design rules for different AM processes. Moreover, the selection of specific AM processes for different geometries requires expert knowledge, which is difficult to replicate. An automated and data-driven system is needed that can capture the AM expert knowledge base and apply it to 3D-printed parts to avoid manufacturability issues. This research aims to develop a data-driven system for AM process selection within the design for additive manufacturing (DFAM) framework for Industry 4.0. A Genetic and Evolutionary Feature Weighting technique was optimized using 3D CAD data as an input to identify the optimal AM technique based on several requirements and constraints. A two-stage model was developed wherein the stage 1 model displayed average accuracies of 70% and the stage 2 model showed higher average accuracies of up to 97.33% based on quantitative feature labeling and augmentation of the datasets. The steady-state genetic algorithm (SSGA) was determined to be the most effective algorithm after benchmarking against estimation of distribution algorithm (EDA) and particle swarm optimization (PSO) algorithms, respectively. The output of this system leads to the identification of optimal AM processes for manufacturing 3D objects. This paper presents an automated design for an additive manufacturing system that is accurate and can be extended to other 3D-printing processes.

The layout positioning problem of facilities on a straight line is known as Single Row Facility Layout Problem (SRFLP). The objective of SRFLP, categorized as NP-Complete problem, is to arrange the layout such that the sum of distances between all facilities’ pairs can be minimized. Extended Artificial Chromosome Genetic Algorithm (eACGA) is a promising algorithm that has been proposed recently. eACGA extends the probabilistic model in Estimation of Distribution Algorithms (EDAs) and then hybridize it with Genetic Algorithms (GAs). eACGA is proven to produce an excellent solution for scheduling problem. In this paper, we modify the eACGA to solve SRFLP. Computational results on benchmark problems show the effectiveness of eACGA for solving SRFLP. Key Words: single row facility layout, estimation distribution algorithm, genetic algorithm.

A capacity constrained mathematical programming model for cellular manufacturing with exceptional elements

A new concept is presented in this paper of quasi-dynamic cell formation for the design of a cellular manufacturing system, based on analysing the fact that static and dynamic cell formation could not reflect the real situation of a modern cellular manufacturing system. Further, workforce resources are integrated into quasi-dynamic cell formation and thus a quasi-dynamic dual-resource cell-formation problem is proposed. For solving this problem, this paper first establishes a non-linear mixed integer programming model, where inter-cell and intra-cell material cost, machine relocation cost, worker operation time, loss in batch quality and worker salary are to be minimised. Then, a multi-objective GA is developed to solve this model. Finally, a real life case study is conducted to validate the proposed model and algorithm. The actual operation results show that the case enterprise significantly decreases its material handling cost and workforce number and obviously increases its product quality after carrying out the obtained scheme.

In this paper, we have proposed a hybrid approach combining Artificial Bee Colony Algorithm (ABC) with Estimation of Distribution Algorithm (EDA) for Minimum Weight Dominating Set (MWDS) problem. By combining ABC algorithm with EDA, we are able to guide the search process toward more promising solutions in comparison with any of the two constituent approaches. We have also used a solution improvement method which further trims down the solution in order to minimize its fitness value. Computational results on standard benchmark instances of the MWDS problem show that the hybrid ABC-EDA performs as good as or better than existing approaches in terms of solution quality on most of the instances.

The cellular manufacturing system is a well-known strategy which improves the production efficiency and cutting down the manufacturing cost. The main problem in designing cellular manufacturing system is cell formation, which is concerned with grouping parts with similar processing required into part families and associated machines into machines and minimises the exceptional elements. This paper presents the artificial immune system method to solve the manufacturing cell formation problems with the objective to minimise the exceptional elements. This method is applied to the existing datasets found in the literature and it is found to out performs other methods.