Optimization and Simulation of Production Line Layout Based on Plant Simulation

Poor layout designs in manufacturing facilities severely reduce production efficiency and increase short- and long-term costs. Analyzing and deriving efficient layouts for novel line designs or improvements to existing lines considering both the layout design and logistics flow is crucial. In this study, we performed production simulation in the design phase for factory layout optimization and used reinforcement learning to derive the optimal factory layout. To facilitate factory-wide layout design, we considered the facility layout, logistics movement paths, and the use of automated guided vehicles (AGVs). The reinforcement-learning process for optimizing each component of the layout was implemented in a multilayer manner, and the optimization results were applied to the design production simulation for verification. Moreover, a flexible simulation system was developed. Users can efficiently review and execute alternative scenarios by considering both facility and logistics layouts in the workspace. By emphasizing the redesign and reuse of the simulation model, we achieved layout optimization through an automated process and propose a flexible simulation system that can adapt to various environments through a multilayered modular approach. By adjusting weights and considering various conditions, throughput increased by 0.3%, logistics movement distance was reduced by 3.8%, and the number of AGVs required was reduced by 11%.

An evolutionary optimal green layout design for a production facility by simulated annealing algorithm

The accuracy of segmenting Chinese character, especially connected Chinese characters, is essential for the performance of a Chinese character recognition system. In this paper, a new approach for segmenting connected Chinese characters based on genetic algorithm is proposed. The best segmentation path is evolved by genetic algorithm from a fixed area located in the middle of character image which is defined as segmentation path zone (SPZ). The initial population is composed of each point line in SPZ. The individual coding, fitness function, crossover operator and mutation operator are also defined for this task. Experimental results on a dataset extracted from the four vaults show that our approach can get an average accuracy of 88.9% on test set and can handle some complex types of connected Chinese characters without special heuristic rules.

Structuring the modeling space and supporting evolution in software product line engineering

A new concept of adjacency for concurrent consideration of economic and safety aspects in design of facility layout problems

Optimal arrangement of turbines in wind farms is very important to achieve maximum energy at the lowest cost. In the present study, the use of Vestas V-47 wind turbine and uniform one-way wind in achieving the optimal arrangement of horizontal axis turbines in Manjil with genetic and Monte Carlo algorithms has been investigated. Jensen model is used to simulate the wake effect on the downstream turbines. The objective function is considered as the ratio of cost to power of the power plant. The results show that the Monte Carlo method compared with genetic algorithm will give a better result. Under the same conditions, the Monte Carlo algorithm will give 29% and 40% better results in terms of the number of turbines and output power, respectively. In terms of optimization, in the Monte Carlo algorithm, its fitness value is 16% less than the genetic algorithm, which indicates its better optimization.

Reuse and Requirements Engineering are very important for efficient and successful product development. However, there are many open issues for performing them well in practice, especially reuse of requirements . This paper addresses several of these issues by making use of parameters and discriminants for product line requirements. Discriminants are a special kind of requirement that differentiate one product from another. They represent qualitative variability in a product line model, while parameters represent quantitative variability. In this paper these techniques are combined in the form of parameterized discriminants. Using the techniques and a metamodel for the representation of a product line model, a stakeholder‐viewpoint oriented process is defined for capturing product line requirements and constructing a product line model. From such a generic model and with well‐defined semantics, selecting single product application requirements can be done systematically, guaranteeing the property that the resulting single product satisfies the constraints of the product line model. Even for unsystematic free selection as often used in practice, it can be formally verified whether this property holds. The approach is illustrated using a hypothetical mobile phone example and draws upon case study work with real‐world requirements. © 2007 Wiley Periodicals, Inc. Syst Eng

Based on the study of the unidirectional loop layout, this paper analyzed the necessity of genetic algorithm to the workshop layout optimization. To minimize transportation travel, the mathematical model of the unidirectional loop workshop facility layout was set up, using the niche genetic algorithm with introduction of penalty function and elite reservation strategy to accomplish the facility layout optimization. Through the calculation of the example, the feasibility and effectiveness of this algorithm in facility layout optimization design is verified.

Making innovations to become competitive is not always an easy task, and in the industrial sphere, this thinking becomes even more complex. In this sense, proper use in raw material transformation processes becomes very challenging for managers, since improving processes is a condition where more can be done with less. Thus, many organizations seek to develop improvements through existing activities using a variety of techniques that are addressed in the literature, such as value flow mapping, lean production, simulations, among others. Therefore, this article aims to study and apply the computational simulation, through the use of Tecnomatix Plant Simulation © software, to obtain the best relation between financial return and productivity of a upholstery production line. In the methodology of this work was carried out the structural proposition of five scenarios. For the construction of these, a current scenario of the production line was carried out and for each new scenario, operators were added with new tasks to be performed. Although the final results show a better financial return for scenario three, the results obtained in scenario five are significant in terms of productivity indicators, although the cost with extra operators is much higher than in the other scenarios. Thus, it was clear the relevance of applying simulation in the production line, since the model assisted the managers in the decision making.

Production of functional products using local raw materials with a high content of biologically active substances is the main trend in the production of non-alcoholic beverages. In this regard, creation of a technological line that ensures not only the quality of the finished product, but also the safety of the functional properties of the feedstock is of great interest. A computer model of a functional soft drink production line, developed using the MasterSCADA 4D software created by a leading domestic company has been. The model emulates the entire production process including the stage of filling the finished product. It is possible to control a real production line provided that communication with an industrial controller, sensors and actuators is installed and configured. A set of technological equipment has been selected for each production stage, from processing raw materials and on down to functional soft drink packaging. Recommendations have been given for water treatment, including a number of technological processes, such as rough water purification and disinfection. There are instructions for preparing sugar syrup using hot method. The characteristics of the recommended plant for hydrodynamic extraction from plant raw materials has been presented. A factor intensifying the extraction process, in the pulsating action of the extractant between the solid and liquid phases. Production of a functional drink implies using of water as an extractant, so additional methods of intensifying mass transfer processes have been considered in order to increase the percentage of extraction of target components. The use of the effect of ultrasonic, electric, pulse and discrete-pulse fields on raw materials is considered to be the most promising method for the extraction process intensification.

This paper focuses on the intelligent transformation of automobile hub production, aiming to achieve efficient intelligent production line design and virtual commissioning using PQ Factory. It analyzes the current situation of automobile hub production and the requirements for intelligent production lines, and elaborates on the crucial role of PQ Factory in this field. Based on PQ Factory, a model of an intelligent hub production line is designed. Programs are post-generated by adding position points, and PLC programs are written. The real PLC is connected to PQ Factory through a SymLink gateway to conduct virtual commissioning of the production line instead of actual robots, CNC lathes, and other equipment. Experimental results show that this production line has significant advantages in improving production efficiency and optimizing management. Moreover, compared with offline commissioning, it greatly reduces time and cost. It provides an innovative path and practical reference for the intelligent upgrading of the automobile manufacturing industry, has important application value and promotion significance, and also offers useful reference for research and application in related fields.

This paper deals with the topic of optimal wind farm layout design on complex terrains. The paper proposes optimization model that reflects the actual requirements of realistic wind farms. Fuzzy based computational efficiency model is proposed. Computational efficiency model takes account of environmental impact of a wind farm, land costs, costs of auxiliary roads, installation and maintenance costs, costs of electrical infrastructure, etc. Fuzzy logic deals with uncertainties that can occur while quantifying computational efficiency. Using genetic algorithm, the proposed model has been tested on a realistic wind farm terrain in Serbia.

The mathematical models of production lines and its stability analysis

In this paper, we study the initial butter decision (IBD) problem for a class of periodic production lines and the stochastic approximation (SA) algorithm for the problem. We establish the generalized semi-Markov process (GSMP) model of production line and the formulation of the IBD problem that is a bi-objective stochastic optimization problem. Considering the high computation cost of objective functions under middle scale stations, we employ SA algorithm to solve the optimization problem. To improve the performance to search the solutions on the boundary of feasible decision set, we propose an modified SA algorithm, called density stochastic approximation (DSA). Numerical results show SA algorithm is effective for the problem and DSA outperform SA and other two well-known variants of SA on searching the solutions on the boundary.

Production line is the lifeblood of national manufacturing industry. This paper adopts empirical analysis research methods. Based on the understanding of the current situation of the traditional manufacturing industry production line, this paper systematically analyzes the core pain points of the traditional production line. The traditional production line has problems such as production efficiency bottlenecks, quality control defects, and comprehensive cost pressure. It studies and puts forward intelligent transformation paths such as automatic equipment upgrading scheme, data acquisition system deployment, and intelligent control center construction. It also puts forward implementation guarantee systems such as phased transformation scheme design, cross departmental collaborative team formation, and continuous optimization evaluation mechanism. It also looks forward to the future direction of production line upgrading. The purpose of this study is to provide reference and practical guidance for the transformation and upgrading of manufacturing industry.